Low Fuel Pressure LED Alarm Instructions

Low Fuel Pressure LED Alarm Instructions
29 September 2005
Dodge Cummins Low Fuel Pressure Alarm Light Kit 1081130-33
1999-2005 Dodge Ram 5.9L Cummins
1
LOW FUEL PRESSURE ALARM LIGHT
- Installation Manual Part Number Sequence:
1081130
Red
1081133
Amber
NOTE: If this kit is being installed in conjunction with a BD X-Monitor or
Cool Engine Shutdown (CES) and you wish to split the power connection
off of the control module, order part # 1801119 for a Y-wire.
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION.
Please read the disclaimer before proceeding to install this unit.
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
29 September 2005
Dodge Cummins Low Fuel Pressure Alarm Light Kit 1081130-33
2
Introduction
The purpose of this kit is to indicate to the driver with the red/amber LED, if the
supply fuel pressure of the VP44 injection pump is dropping below 5psi. Also note
that damage may result to the VP44 if it is starved for fuel. If you are finding that
your existing setup cannot supply enough fuel for the VP44, you may want to look at
some additional kits to protect your system.
On newer ISBe engines the purpose of the kit is to alarm the driver once the fuel
pressure drops below 5psi, indicating that an auxiliary pusher pump is needed. For
safety anything over about 400 HP will need an auxiliary pusher pump.
Reasons For Low Supply Pressures
• Plugged filter
• Plugged fuel tank pickup
• Weak or dead factory lift pump
• Too much demand and not enough supply (High horsepower)
Available Accessories
• BD High flow banjo bolts (gains of > psi fuel pressure)
• BD High flow auxiliary lift pump kit (gains of 15psi, supports +500HP)
Kit Contents
Part Number Description
5psi Pressure Switch
1801130
LED Assembly w/ 2 pc. Bezel
108112x *
Female Blade Connector
1300353
Mini-Fuse Tapper
1300337
2-520334-2 Flag Connector (for use with mini-fuse tapper)
Tapped Banjo Bolt (2000+ Dodges only)
1502017
Sealant Washer
1502019
Qty.
1
1
1
1
1
1
2
*Depending on which color LED you have, the “x” in the LED number will be “1” – Red or “3” – Amber
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
29 September 2005
Dodge Cummins Low Fuel Pressure Alarm Light Kit 1081130-33
3
Installation
1. Disconnect the battery terminals before starting installation.
2. Find an installation point for the LED and bezel
assembly. Typically, a close proximity to the
optional X Monitor or auxiliary gauges is a good
idea or even somewhere visible. Use a ¼” drill
bit to drill a hole for the bezel and LED to fit into.
IT IS CRITICAL THAT YOU CORRECTLY DRILL THE ¼“
PERFECTLY 90° OR PERPENDICULAR TO THE DRILLING
SURFACE.
3. Insert LED & wiring assembly through the ¼” hole, route the black
and red wire first and pull the entire six feet through. Before
inserting and locking the LED bezel in the hole, place a small
amount of silicone on the bezel. Now firmly insert the LED bezel as
it should lock in place. The silicone should lock the bezel in place
and resist any movement from vibration.
4. Route the Red 18ga wire to 12V switched power, a supplied fuse
tapper is provided for easy installation in the factory fuse panel. An
accessory fuse is adequate, as the LED will draw less than 0.5 Amp.
Use a 90° pink flag connector (supplied) for a much easier
installation.
5. You will need to locate the appropriate fuel port for your application.
Please note that closer to the actual injection or high pressure pump
the better. Use the new supplied sealing washer to ensure a tight
seal and eliminate any fuel leaks.
a. On 1998-99 model year ISB trucks, there will be a 1/8” NPT
test port located on the fuel filter cap. Unscrew the cap closest
to the engine and thread in the pressure switch.
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
29 September 2005
Dodge Cummins Low Fuel Pressure Alarm Light Kit 1081130-33
4
b. On later 2000-2002 ISB trucks, thread the supplied banjo bolt
into the inlet of the VP44; you’ll need to remove the factory
Schrader valve.
c. On 2003+ ISBe HPCR engines you will need to use the
supplied banjo bolt to replace the factory front most banjo bolt
located directly on the side of the CP3 pump. To locate this
bolt just follow the larger fuel supply line from the fuel filter.
