BD Diesel 1086210 Electronic Multi Purpose Gauge Installation

BD Diesel 1086210 Electronic Multi Purpose Gauge Installation
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
BD X-MONITOR
2001-2006 GMC/Chevy 6.6L Duramax
I n s t a l l a t i o n
M a n u a l
Date Purchased
Purchased from
Installed by
READ THIS MANUAL COMPLETELY BEFORE INSTALLING THIS PRODUCT.
OWNER’S MANUAL - LEAVE IN GLOVE BOX
Installation Manual Part # I1086210
Printed in Canada
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
1
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
2
Table Of Contents
Kit Contents................................................................................................................3
Welcome ....................................................................................................................4
Pre-Installation ...........................................................................................................4
Installation ..................................................................................................................5
Pyrometer Sending Unit (Thermocouple)..........................................................5
Thermocouple Wiring...............................................................................6
Boost Pressure Sender Installation...................................................................6
LB7 Motor ................................................................................................6
LLY & LBZ motor .....................................................................................7
Manual Transmission / Diff Temperature Sensor..............................................8
Wiring Diagram - w/Remote Temp Sensor ..............................................9
Exhaust Brake Pressure Sensor .....................................................................10
Wiring Diagram – Back Pressure...........................................................11
Engine Oil Pressure Sensor............................................................................12
2001-02 Duramax ..................................................................................12
2001-02 Duramax Oil Pressure Wiring Diagram ..........................13
2003+ Duramax .....................................................................................14
2003+ Duramax Oil Pressure Wiring Diagram .............................15
Auxiliary Fuel Tank Level ................................................................................16
Auxiliary Fuel Tank Level Wiring Diagram .............................................16
Power and Ground ..........................................................................................17
Display Assembly Installation..........................................................................17
Programming and Set Up.........................................................................................18
Programming Chart ..................................................................................................19
Operation..................................................................................................................20
X-Monitor Display Settings Flowchart ......................................................................21
Maintenance & Troubleshooting...............................................................................22
LIMITED WARRANTY STATEMENT .......................................................................23
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
3
Kit Contents
1830030
Universal Installation Kit
(Includes thermocouple, bushing, control module vacuum tube boost
connection, 6ft of 1/8” air tubing, & fused power wire with ground wire)
1830010
Sensor Wire Kit
1820210
1806200
Display Kit (Side)
1300838
Control Module
LB7
Boost Kit
1300835
LLY-LBZ
Boost Kit
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
4
Welcome
Thank you for purchasing the BD X-Monitor. Your kit should have the items
mentioned on the previous page for your installation. This manual is divided into
different areas to assist you with your installation and operation of your unit.
Pre-Installation
If you have existing gauges installed, you may have to determine where to
reposition them to accommodate the X-Monitor. The X-Monitor mounts on the
driver’s side A-pillar panel, or, a custom dash-top universal kit can be purchased as
well.
This X-Monitor comes with all the programming to measure exhaust temperature
and boost pressure, plus, the option of adding one of the following: automatic
transmission temperature (using the OEM sensor), remote temperature sender (for
use with differentials for example), exhaust brake backpressure, and aftermarket
fuel tank levels.
Here are the standard list measurements:
Exhaust Gas Temperature
Turbo Boost Pressure
(PYRO)
(TURBO)
The above two measurements can be displayed by themselves or you can add one
of these options along with them:
Description
Transmission Temperature
Remote Oil Temp
Exhaust Brake Back Pressure
Auxiliary Tank Level
Value
(TRANS)
(OIL)
(B-PSI)
(FUEL)
BD P/N#
INCLUDED
1080126
1080136
1080160 *
The standard kit comes with all the components and wiring to hook up the exhaust
temperature, turbo boost pressure and automatic transmission temperature (using
the trucks OEM sensor); all other applications will require one of the accessories
above to install.
* The fuel tank level accessory kit interfaces with an aftermarket level sender with a
range of 240ohms (Empty) to 33ohms (Full). Sender not included.
Once the components have been installed, the X-Monitor will have to be
programmed to match the application and the measurements being monitored. This
will be done via the buttons on the display and will be explained further in this
manual. If you wish to change from one optional measurement to another, the X
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
5
Monitor can be reprogrammed to that application but an additional accessory kit
may be required.
