bd air activated exhaust brake

bd air activated exhaust brake
12 June 2007
BD Air Activated Exhaust Brake
WARNING TO DRIVER
The use of Exhaust Brakes for
engine retarding below 1000 rpm
could result in high exhaust
temperatures, excess emissions,
or engine stalling.
BD AIR ACTIVATED EXHAUST BRAKE
Motorhome/Truck 5.9/8.3L/L10 - Cat 3208T/3116 – IHC DT466/7.3L
Ford Truck 6.6/7.8L - Ford 6.9/7.3L - Chev 6.2/6.5L - Dodge 5.9L
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
1
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
2
TABLE OF CONTENTS
Kit Contents................................................................................................................3
Welcome ....................................................................................................................3
Pre-Installation ...........................................................................................................3
Valve Assembly Installation........................................................................................3
Control Box.................................................................................................................5
Throttle Switch............................................................................................................5
Cummins Motorhomes & Trucks.......................................................................5
Caterpillar Air Throttle .......................................................................................6
Generic .............................................................................................................6
Ford Pick-up (Non Powerstroke).......................................................................6
Dodge – 1994 to 1998 ......................................................................................9
Dodge – 1998½ to 2002 ...................................................................................9
For 6spd manual transmission only..............................................10
For all applications........................................................................11
Dodge - 1988 to 1993 .....................................................................................11
Chev/GMC 1994-Present................................................................................12
On all applications ........................................................................12
DFIV Calibration .......................................................................................................13
Power Switch & Optional Gauge ..............................................................................16
Optional Shifter Switch .............................................................................................17
Cruise Disable Function ...........................................................................................18
Chevy/GMC (1994-up) ....................................................................................18
Ford.................................................................................................................18
Exhaust Brake Testing .............................................................................................20
Maintenance.............................................................................................................20
Trouble Shooting ......................................................................................................21
Cummins 5.9L Turbo Mount Exhaust Brake Addendum ..........................................23
Additional Wiring Instructions (Ford Powerstroke) ...................................................24
OPERATING GUIDELINES......................................................................................27
OPTIONS .................................................................................................................29
LIMITED WARRANTY STATEMENT .......................................................................30
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
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Kit Contents
o
o
o
o
Valve Assembly
Adapter Kit
Control Box Assembly
Application Kit
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 your with your installation and operation of
your braking unit. We strongly suggest that you fill out the information card and
return it to the factory and retain this manual for future reference.
Please fill out and mail registration card as soon as possible.
Pre-Installation
Before installation can begin, we must take a look at any other requirements or
options for your particular application.
If the driver likes gauges, another handy option is the Brake Pressure Gauge Kit.
This gauge will allow you to monitor the pressures being developed by the exhaust
brake.
Valve Assembly Installation
In the engine compartment, locate the factory Vacuum Pump and if none is present
(i.e. some 1988-93 Chevrolets), then the purchase of a BD Vacuum Pump kit (Part
#1030120) is needed to supply the vehicle’s retarding needs.
Inspect the vehicles exhaust system between the engine and the muffler. A straight
section of pipe will have to be cut to accommodate the butterfly style valve of the
Exhaust Valve Assembly, being approximately 7 to 8 inches. On 1994 or newer
Dodges, the valve is mounted before the Catalytic Converter, on Ford and Chev/GM
vehicles with Catalytic Converters, the valve is mounted between the Cat and
muffler.
There should be no exhaust-flex pipe between the engine and exhaust brake valve.
However, if there is a flex pipe after the valve, then it is acceptable. Cut the exhaust
pipe in a straight section of the system. You will need to weld one of the supplied
adapters to the section of pipe coming from the front of the vehicle’s engine.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
4
Rear of Truck
Weld
Here
Use V
Clamp
Use SS
Band Clamp
Temporarily mount the Exhaust Valve Assembly on the adapter, with the supplied V
clamp on the valve sliding. From here, cut off as much of the remaining exhaust
needed to accommodate the valve and remaining adapter. Remove the Exhaust
Valve Assembly, and clamp or weld the rear adapter to the other section of exhaust
pipe.
Temporarily mount the Valve Assembly on the adapter, with the stud on the valve
sliding into the notched corner of the flange. Cut off enough of the remaining
exhaust required to accommodate the valve.
