BD Diesel 2023144 Exhaust Brake Installation Instructions

BD Diesel 2023144 Exhaust Brake Installation Instructions
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
1
1999-2002 Ford 7.3L Powerstroke
BD Turbo Mount Air Exhaust Brake
Part# 2023144
Serial #
Date Purchased
Purchased from
Installed by
* Please fill out and mail registration card as soon as possible. *
OWNER’S MANUAL – LEAVE IN GLOVE BOX
Installation Manual Part # I2023144
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
2
TABLE OF CONTENTS
Brake Kit Contents .................................................................................. 3
Welcome................................................................................................... 3
Options..................................................................................................... 3
Installation ............................................................................................... 4
Battery & Intercooler Pipe Removal .................................................. 4
Stock Vacuum Pump & Reservoir Removal...................................... 5
Valve Installation ............................................................................... 5
Air Compressor Reservoir Installation............................................... 7
Pump Relay Harness and Wiring ...................................................... 7
Engine Compartment Wiring & Hose Connections ........................... 8
Cab Wiring and Wiring Diagram........................................................ 9
Optional Shifter Switch (Push-Pull Style) ........................................ 10
Optional Shifter Switch (Rocker Switch Style) ................................ 11
Cruise Control Disconnect Wiring (if equipped) .............................. 12
Control Wiring ................................................................................. 13
Battery Reinstall .............................................................................. 13
DFIV Calibration.............................................................................. 13
Adjustment & Testing ...................................................................... 14
Measuring Idle Brake Pressure....................................................... 14
Ford Exhaust Brake RetroFit Kit (California Trucks) ....................... 15
Maintenance & Trouble Shooting ........................................................ 16
Operating Guidelines ............................................................................ 16
Warranty Statement .............................................................................. 19
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
3
Brake Kit Contents
2023144 – Ford 7.3L Powerstroke Exhaust Brake
Part #
2123144
1321039
1330440
1030124
1030125
1220145
1057020
Qty.
1
1
1
1
1
1
1
Description
Valve Assembly
DFIV Control Kit
Vacuum Pump / Relay harness
Vacuum Pump relocation kit
Air Pump Kit (w/ bracket)
Air control kit
Retrofit Kit (California Trucks only)
Welcome
Thank you for purchasing a BD Engine Exhaust Brake. Your kit should have the
above-mentioned items for your installation; please check to make sure that you
have everything. This manual is to aid you with your installation and operation of
your braking unit. We strongly suggest that you fill out the information below and
retain this manual for any future reference.
Options
Description
Manual Transmission Shifter Switch Kit
Brake Pressure Gauge Kit
Pyrometer Gauge Kit
Boost Pressure Gauge Kit (30 lb.)
Transmission Gauge Kit (Auto Trans)
Cockpit Gauge Mount (Single)
Molded Gauge Clusters (2 & 3 gauges)
Performance Torque Convertor
TowLoc Convertor Control
BD Evolution Performance Tuner
Part #
1300210 / 1030900
1030551
1030512
1030570
1030584
1030600
Call
1030223
1067700
1057100
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
4
Installation
Battery & Intercooler Pipe Removal
Disconnect the negative terminals on both of the vehicle’s batteries, and then
disconnect the positive terminals. Remove passenger side battery.
To gain access to the
EBP Valve and wiring,
remove the intercooler
pipe on passenger side
by loosening off the
clamp on the rubber
bellows that is attached to
the intercooler rad and
the clamp on the rubber
bellows that attaches the
intercooler pipe to the
intake manifold.
Remove the sensor hose
and wire connector from
the MAP sensor.
When removing the pipe, the lower rubber bellows that connects to the intercooler
rad should remain on the pipe. The pipe slides out of the rubber bellows that is still
attached to the intake manifold.