The following sections will give detail on the install of each measurement available
but not all will apply to your installation.
Installation
NOTE: The ground terminals of the vehicle’s batteries should be disconnected
before performing any welding or taping onto any ECM/PCM wire.
Pyrometer Sending Unit (Thermocouple)
If your existing exhaust does not have a fitting to install a pyrometer sender unit
(thermocouple), you will have to install the bushing supplied in this kit. The best
place to locate the thermocouple is in the turbo charger down pipe.
If you have a TURBO-MOUNT
EXHAUST BRAKE or an after
market down pipe installed there
may be a ¼” NPT plug already
in the system. Remove this plug
and install thermocouple into the
¼” NPT hole and tighten with an
open-end wrench.
If you have an OEM or stock
down pipe you will have to drill a
hole and then weld the bushing
that is supplied with this kit in
place. It is recommended that
you remove the existing down
pipe for ease of drilling and
welding but it is possible to
install with pipe in place. Install
thermocouple into the 1/4 pipe
tap hole and tighten with an
open-end wrench.
For advanced users, the thermocouple can be directly installed into the manifold
before the turbo. This is a more difficult installation and should only be attempted by
an experienced mechanic. When drilling and tapping the ¼” hole, be sure not to drill
into any webbing or critical areas of the exhaust manifold. When monitoring the
exhaust temperature before the turbo the critical temperature is ~1250-1300°F.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
6
Thermocouple Wiring
Route the wire toward the firewall taking precaution to keep it away from hot and
moving parts, and then run it through the firewall by piercing a large rubber grommet
in the firewall beside the brake booster canister.
Do NOT cut or splice the thermocouple lead wire as it is special wire that
provides correct reading to the gauge. Simply coil any excess wire out of the
way.
From under the dash, retrieve the thermocouple wire and route it to the X-Monitor
Control Module. Install the wires onto the Control Module as shown in the diagram.
DO NOT MIX UP THESE WIRES, ENSURE YELLOW TO YELLOW AND RED TO
RED OR DAMAGE WILL RESULT AND WARRANTY WILL BE VOIDED.
Boost Pressure Sender Installation
LB7 Motor
Locate the Turbo Wastegate hose
and follow it along to the Plenum.
Install the other end of the fitting
with the 3” hose onto the fitting of
the plenum as shown in the
photos.
Connect the supplied tubing to the
fitting and route to the inside the
cab.
Push this end into the
supplied fitting (see diagram
above) and connect the short
section of rubber hose (with the
female quick-connect fitting) to the
pressure sensor on the back of
control box.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
7
WARNING: BE SURE TO USE THE RUBBER HOSE AND NOT THE PLASTIC
TUBING WHEN MAKING THE CONNECTION TO THE CONTROL BOX.
NOTE: The module should be mounted with the boost fitting pointed down to avoid
condensation from collecting inside the module.
LLY & LBZ motor
Using a 7/16 deep socket, remove the ‘T’ clamps at either end of the intercooler
tube on the passenger side of the engine. Once this pipe is removed, drill a 3/8”
hole on the top of the pipe closest to the turbo. Use a file or de-burring wheel to
clean to hole. Coat the nutsert or rivnut with a moderate temperature silicon or
gasket maker. Insert the coated nutsert or rivnut into the 3/8” hole in the pipe. Insert
the Allen head screw through the install nut with the serrated end facing towards the
nutsert or rivnut. Use a wrench to hold the nut in place while tightening the Allen
screw with the provided Allen key. Continue to tighten the Allen key until the force
needed to turn it drastically increases. Reinstall the tube into place on the truck,
making sure the all the intercooler boots are clean of oil and the clamps are tight.
Fuel Filter
Insert and tighten the
rivnut.
Install the 90° quick connect swivel fitting into the small brass adapter and tighten it
before installing the assembly into the nutsert. When installing the adapter assembly
into the nutsert use a small amount of silicone sealer/gasket maker around the base
of the brass adapter being careful not to obstruct the hole in the end. When
tightening the assembly into the nutsert, do not over torque or breakage will result!
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
8
You can now route the nylon tubing from the quick connect nutsert assembly to the
boost input on the X-monitor.