Remove the Valve Assembly and weld or clamp the other adapter to the other
section of exhaust pipe, with the notched corner in the same position as the other
flange. Mount the Valve Assembly onto the flanges, with the studs of the valve
sliding into the notched corners of the mounting plate and the air cylinder pointed
away from engine, tighten nuts and bolts.
Connect with a female flared silver hose fitting, a piece of braided hose long enough
to go from the valve to the control box, to the male flare fitting on the Quick Release
Valve on top of the Air Cylinder.
Connect the other piece of braided hose to the flared fitting on the valve with the
female silver hose fitting which has the flared end. Attach a silver hose fitting with a
female 1/8npt (pick-up) or female flare (motorhome) to the opposite end of the
braided hose.
For pick-ups & trucks, screw in a male 1/8” NPT compression fitting into the free end
of the braided hose (with silver hose fitting) and attach the 1/8” black plastic tubing
to it. From here, the hoses have to be run up into the engine compartment and to a
fender well area close to an air source.
Run the hoses and/or tubing on a path away from moving parts and excessive heat.
Secure the cable and hose with tie straps.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
5
For motorhomes, run the hoses towards the area where the control box is going to
be installed, near an air source and secure with some tie straps.
Control Box
For pick-ups & trucks, mount the Control Box Assembly on or near a side fender
well in the engine compartment. For motorhomes, mount the Control Box Assembly
in a compartment or a convenient location, preferably away from water and dirt
spray. For models equipped with a regulator, connect the Regulator Assembly to
the Electric Control Valve.
Connect the braided or plastic hose coming from the Quick Release Valve, on the
Exhaust Valve Assembly, to the output side of the Regulator Assembly on the
Control Box Assembly using a silver female flared fitting. Connect the braided hose
or plastic tubing from the Valve Assembly to the tee fitting on the Control Box
Assembly, using an appropriate fitting supplied in the Application Kit.
Attach a wire from the ground screw on the Control Box Assembly, there should
be a wire running from the same screw to the Electric Air Valve, and ground wire to
battery or chassis.
Throttle Switch
NOTE: Not all kits come with a Throttle Switch, which in most cases, the brake
would be wired into the transmission.
Cummins Motorhomes & Trucks
The bracket and throttle switch mount on the inline injection pump, so that the silver
button on the throttle switch is activated when the throttle linkage/lever returns to its
resting/idle position. If throttle return spring(s) are weak, another spring may have
to be installed.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
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Motorhome with Cummins/Bosch inline fuel pump
NOTE: If you have an Allison MD3060 transmission, and have it programmed
for the exhaust brake option, do not install the throttle switch.
Caterpillar Air Throttle
On the air throttle cylinder attached to the throttle lever of the injection pump,
disconnect air line and reattach with tee fitting. Screw in supplied air pressure
switch.
Generic
The throttle switch assembly consists of an L-shaped bracket and a switch with a
long flexible arm. The switch is activated when the flexible arm is moved. Mount
the bracket and switch around the accelerator pedal, so that when the accelerator
comes back to the rest/idle position, the pedal arm presses against the flexible arm
of the switch.
Ford Pick-up (Non Powerstroke)
Loosen the two lower nuts holding the Accelerator Pedal Assembly to the
floorboard then slide the bracket, with two large grooves, all the way to the left under
the nuts and tighten.
Mount the throttle switch on the bracket with the silver button of the switch facing the
rod of the Accelerator Pedal so that the rod will contact the silver button when it is
in the rest/idle position.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
7
Ford Pick-up Powerstroke
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 the lower section of the 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 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 (TPS) at the throttle pedal and use a Posi-Tap
connector to attach the yellow wire from the DFIV module to the grey w/white tracer
wire (99-03 trucks) or the red w/gray tracer wire (94-97 trucks) onto 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 away from moving objects and heat sources.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
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
8
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
9
Dodge – 1994 to 1998
Place the Throttle Switch on the bracket as shown in diagram below using the two
bolts of the engine front cover located by the injection pump throttle linkage. With
the bracket mounted, loosen the screws for the throttle switch enough to adjust the
position and move it forward so that the silver button of the switch is fully depressed
when the linkage is in the rest/idle position. If the throttle return spring(s) are weak
another spring may have to be installed.