Remove the turbo outlet housing. Inspect the turbo exhaust clamp, turbo down pipe
and turbo outlet for any carbon build-up or damage that may cause problems
sealing on exhaust mating surfaces.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
5
Stock Vacuum Pump & Reservoir Removal
Locate the small electric vacuum pump and reservoir on the passenger side fender
well. Remove the reservoir by removing the bolts on the under side of fender well,
and disconnect the hoses. Remove the small electric vacuum pump by removing
the screws, unplugging the electrical plug and pulling off the supply tube to the
reservoir.
Remove the electric vacuum pump from the stock mounting location and re-install it
on the new mount provided. Trim the rubber ends on the three vibration dampers to
clear when reinstalling. Install on the right hand side of radiator support bracket with
the two bolts and washers provided.
Cut the power supply wires for the stock electric vacuum pump approximately 4”
from the connector and splice in the black and blue wires supplied using the butt
connectors and shrink tubing. The 1/8” plastic tube will run inside the same loom
against the fender.
Valve Installation
Remove the engine-lifting
eye by the turbo outlet.
Remove and retain the
turbo
exhaust
clamp
between the turbo and
exhaust pipe. Loosen off
the two (2) bolts that
secure the turbo down
pipe to the catalytic
convertor under the truck.
Remove and retain the
seven (7) mounting bolts
of the outlet housing on
the turbo using a 5/16”
12pt socket. Loosen the
outlet housing and turn it
downward to expose the
valve actuation rod.
Disconnect the actuation
rod from the bottom of
the
outlet
housing.
NOTE: The clip that holds the rod to the outlet housing is similar to that found on
carburetors.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
6
To prevent the rod from hanging, which can cause the rod seal to leak due to
vibration, install the supplied rod support fitting. This is a brass fitting that has a cut
in it, which fits around the rod and holds the rod securely.
The EBP Valve will not be required with the installation of the BD Exhaust Brake. It
is recommended that the EBP Valve wiring harness be disconnected to prevent the
actuator rod from moving to protect the seal.
NOTE: ON CALIFORNIA MODEL VEHICLES THE EBP VALVE WIRING MUST BE
CONNECTED TO ENSURE THE ECM DOES NOT SET AN ENGINE TROUBLE
CODE.
Install the BD Brake Valve Assembly on the turbo, using the original mounting bolts.
Secure the exhaust pipe to the BD Brake Valve, using the original turbo exhaust
clamp then reinstall the intercooler pipe and tighten bolts on catalytic convertor.
Reconnect the sensor hose and wire connector from the MAP sensor.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
7
Air Compressor Reservoir Installation
Install the mounting bracket of the BD High Capacity Air Compressor in the same
location that the small electric vacuum pump was removed from. Secure it to the
side of the engine compartment with the supplied fender screws.
Install the BD Air Compressor onto the bracket with washers & lock nuts supplied,
and re-install the reservoir back into its original location. Re-attach all hoses that
were previously disconnected.
Pump Relay Harness and Wiring
Consult the "Engine Compartment Wiring and Hose Connections" diagram for
proper connections. Counting from the relay, plug the first connector (w/Red wire)
to the Red wire on the BD Air Compressor. Plug the second connector (w/Blue
wire) to the Black wire on the Valve bracket.
Install Control Valve & Regulator on top of the AC unit where the boost pressure is
measured. Install the relay mount on one of the existing screws and route the
harness over to fender and secure. Make wire connections as per wiring diagram.
With the last two connectors at the end of the harness, attach the Black wire to the
negative terminal on the passenger side battery and the fused Orange wire to the
positive terminal. Battery terminal nuts are provided in the kit.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
Engine Compartment Wiring & Hose Connections
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
8
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
9
Cab Wiring and Wiring Diagram
CAUTION: Before installing any wiring modifications or equipment ensure to
disconnect the battery Ground (Negative) terminals on all the vehicle batteries as
damage to the vehicle’s ECU and/or installed components may result.
Remove lower section of dash, under the steering column, and mount the DFIV
module to the cross member under the steering column. Connect the Black wire
from the DFIV module to a good ground.