Black Nylon hose
To X Monitor
Quick Connect
Swivel Elbow
DO NOT OVER
TORQUE!
Brass Adapter
Use sealant here
Nutsert
From Intercooler
To Intake Manifold
Manual Transmission / Diff Temperature Sensor
Using parts supplied in X-Monitor kit, insert the Temperature Sender into the large
bushing. This will replace the rear differential housing fill plug on the back cover. For
manual transmission temperature, locate the appropriate location for sender to fit.
NOTE: Not all locations will accommodate the size of the sender or the bushings
supplied in the kit. An alternative location may need to be found, or a sender or
bushing may have to be purchased to be installed in the desired location.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
Wiring Diagram - w/Remote Temp Sensor
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
9
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
10
Exhaust Brake Pressure Sensor
Install the supplied stainless steel line and fitting into the test port of the exhaust
brake. Secure the line and attach the plastic hose.
Route the hose up along the vehicle frame and into the cab then attach the hose to
the interface filter and connect the wires as per the “Back Pressure” diagram that will
follow after this section.
Use the following diagram/photo as a guide. Install the filter and tubing together and
insert onto the inlet of the RPS Module.
The plastic filter housing will need to be changed out after 6-12 months of use. This
time is dependant on air humidity and the amount moisture trapped in the actual
filter. The replacement filter part number is 1800135. This filter should be mounted
in an easy to access, visible location.
Because of the moisture accumulating in the line and filter, it is highly recommended
that the RPS unit be mounted at the highest point of the air line causing all the
moisture to run back down the line into the exhaust.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
Wiring Diagram – Back Pressure
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
11
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
12
Engine Oil Pressure Sensor
2001-02 Duramax
Remove the front skid plate from
the bottom of engine and locate
the oil pressure-sending unit on
left side of engine block by the
steering box.
This sensor has only one (1)
wire attached.
Install a gray Posi-Tap onto the
tan w/white tracer wire of the
sensor then insert one end of the
green wire from the oil pressure
sensor kit to the gray Posi-Tap
and run the wire up into the cab.
Attach the other end of green
wire to the ‘DO NOT USE’ terminal on the control box. That’s right, this wire goes to
the ‘DO NOT USE’ terminal (this should have been labeled 'Future Expansion').
Secure the green wire in place away from any moving and/or hot parts and install
the skid plate that was removed in the first step. Tighten all fastening bolts. See
page 13 for the wiring diagram.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
13
2001-02 Duramax Oil Pressure Wiring Diagram
NOTE: THE GREEN WIRE FROM THE OIL PRESSURE SENSOR IS ATTACHED
TO THE ‘DO NOT USE’ TERMINAL OF THE CONTROL BOX NOT ‘SENSOR’.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
14
2003+ Duramax
The engine oil pressure sensor
is located just in front of the
engine oil filter and housing.
This sensor has 3 wires
attached.
Install a gray Posi-Tap onto the
tan w/white tracer wire of the
sensor harness then insert one
end of the green wire from the
oil pressure kit to the gray
Posi-Tap and then run the wire
up into the cab.
Attach the other end of the
green wire to the #4 ‘Sensor’
terminal on the control box.
Secure the green wire in place away from any moving and/or hot parts and install
the skid plate that was removed in the first step. Tighten all fastening bolts. See
page 15 for the wiring diagram for reference.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
2003+ Duramax Oil Pressure Wiring Diagram
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
15
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
16
Auxiliary Fuel Tank Level
This wiring for the auxiliary fuel tank level is virtually similar to the remote
temperature installation. Consult the literature for the sender for the correct terminal
or wire for the output.
Auxiliary Fuel Tank Level Wiring Diagram
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
17
Power and Ground
Locate a switched 12-volt power source under the dash and install the Red wire to it.
Install the other end to the Power connector of the control box.
Install the Black ground loop to a good ground and install the other end to the
Ground connector of the control box.
Display Assembly Installation
*** EXTREME
CAUTION ***
THE DISPLAY IS VERY FRAGILE AND IS INSTALLED AND
TESTED AT THE MANUFACTURER. IF YOU MUST REMOVE
THE DISPLAY IN ORDER TO PAINT THE PILLAR MOUNT
TAKE EXTREME CARE WHEN REINSTALLING. DO NOT
OVERTIGHTEN MOUNTING SCREWS OR DISPLAY WILL BE
DAMAGED AND WARRANTY WILL BE VOIDED. ***
Place the display assembly on the A-pillar to determine the best mounting location
and mark this location on the pillar. Remove the A-pillar for ease of installation.