6. With the supplied 5psi pressure switch, coat the threads with liquid
pipe sealant or Teflon tape and install into the fuel pressure port. Be
careful not to contaminate the fuel system with using too much tape
or sealant.
7. Now route the black 18 AWG wire through the firewall into the
engine compartment and attach the supplied female blade
connector. Slide the blade connector onto the male blade connector
on the back of the pressure switch.
8. Start the truck and check for leaks around the pressure switch.
9. To verify operation the LED should light for a brief second before the
truck is started.
The theory behind the unit is that the pressure switch will provide a ground when the fuel
pressure drops below 5 psi. With 12 volts supplied through the LED, a ground now
supplied, the LED will illuminate warning the driver.
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
29 September 2005
Dodge Cummins Low Fuel Pressure Alarm Light Kit 1081130-33
1998½-2002 VP44 Engines
2003+ HPCR Engines
Banjo bolt location
If you have any technical problems or concerns, please give our
Technical Support hotline a call at (800) 887-5030,
Monday to Friday, 8:30am-4:30pm, Pacific Standard Time (PST).
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
5
29 September 2005
Dodge Cummins Low Fuel Pressure Alarm Light Kit 1081130-33
6
BD Engine Brake
Disclaimer of Liability
Other than as expressly set forth herein, BD ENGINE BRAKE, Inc. (hereafter collectively, "SELLER"), together with
its distributors, jobbers and dealers shall in no way be responsible for the PRODUCT’S proper use and service. In no
event shall SELLER be liable for any special, incidental, indirect or consequential damages of any kind or nature,
whether or not BUYER was advised of the possibility of damage, arising or resulting from the use or performance of
the PRODUCT, and BUYER hereby waives any and all such claims.
BUYER acknowledges that he/she/it is not relying on SELLER’S skill or judgment to select or furnish goods suitable
for any particular purpose and that SELLER has no liability that will extend beyond the scope of the limited warranty
contained herein, and BUYER hereby waives all remedies or liabilities, expressed or implied, arising by operation of
law or otherwise, (including, without limitation, any obligations of SELLER with respect to fitness for any particular
purpose; merchantability; and special, incidental, indirect or consequential damages) or whether or not occasioned by
SELLER'S negligence.
SELLER disclaims any warranty and expressly disclaims any liability for personal injury or damages related to
BUYER’S use of the PRODUCT. BUYER acknowledges and agrees that the disclaimer of any liability for personal
injury is a material term for this agreement and BUYER agrees to indemnify SELLER and hold SELLER harmless
from any claim related to the PRODUCT and its use or performance. Under no circumstances will SELLER be liable
for any damages, liabilities, costs or expenses incurred as a result of by reason of the use, performance or sale of the
PRODUCT, including, without limitation, any damages, liabilities, costs or expenses incurred by reason of BUYER’S
negligence related to those uses of the PRODUCT.
SELLER assumes no liability regarding the improper installation or misapplication of the PRODUCT. It is the
installer's responsibility to check for proper installation, and, if in doubt, contact the manufacturer.
LIMITATION OF WARRANTY
SELLER hereby provides the following limited warranty as to description, quality, merchantability, fitness for any
product’s purpose, productiveness, or any other matter of SELLER'S product sold herewith. The SELLER 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
SELLER and BUYER.
The Warranty is Limited to one (1) year from the date of sale and limited solely to the parts contained within the
product's kit. All products that are in question of Warranty must be returned shipping prepaid to the SELLER and
must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by BD
ENGINE BRAKE, Inc.
Under no circumstances shall the SELLER be liable for any labor charged or travel time incurred in diagnosis for
defects, removal, or reinstallation of this product, or any other contingent expenses.
Under no circumstances will the SELLER be liable for any damage or expenses insured by reason of the use or sale of
any such equipment.
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. THE INSTALLATION OF THIS PRODUCT
INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND
ACCEPTS ITS TERMS AND CONDITIONS.
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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