Locate the one of the ignition switched Red /Black tracer wires under the steering
column (one is 10/12ga and the other is 14/16ga) and connect an appropriate PosiTap connector to it (green/yellow for 10/12ga and black for the 14/16ga wire).
Connect the fused Red wire from the Toggle Switch to this Posi-Tap and then mount
the Toggle Switch in a convenient spot on the dash.
Locate the Throttle Position Sensor at the throttle pedal and, using a gray/red PosiTap connector, attach the Yellow wire from the DFIV module to the Grey wire
w/White tracer on the TPS.
Ensure the Green wire is connected to the ‘COM’ terminal of the DFIV module, the
Blue wire is connected to the ‘FORD’ terminal of the DFIV module, and the Pink wire
is connected to the ‘BRAKE’ terminal of the DFIV module. Also check to ensure all
other wires at the DFIV module are secure.
NOTE: If the vehicle does not have Cruise Control, remove the Green and Blue wire
from the install and discard.
Run the other end of these wires through a grommet on the firewall, making sure all
wires are secure and are far enough away from moving objects or heat sources.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
10
Optional Shifter Switch (Push-Pull Style)
To install the optional Manual Shifter
Switch Kit, mount the switch onto the
shift lever using the clamp supplied.
Run the cable down the shifter shaft,
securing the cable with zip-ties or
electrical tape, and run under the
carpet to the firewall and under the
dash to the relays, leaving enough
slack for proper shifting of the
transmission lever and to prevent
any rubbing of wire.
At the end of the cable, cut off any
excess and strip away about 1 to 2
inches of the black rubber covering,
exposing the black and white (or
Green) wires then strip the insulation
from the ends of the two wires.
Connect the White (or Green) wire to
the “Switch” terminal on the DFIV
Module.
Attach a male blade connector to the Black wire. Remove the fused Red wire from
the toggle switch (the toggle switch and remaining Red and Black wire attached to
the switch will no longer be needed) and attach to the Black wire from the optional
switch to the female connector of the fused Red wire.
Locate one of the ignition switched red/black tracer wires under the steering column
(one is 10/12ga and the other is 14/16ga) and connect an appropriate Posi-Tap
connector to it (green/yellow for 10/12ga and black for the 14/16ga wire) then
connect the fused Red wire to this Posi-Tap.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
11
Optional Shifter Switch (Rocker Switch Style)
Mount the shifter switch onto the shift lever using the clamp supplied (either 5/8” or
3/4”). Run the electrical cable down the shifter shaft, securing the cable with zip-ties
or electrical tape, and run it under the
carpet to the firewall and under the dash
to the relays, leaving enough slack for
proper shifting of the transmission lever
and to prevent any rubbing of wire.
At the end of the cable, cut off any excess
and strip away about 1-2” of the black
rubber insulation exposing the black,
white and green wires, then strip the
insulation from the ends of the three
wires.
Connect the green 12V output green wire
to the “Toggle Switch” input terminal on
the DFIV.
Attach the 5/16” ring connector to the
black ground wire and attach it to a good
ground nearby.
Locate one of the ignition switched power
fuses in the fuse panel underneath the
steering column. Use the supplied fuse
tap to supply ignition switched power to
the “Keyed 12 Volts” (white) wire of the
rocker switch assembly.
Also provided in the kit is a Posi-Tap
connector as an alternative to the fuse tap
and flag connector. If you want to use the
Posi-Tap instead of using the fuse tap in
the fuse panel, then you will need to
locate a 12V switched ignition wire to
power the switch. You could also use the
12V Switched Power source that powers
the DFIV.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
12
Cruise Control Disconnect Wiring (if equipped)
NOTE: If the vehicle does not have Cruise Control, remove the Green and Blue wire
from the install and discard. Jump to the Control Wiring section.
Consult the wiring diagram for proper connections and locate the Brake Applied
Switch on top the hydraulic brake booster.