Hold the display assembly in place on the A-pillar. Drill 3/16” holes into the corners
of the display assembly mount and also through the pillar.
Drill a hole through the A-pillar large enough for the display control wiring connector
to pass through. This hole is NOT required if you decide to run wiring along the
outside of the A-pillar.
Install the telephone-type communication cable into the back of the display circuit
board and route the wiring through the drilled hole or along the outside of the pillar
as preferred.
Insert the supplied ratchet fasteners through the drilled holes and into the A-pillar,
securing the X-Monitor display assembly to the A-pillar. Install the A-pillar into place
and route the control wiring down to the control box.
Insert the other end of the communications cable into the socket of the control box.
Once all connections are made, secure the box in place under the dash and away
from moving parts.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
18
Programming and Set Up
Press both buttons in on the X-Monitor display
and turn on the ignition. You will get a screen
that the first line on the display will read “SIDE
OR TOP BTN?” and the bottom line reads
“SIDE”. Let go of both buttons. Press the
bottom button to go to the next screen.
You will now get a screen that will read
“PART:” on the top line and “1080000” on the bottom line. Using the programming
chart located on the next page, find the program number that matches the
application and measurements you are going to program the X Monitor for. Press
the upper button until the program number appears, then press the bottom button to
activate that program. The display will now cycle through the normal start-up
screens that will appear every time the ignition is started.
It should display the following:
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
Programming Chart
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
19
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
20
Operation
Once the display has gone through the startup cycle it should end up with the
following, default display.
To change the settings and set
alarm values there are 2 buttons
on the side of the display, the
bottom (MENU) button cycles
through the different modes and
the upper (MODIFY) button
controls the setting of the values.
RECOMMENDED ALARM SETTINGS:
PYRO * 900°F *
TURBO 25
TRANS 200
OIL
Dependant On Location of Sender
User Defined – Consult Exhaust Brake
B-PSI
Manual for safe ranges
F-PSI
3
FUEL
25
* This value based on a pyrometer probe mounted post-turbo.
These are only suggested settings and will vary depending on vehicle condition,
performance enhancements and driving techniques.
NOTES: All temperature readings are in Fahrenheit (°F), pressures are in poundsper-square-inch (PSI) and fuel level is displayed in percentages. All readings are
approximate and may vary due to characteristics of sensor, sender or probe, and,
certain conditions can cause interference or sway reading.
The alarm settings for fuel pressure (F-PSI), oil pressure (O-PSI) and fuel level
(FUEL) are for will display an alarm with the measurement drops below the set
value; all other measurements will alarm when the value is above the setting. The
history value also works the same where it records the lowest achieved value on FPSI, O-PSI and FUEL and the highest value on all others.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
21
X-Monitor Display Settings Flowchart
When placed in Display Shutdown Mode, the X-Monitor counts down from 9 to shut
off the display ONLY; all the functions still continue to work in the background. Press
the MENU (lower) button to turn the display back on.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
22
The X-Monitor is calibrated to the thermocouple that is supplied with the kit and may
not register accurately if an existing or different thermocouple is used.
If the thermocouple was installed after the turbo, in the exhaust pipe, all
temperatures will indicate lower and the maximum safe temperature is 900 degrees.
DO NOT RUN ENGINE AT HIGHER THAN 900 DEG INDICATED FOR
EXTENDED PERIODS OR ENGINE DAMAGE MAY RESULT. DO NOT run
transmission at higher than 250 degrees indicated for prolonged periods or
transmission damage may result.
THE X-MONITOR IS A VERSATILE GAUGE PACKAGE THAT CAN BE
PROGRAMMED TO MONITOR DIFFERENT SYSTEMS OF THE VEHICLE.
THESE INSTRUCTIONS ARE FOR GENERAL INSTALLATION AND SPECIFIC
APPLICATIONS WILL RECEIVE INDIVIDUAL APPLICATION INFORMATION.