Note: 2001+ HO standard transmission vehicles will need to utilize a DFIV part
#1321039.
Dodge – 1998½ to 2002
Use the wiring diagram below as a reference to guide you with the installation of the
electronic DFIV (Dodge/Ford Idle Verifier) brake activation system.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
10
For 6spd manual transmission only
To obtain access to
the Cruise Control
wiring
harness,
remove the lower
steering
column
panel by removing
the mounting screws
and unsnapping the
panel
from
the
instrument panel.
Under
the
dash
running vertical by
the left of the
steering
column,
locate the smaller
wiring harness that
runs out of the main
harness.
Remove some of the black electrical tape to gain access to the smaller wire bundle.
***DANGER***
THERE IS A BLACK WIRE WITH A TWISTED LIGHT BLUE/GREEN TRACER DO
NOT CONNECT OR TEST THIS WIRE AS IT IS CONNECTED TO THE AIR BAG
AND THE BAG MAY DEPLOY CAUSING DAMAGE AND/OR INJURY.
Remove some of the black electrical tape from the small bundle to gain access to
the small Black wire with Light Blue tracer and install a gray Posi-Tap to it. Insert
the Blue wire from the DFIV module into this connector.
In this same wiring harness, locate the Red wire with Light Green tracer and install
another Gray Posi-Tap. Insert the Green wire from the DFIV module into this
connector.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
11
For all applications
Locate a grommet on the
firewall and cut an opening in it
to run the wiring through the
firewall.
Route the Yellow wire from the
DFIV module along the driver
side of the engine to the
throttle linkage and APPS
Sensor. Remove the cover of
the throttle linkage then locate
and disconnect the wiring
connector for the APPS.
NOTE:
This connector is
located on the underside of the
throttle linkage assembly and
is in a difficult position.
Open the loom and locate the
Light Blue w/Black wire and
install a Gray Posi-Tap to it.
Connect the Yellow wire from
the DFIV Module to this PosiTap and reconnect the APPS
connector then reinstall the
throttle linkage cover.
Dodge - 1988 to 1993
The Throttle Switch Bracket mounts behind the throttle linkage located on the driver
side, behind the injection pump. Mount the throttle switch on the bracket with the
switch on the outside of the bracket but do not fully tighten the screws. Secure the
throttle switch bracket to the engine using two bolts. If the throttle spring(s) are
weak, another spring may have to be installed.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
12
Chev/GMC 1994-Present
Below the throttle pedal you will need to remove the two nuts below the
potentiometer, holding the Accelerator Pedal Assembly to the floor board, and
mount the throttle switch bracket to the Accelerator Pedal Assembly with the two
screws so that the bracket angles off to the right. Mount the throttle switch on the
bracket, with the silver button of the switch facing the rod of the Accelerator Pedal,
so that the rod will hit the silver button when it is in its resting/idle position.
NOTE: 1993 and older Chev/GMC will use the Generic throttle switch.
On all applications
Manually move the linkage back and forth to ensure the proper activation of the
throttle switch. The throttle switch may have to be adjusted on occasion. Note:
With mechanical injection pump systems, the linkage is moved during cruise control
and/or fast idle operations, so the switch should not be activated during these
occurrences. Electronic throttles: advise driver that the brake should be
turned off during cruise control operations.
Cut a length of wire to go from the throttle switch to the Control Box Assembly.
Using a female bullet style electrical connector, connect the wire to the free wire
coming from Pressure Switch in the box, which has a male bullet style connector
on it. Route the wire over to the throttle switch, out of the way of moving parts, and
connect to the throttle 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
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
13
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.
DFIV Operation
Input
TPS/APPS
Ground
Description
Locate the TPS/APPS wire from the Accelerator
pedal position assembly. This wire should rise
linearly in voltage with the amount of throttle
depressed. Typical values range from 1.5 Volts
and rise to 3.5 Volts.
Connect to Vehicle electrical ground
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
Switch (12V)
Dodge
Common
Ford
Brake
14
This connection will supply 12 volt power to the
DFIV. This will usual come from an output of a
switch.