Locate the Black w/Yellow wire at the Cruise Control Disable (Brake Applied) switch
located on the brake master cylinder and expose the wiring approximately 4 to 6
inches from the switch to allow for a good length to work with.
NOTE: This wire may be a different color in various applications. If there is no Black w/Yellow wire
going to this switch, use a test light to check which wire changes state (power to no power) when
the brake pedal is applied.
Cut the black wire w/yellow tracer (BK/Y), and attach the blue Posi-Lock connectors
to both sides of the cut wire.
Run the green and blue supplied wires that were brought through the firewall to the
Brake Applied Switch at the brake booster and trim to fit. Now connect the blue and
green wires to Posi-Lock connectors that were installed earlier to the Black w/yellow
wires. It does not matter which wire which wire is connect where.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
13
Control Wiring
Run the pink wire that came through the firewall with the other two wires to the
Exhaust Brake Control (Spool) Valve and trim off any excess. Strip away some of
the insulation and install a female bullet connector then plug the connector on the
free Control (Spool) Valve wire. Secure all wires and hoses to ensure they are out
of the way of moving and heated items.
Battery Reinstall
Reinstall the passenger side battery. Reconnect the positive terminals on both
batteries then reconnect the negative terminals.
DFIV Calibration
Ensure the connections of the corresponding wires to the DFIV Control Module are
correct as shown in the wiring diagram.
To achieve the correct setting for the
activation of the exhaust brake in relation to
the throttle pedal the DFIV Module must be
calibrated for your vehicle.
Connect one end of a test light to the
“BRAKE” terminal of the DFIV module and
the other end to a good ground.
With the throttle at idle, start the engine and turn on brake switch. Then, using a
small flat bladed screwdriver, turn the small adjusting screw in the DFIV Module
counterclockwise or clockwise until the test light JUST turns on.
CAUTION: THE ADJUSTING SCREW IS A MICRO-SWITCH THAT IS VERY
DELICATE, SO TURN USING SMALL ADJUSTMENTS.
Test by revving up the engine to approximately 1200 RPM and releasing the throttle.
As the accelerator pedal is applied the test light should turn off just before the
engine starts to rev, indicating proper calibration of the DFIV Module with the APPS.
Then the test light should activate again when the throttle pedal returned to idle. If
not, readjust the DFIV Module so that it does. Reinstall lower dash cover.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
14
Adjustment & Testing
Start the engine and turn the Exhaust Brake on. Press on the Accelerator Pedal to
rev-up the engine to approximately 1200 RPM and release. The brake should have
disengaged then activated again when the engine returns to idle.
The idle pressure should be 10–15 lbs and CANNOT be raised using the stop bolt
as adjustment. If an adjustment is thought to be necessary, contact BD Technical
Support FIRST. NOTE: The butterfly valve has been preset at the factory and
should not be adjusted.
The Regulated Pressure is adjusted with the regulator on the Control Assembly and
has been preset to a MAX of 45 Lbs.
CAUTION: Do NOT exceed this pressure in the exhaust system.
While driving, turn Cruise Control on, then try to activate brake, the activation of the
brake should disconnect cruise. Turn brake off and activate cruise again, this time
pressing down on the hydraulic brake pedal to ensure cruise disconnects when the
brake pedal is applied.
Measuring Idle Brake Pressure
As mentioned in these installation instructions, the backpressure must be
measured and adjusted when the vehicle is at idle. For easier hook up of a
gauge, the pressure can be measured by removing the backpressure switch
behind the belt idler pulley on the front of the engine and plumb the gauge to
the pressure tube.
It is required that a standard pressure gauge be used to make the necessary
adjustments to the brake valve. Adjust the brake to reach approximately 10-15 lbs
while the engine is at idle.
NOTE: Over the next two weeks, the backpressure at idle may rise due to initial
carbon build up and the brake valve will need to be adjusted again.