It is recommended that when mounting/securing the X Monitor module or RPS
module (used in Back Pressures applications), the barb of the pressure sensor on
the modules point downward to prevent any condensation from the tubing collecting
inside the modules.
Maintenance & Troubleshooting
Following the diagrams in this manual, tracing hoses and wiring, checking continuity
through electric components or checking for any lines that are disconnected, should
solve any problems that may arise.
NOTE: Analog signals are naturally affected by RF (radio frequency) noise. To
eliminate any possible chance of an erratic signal please choose a clean ground
signal for the X Monitor, that is clearly mounted away from the alternator wires or
any other voltage sources (positive battery cables, etc.). If for some reason you still
have erratic sensor readings try a direct ground connection to the battery.
Thermocouple wires should also be clear from any RF noise sources as well (i.e.
alternator, positive battery cables, etc). If the thermocouple signal is erratic then the
copper ground wire that is contained inside of the thermocouple wire can be
connected to ground to reduce a small amount of noise. Be sure to connect only
one end of this copper wire to eliminate any ground loops from forming.
If you have any problems or need replacement parts, call us at 1-800-887-5030,
between 8:30am and 4:30pm Pacific Time.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
12 May 2005
1086210 GMC/Chevy Duramax X-Monitor
23
BD ENGINE BRAKE, Inc.
LIMITED WARRANTY STATEMENT
THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND
UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS.
DISCLAIMER OF LIABILITY
BD Engine Brake Inc., its successors, distributors, jobbers, and dealers (hereafter “BD”) shall in no way be
responsible for the product's proper use and service. THE BUYER HEREBY WAIVES ALL LIABILITY
CLAIMS.
BD disclaims any warranty and expressly disclaims any liability for personal injury or damages. BD also
disclaims any liability for incidental or consequential damages including, but not limited to, repair labor,
rental vehicles, hotel costs, or any other inconvenience costs by reason of use or sale of any such
equipment. The BUYER acknowledges and agrees that the disclaimer of any liability for personal injury is a
material term for this agreement and the BUYER agrees to indemnify BD and to hold BD harmless from
any claim related to the item of any equipment purchased.
This warranty shall not apply to any unit that has been improperly stored or installed, or to misapplication,
improper operation conditions, accidents, neglect, or which has been improperly repaired or altered or
otherwise mistreated by the BUYER or his agent. BD also assumes no liability regarding the improper
installation or misapplication of its products. It is the installer's responsibility to check for proper installation
and if in doubt, contact the manufacturer.
LIMITATION OF WARRANTY
BD Engine Brake Inc. (hereafter "BD") warrants to the BUYER that any parts purchased shall be free from
defects in material workmanship. A defect is defined as a condition within the product that would render the
product inoperable. BD gives Limited Warranty as to description, quality, merchantability, fitness for any
product’s purpose, productiveness, or any other matter of BD's product sold herewith. BD shall be in no
way responsible for the product’s open use and service and the BUYER hereby waives all rights other than
those expressly written herein. This Warranty shall not be extended or varied except by a written instrument
signed by BD and the BUYER.
The Warranty is Limited to one (1) year from the date of sale and labor costs incurred by the
removal and replacement of the BD product, while performing warranty work, will be covered for 1
(one) year, payable at BD rates, at authorized centers and with prior approval. Until BD has
approved the claim, the consumer may be responsible for these costs.
A Return Authorization (WA) number, obtained in advance from BD, must accompany all products returned
for warranty consideration. All products must be returned, shipping prepaid, to BD and must be
accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by BD and
repaired or replaced product will be returned to the customer freight collect. Accepted warranty units, which
have been replaced, become the sole property of BD.
This warranty is in lieu of all other warranties or guaranties, either expressed or implied, and shall not
extend to any consumer or to any person other than the original purchaser residing within the boundaries of
the continental U.S. or Canada.
IN THE EVENT THAT THE BUYER DOES NOT AGREE WITH THIS AGREEMENT, THE BUYER MAY
PROMPTLY RETURN THIS PRODUCT, IN A NEW AND UNUSED CONDITION, WITH A DATED PROOF
OF PURCHASE, TO THE PLACE OF PURCHASE WITHIN THIRTY (30) DAYS FROM DATE OF
PURCHASE FOR A FULL REFUND.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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