This input should only be used for Dodge
applications as it disables the cruise control
specifically for Dodge trucks.
Common cruise inputs between the Dodge and
Ford inputs. The second cruise wire should be
connected here.
This input can be used for other generic
applications. When the brake is activate the
connection between the Ford input and the
Common are severed.
This is the 12 Volt output of the DFIV. Once the
throttle has come to a rest at the idle position
and the switch is provide power and the pedal
adjustment is correct the DFIV will power the
brake.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
16
Power Switch & Optional Gauge
Mount the toggle switch (automatic transmissions) in a convenient location in the
dash, or mount the push/pull switch (manual transmissions) on the shifter lever,
using the switch clamp, and secure its cable on the lever. Locate a wire under the
dash, which is a 12v ignition switched source, and then connect the in-line fuse
connector to that wire with a line tapper.
Using a butt connector, attach a section wire to the in-line fuse holder and cut
enough length for the wire reach the toggle switch or push/pull switch cable, and
connect using appropriate electrical connector. Cut another piece of wire to go from
the switch/cable to the throttle switch.
On the toggle switch, there is a third terminal marked Amber, ground this terminal.
Run the wire and attach to the switches using appropriate connectors.
Attach and run black plastic tubing from the free compression fitting (no red
markings) on the tee fitting of the Control Box Assembly, to where the gauge is
going to be mounted. The kit comes with a bracket to mount the gauge under the
dash, but it could be mounted in any optional 2” gauge mount. Connect the black
plastic tubing to the back of the gauge using a 1/8npt female compression fitting.
Using electrical connectors, connect the wire coming from the light bulb holder to a
power source, preferable to one that is switched by the head light switch, and
connect a ground wire to the mount screws of the gauge. Mount the gauge 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 June 2007
BD Remote Mount Air Activated Exhaust Brake
17
Optional Shifter Switch
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 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: 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 June 2007
BD Remote Mount Air Activated Exhaust Brake
18
Cruise Disable Function
Chevy/GMC (1994-up)
For 1994-up Chevrolets you will
need to utilize the relay that is
provided in the kit to connect the
Cruise Control disable system.
On 1994-up Chevrolets, right
below the steering column, under
the dash, there is a wire
connector assembly with a large
amount of wires connected to it.
One of the purple wires leads up
to another 8-pin connector just
above it. You can verify the wire
by tapping the wire with a test
light and grounding the clip; with
the ignition turned on, the light should be on, but, no light when you press on the
brake pedal. Cut this wire and connect both ends (Dia. 9) to the Purple (or Blue)
wires coming from the supplied relay using un-insulated butt connectors and shrink
wrap.
Of the two remaining wires on the relay, the Yellow wire connects to the same
terminal on the Throttle Switch as the wire coming from the Toggle or Shifter switch.
Mount the relay under the dash and ground the Black wire.
Ford
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), then strip both ends and attach a male
bullet connector on one end and a female bullet connector on the other. (NOTE: It
does not matter which wire the male or female connector goes on.)
Run the Green and Blue wires that were brought through the firewall to the Brake
Applied Switch at the brake booster and cut off any excess.
Attach a male bullet connector to one of these wires and attach a female bullet
connector to the other wire. Connect these to the connectors just attached to the
Black wire w/Yellow tracer.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
20
Exhaust Brake Testing
Turn the ignition to the first position and turn the power switch on to make sure the
brake activates. If the brake does not activate or operates very slow, start the
vehicle and try the operation again (Low air pressure will result in lack of operation
while vehicle is turned off).
Depress the throttle pedal and let up on it to check the operation of the throttle
switch, allowing the brake to engage when the throttle is in the resting/idle position.
The brake pressure at idle may have to be adjusted to accommodate your system.
If a Brake Pressure gauge is installed check the rating of the Pressure Switch on
the Control Box Assembly, the tag will have a pressure value or it may even be
written in red paint on the tee fitting. If it is below 40 psi, adjust the pressure
regulator on the Pump Assembly so that the pressure reads between 4-6 lbs at
idle.