Check for any exhaust leaks and recheck all connections and hoses for security and
interference from moving or heated items. After about 100 miles (160 km), retorque the turbo exhaust clamp and flange bolts.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
15
Ford Exhaust Brake RetroFit Kit (California Trucks)
The purpose of this kit is to cure the problematic Ford P-Code in regards to exhaust
back pressure being too high.
This code is normally set with California
Powerstrokes when using an exhaust brake. This kit should only be used on
California trucks that exhibit the problem.
To install, locate the Exhaust Back Pressure sensor at the front of the engine, just
behind the idler pulley and to the left of the water pump outlet hose.
Install the supplied
Posi-Tap™
connector on to the
Violet with Light
Blue wire (2000 –
03) or the Pink with
Light Blue wire
(1999).
Connect the black
wire pigtail to the
Posi-Tap™
using
connector
the male blade
connector. Run the remaining wire away from the belt and the pully and use the
nearest engine bolt as a ground.
Do not cut or shorten the supplied wire. There is a diode located inside of it.
Exhaust Brake
Pressure Sensor Wire
2000-03 – VT/LB
2000 – PK/LB
GROUND TO NEAREST
ENGINE BOLT
Exhaust Brake
Pressure Sensor
Kit Part # 1057020
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
16
Maintenance & Trouble Shooting
To extend the life of the exhaust brake, do not operate the vehicle for extended
periods of time without activating the brake. On a twice-yearly interval, check and
adjust the brake pressure to 10-15 lbs while the engine is at idle. The hoses, wires,
fittings and clamps should be inspected on a regular basis for any deterioration,
damage, or leaks.
By following the diagrams in this manual, trace hoses and wiring, check continuity
through electric components, and check for any lines that are disconnected.
This should solve any problems that may arise but if you should need any
assistance or need replacement parts, call our Technical Service department at 1800-887-5030 or 1-604-853-6096, between 8:30am and 4:30pm Pacific Time.
Operating Guidelines
Thank you for taking interest in the BD Engine Exhaust Brake. As a driver, you
probably already know the need for extra braking power that your vehicle requires
on the hills and long grades. With loads being towed behind you, the extra push
when slowing down or maintaining speed on downward grades can prove to be a
great strain on the vehicle hydraulic braking system, even to point of “burn-up”.
These guidelines were designed to offer a better understanding of the benefits of
using exhaust brakes and are based on material developed by the US Department
of Transportation National Highway Traffic Safety Administration.
The emphasis on today’s vehicles is to give the consumer a product that can give
them usable power with fuel efficiency. But, in the transition, the vehicles have lost
their natural braking power, making it more easy for the vehicle to continue to roll
and harder to stop. Of course, this gets more noticeable with the increase of weight,
on or behind the vehicle. This is where an exhaust brake becomes a useful tool in
increasing the driveline drag of the vehicle without the use of the hydraulic brakes.
It is a tool that with maximum use, or even occasional use, can reduce wear on
hydraulic braking parts and at the same time increase safety. The BD Exhaust
Brake can be used to help maintain a controlled vehicle speed on a downward
grade, as well as slowing the vehicle down for such times as turns or exit ramps,
without you using your hydraulic brakes. However, the exhaust brake cannot be
used as a parking brake or a service brake to bring your vehicle to a complete
stop.
By using a BD Exhaust Brake, the life and effectiveness of your hydraulic brakes will
increase. This is because of the decreased use of the hydraulic brakes in situations
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
17
like hills, the wear factor is reduced and there is less opportunity for your hydraulic
brakes to heat up which would reduce the efficiency.
When you ride your hydraulic brakes, make hard stops or have poorly adjusted
brakes, this creates high temperatures and as your brakes get hotter, the more
chance there is for fading or failure. With terrain that is a series of up and down
grades, the BD Exhaust Brake will aid in reducing exhaust valve warpage. Because
of the power needed to pull your vehicle and load up a hill, this generates a lot of
heat.