For ratings of 40 - 50 psi, then adjust for 6-10 lbs at idle. And pressure ratings
above 50 psi, adjust for 10-15 psi at idle. 3208 Cat applications can only be set on
the road; pressure should be 0 psi at idle, 28 psi in 3rd gear at 2500 rpm, and 20 psi
at 2200 rpm. This idle pressure adjustment can be made by adjusting the stop bolt
mounted on the exhaust brake support bracket. Loosen the stop nut and turn the
bolt clockwise for less pressure and counter-clockwise for more idle pressure. Be
sure to tighten the stop bolt once your adjustments are done.
Note that brake’s warranty will be voided if it is found that the exhaust valve comes
in contact with valve casting. To avoid this be sure the stop bolts is infact providing
a limit for the valve.
Maintenance
The brake valve requires periodic maintenance to free up the flap and remove
carbon build up or rusting due to condensation in the exhaust, as well as adjustment
of linkages. To prevent premature service or seizing of the valve, we suggest
continual use of the brake or refrain from extended periods of non-usage. With
condensation build up or dirt in the air lines, the electric air valve may have to be
taken apart to be cleaned. The backpressure line will require blowing out (from
Control Valve to Brake Valve) once or twice a year.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
Trouble Shooting
If problem occurs with operation of unit, then consult list below.
Complaint
Cause
Brake slow to operate Low or no air pressure
Delayed release Hose too long
Brake valve cycles
Valve pressure set too high
excessively
Braking performance Valve set too low or drive
not effective train problem
Check/Correction
Check air source.
Clean electric air valve.
Ensure hose is 4ft or shorter in
length
Adjust valve to open more, with
lower brake pressure at idle.
Check effect in lower gear.
Check automatic trans stall speed.
Adjust valve to close more for
increased pressure at idle.
Brake quit operating Electrical problem
Check fuse at in-line fuse holder.
Check function of throttle switch.
Check power at connections
between line-tap and Control Box.
Gauge not reading, but
Plugged pressure line
brake working
Disconnect pressure line from
Control Box and blow compressed
air through pressure line.
Brake valve seized Valve needs service
Service valve.
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
21
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
22
If a problem still occurs, then please call our BD Technical Department Monday to
Friday, 8:00am to 4:30pm Pacific Time at 1-800-887-5030 or (604) 853-6096. Or
we can be reached by fax at (604) 853-8749.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
23
Cummins 5.9L Turbo Mount Exhaust Brake Addendum
For installation of Turbo Mount valve, hold valve with adapter pipe up to turbo to
estimate where to cut stock exhaust, keeping in mind that the adapter pipe will slide
into the stock exhaust pipe. Remove and retain the turbo exhaust clamp securing
the exhaust pipe to the turbo. Cut the exhaust at the estimated spot. Securely bolt
the adapter pipe to the Turbo Mount valve and push adapter pipe into stock
exhaust.
Inspect turbo exhaust clamp and turbo outlet for any carbon build up or damage that
may cause problems sealing on exhaust mating surfaces. Install Turbo Mount valve
onto turbo outlet using the stock turbo clamp, and then seal clamp (or weld) the
adapter pipe and the stock exhaust together.
All other instructions in this manual will remain in effect for this installation.
THIS KIT MAY ALSO REQUIRE THE ADAPTER #1040037 ON SOME 1999 AND
UP MODEL MOTORHOMES.
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
24
Additional Wiring Instructions (Ford Powerstroke)
Take off the lower panel below the steering column. Mount the relays and ground
the wires from terminal # 85 on both relays to the steel cross brace.
On the Throttle Pedal Assembly, there is an Idle Position Verification Switch (with
two wires connected) that is pressed in when the Throttle Pedal is at rest/idle. Strip
away approximately 1 (one) inch of the tape/covering around the two wires going to
the switch.
Attach the Red wire, coming from the two relays, to the Red wire with Gray tracer
(R/G) on the Idle Verification Switch using a line tapper. The wire that needs to be
tapped will have 12 volts on it when the throttle pedal is pushed down.
For the Powerstroke’s that have Cruise Control, locate the Brake Applied Switch on
top of the Hydraulic Brake Master Cylinder. Expose the two wires, about 3 to 6
inches from the switch, and cut the Black wire with Yellow tracer (BK/Y) and strip
both ends. Attach a male bullet connector to one end and a female bullet connector
to the other.
NOTE: It does not matter which end the male or female connector goes on. Run the
two long Black wires from the relays, through the firewall, to the wires you just
attached the bullet connectors to.
Using a line tapper, connect the fused wire from the Toggle Switch to one of the
Red wires with Black tracer (R/B) that are in the group of wires under the steering
column. Ground the Black wire coming from the Toggle 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
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
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
25
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
Caterpillar 3116/3126/3126B
Vehicles WITHOUT an Allison WT transmission WITHOUT ABS braking WITH an on-board air system
NOTE:
• *View shown is looking at the harness side of the connector.
• Relay shown is de-energized.
• Information from this schematic was derived from vehicle systems at the date of this printing.
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
26
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
27
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 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 your vehicle’s chassis brake system, even to the point of “burn-up”. These
guidelines were designed to offer you a better understanding of the benefits of
exhaust brakes and are partly based upon material developed by the U.S.
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 chassis brakes. A
tool that with maximum or even occasional use can reduce wear on chassis brake
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 at such times as turns or exit
ramps, without you using your chassis brakes. But, the exhaust brake cannot be
used as a parking brake or will not bring your vehicle to a complete stop.
By using a BD Exhaust Brake, the life and effectiveness of your chassis brakes will
increase. This is because of the decreased use of the chassis brakes in situations
like hills, the wear factor is reduced and there is less opportunity for your chassis
brakes to heat up which would reduce the efficiency.
When you ride your chassis 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 fade or failure. With terrain that is a series of up and down
grades, the BD Exhaust Brake will aid in reducing exhaust valve warping. Because
of the power needed to pull your vehicle and load up a hill, a lot of heat is
generated. When you have reached the crest of the hill and are now coasting down
the other side, the heated valves are cooled too quickly. With the exhaust brake
engaged, the heat loss to the valves will be reduced, which can prevent valve
warping.
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 micro-switch is deactivated and the valve opens
again. Exhaust brakes are designed to operate with the throttle at idle, not to be
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
28
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.
On the BD Exhaust Brake, there is a Pressure Switch installed to monitor the
created back pressure. If the back pressure reaches the set limit, the switch cuts
power to the system until the back pressure comes back down below the limit. The
pressure switches are set for each engine type, and are not adjustable. If you have
purchased a system that is rated for the stock engine exhaust valve springs, and
you later decide to update to the heavy duty exhaust valve springs, you will have to
replace the Pressure Switch to achieve the 60 lb. capacity.
Never install a 60 lb. system on an engine that has not had the heavy duty
engine exhaust valve springs installed first.
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 chassis 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.
The BD Exhaust Brake was not designed for use in overdrive, so when braking is
required, make sure the overdrive is off.
So, in summary, by using the BD Exhaust Brake, you reduce the need for use of
your chassis brakes in situations where you need to slow down or maintain speed
(i.e. hills, off ramps, corners, approaching speed changes or traffic lights). By
reducing the use of your chassis brakes in these situations, this reduces the heat
build up, as well as wear and damage to linings and drums. And, when you reduce
these factors, you save your chassis brakes for when you really need them (i.e. for
stopping or emergencies).
The BD Exhaust Brake is not a substitute for your chassis 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 and over speed condition.
To increase the life of your exhaust brake we recommend daily operation. This
could simply be switching it on and off a couple times a day. This will prevent the
butterfly from sticking due to carboning up. Pressure tubing from Valve Assembly to
Pressure Switch should be blown out with pressurized air on occasion (see
Maintenance & Trouble Shooting).
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 June 2007
BD Remote Mount Air Activated Exhaust Brake
OPTIONS
Description
BD Performance Torque Convertor
60lb. Exhuast Valve Spring Kit
Performance Injectors
Brake Pressure Gauge Kit (Dodge)
Brake Pressure Gauge Kit (Ford)
Brake Pressure Gauge Kit (Chevy)
Exhaust Temperature Gauge
Cockpit Gauge Mount (Single)
Part Number#
CALL
1030060
CALL
1030550
1030551
1030552
1030512
1030600
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
12 June 2007
BD Remote Mount Air Activated Exhaust Brake
30
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 two (2) years from the date of sale. 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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