When you have reached the crest of the hill and are now coasting down the other
side, the heated valves are too quickly cooled. With the exhaust brake engaged,
the heat loss to the valves will be reduced, which can prevent valve warpage. When
the toggle switch is turned to the “On” position, the valve is activated every time the
driver takes his foot off of the throttle pedal. When the driver puts pressure back on
the throttle pedal, the relay is activated and the valve opens again.
Exhaust brakes are designed to operate with the throttle at idle, not to be used in
conjunction with cruise controls, and not designed to aid in gear shifting. Such
cases could cause damage to engine and/or the exhaust brake. Vehicles may
require downshifting to obtain the necessary retarding force.
Automatic transmissions with lock-up clutches in the converters can achieve the
best retarding force with the use of a clutch control device (i.e. AutoLoc).
During cold weather engine start up, turn the brake on at idle while warming up the
vehicle. This brings up the engine to normal operating temperature in much less
time. Incorporated with the BD Exhaust Brake, there is a pressure regulating
system that will control the created backpressure. If the backpressure reaches the
set limit, the exhaust valve will open slightly to relieve the excess pressure.
The brake pressure at idle is required to be checked and adjusted at time of
installed, two weeks after installed, and on a regular twice a year interval.
Using a standard pressure gauge and the pressure port on the exhaust valve, the
brake pressure at idle must be set between 10 and 12lbs. The best scenario for
exhaust braking is when going down hill, select a gear that lets you maintain a
constant speed with little or no use of the hydraulic brakes, or, the same gear that
would be used to go up the same grade of hill. This also depends on the weight,
load or road conditions that the vehicle will come upon.
Therefore, in summary, by using the BD Exhaust Brake, you reduce the need for
use of your hydraulic brakes in situations where you need to slow down or maintain
(i.e. hills, off ramps, corners, approaching speed changes or traffic lights). By
reducing the use of your hydraulic brakes in these situations, this reduces heat
build-up, and wear and damage to linings and drums. And, when you reduce these
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
18
factors, you save your hydraulic brakes for when you really need them (i.e. for
stopping or emergencies).
The BD Exhaust Brake is not a substitute for your hydraulic brakes and, cannot
correct or compensate for poorly maintained or misadjusted brakes. But, when you
need to slow down or maintain a constant speed, the BD Exhaust Brake will be a
valuable and effective tool. Exhaust Brakes are more efficient at preventing than
correcting an over-speed condition.
To prevent the butterfly from sticking due to carbon build up and increase the
life of your exhaust brake we recommend daily use. This could simply be
switching it on and off a couple times a day.
Thank you and happy motoring,
BD Engine Brake, Inc.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
17 May 2006
Ford Powerstroke (1999-2003 7.3L) Air Exhaust Brake – P/N# 2023144
19
BD Engine Brake, Inc.
Warranty Statement
BD Engine Brake, Inc. (BD) warrants to the original purchaser 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 limits
the liability to the repair or replacement, at BD’s option, of any warrantable product,
returned prepaid with a complete service history and proof of purchase to the
factory. A valid proof of purchase is a dated bill of sale. 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.
A Return Material Authorization (RMA) number obtained in advance from a BD
customer service representative must accompany product returned for warranty
determination. BD will be the final authority on all warranty decisions.
This warranty shall not apply to any unit that has been improperly stored or
installed; or to misapplication, improper operation conditions, accidents, or neglect,
or which has been improperly repaired or altered or otherwise mistreated by the
owner or his agent.
This parts warranty shall terminate at the end of 12 months in service
with the original user. Labor costs incurred by the removal and replacement
of the BD product, while performing warranty work, will be covered for 12
months at authorized centers with prior approval. Until the product has been
approved at the original installing dealer or at one of our distributors, the
consumer should be responsible for these costs.
Except as set forth in our parts outline, BD disclaims any implied warranties of
merchantability and fitness for a particular purpose. BD also disclaims any
liability for incidental or consequential damages including but not limited to,
repair labor, rental vehicles, hotel cost or any other inconvenience costs. 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.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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