electronic positive air shutoff

electronic positive air shutoff
12 January 2015
103675X – Electronic positive air shutdown (I-00336)
ELECTRONIC POSITIVE AIR SHUTOFF
1036750
1036751
1036754
1036755
1036758
1036759
2007-2009 Dodge 6.7L
2010-2015 Dodge 6.7L
2008-2010 Ford 6.4L
2011-2014 Ford 6.7L
2008-2010 GMC 6.6L
2011-2015 GMC 6.6L
PLEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION
U
An Information decal has been provided in this kit. This may
allow safety personal and inspector’s to quickly identify that
your vehicle is equipped with a BD Positive Air Shut Down
unit. Install this decal in a visible location on the inside
glass of the vehicle.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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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12 January 2015
2
103675X – Electronic positive air shutdown (I-00336)
K I T
C O N T E N T S :
Please check to make sure that you have all the parts listed in this kit before you start
the disassembly of your truck.
103675X Kit Contents
1306730
1302380
Electronic Module
Qty: 1
Switch Harness
Qty: 1
1302251
1306790
1302250-RG
1800060
Switch Decal
Qty: 1
Switch Guard Decal
Qty: 1
Switch Guard
Qty: 1
Velcro strips
Qty: 2 x 4”
1300131
1006701
Cable Tie
Qty: 12
Window Decal
Qty: 1
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
3
103675X – Electronic positive air shutdown (I-00336)
1036750
1036751
1302381
1302382
Dodge 2007-09 6.7L Harness
Qty: 1
Dodge 2010-15 6.7L Harness
Qty: 1
1036754
1036755
1302388
1302389
IN DEVLOPMENT
Ford 2008-10 6.4L Harness
Qty: 1
Ford 2011-14 6.7L Harness
Qty: 1
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
4
103675X – Electronic positive air shutdown (I-00336)
1036758
1036759
1302385
1302386
GM 2008-10 6.6L Harness
Qty: 1
GM 2011-15 6.6L Harness
Qty: 1
Introduction
Most late model diesel engines incorporate an electronic throttle body into the intake
manifold to partially restrict intake air to aid in EGR function and meet ever increasing
emission standards. When controlled correctly, this valve can completely shut off the
outside air supply to stop the engine. The BD Electronic Positive Air Shutdown kit
connects to this valve to shut the engine down in emergency situations.
The BD Electronic PAS will automatically shut off the engine if it exceeds a preset engine
RPM or if toggled manually with the supplied switch. The BD module also has an
automatic reset feature which will reopen the valve once the engine has stopped. No
longer does the operator need to open the hood to reset the valve after a system test.
The BD Electronic PAS is easier to install than previous PAS products as it is completely
plug and play with existing parts on the vehicle.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
5
103675X – Electronic positive air shutdown (I-00336)
Before you start
Ensure the intake valve on the vehicle will connect to the harness supplied with your kit,
the connector may be different based on the year of manufacture of the vehicle and care
must be taken to ensure the correct kit is ordered.
Required tools




Drill
1/8” Drill Bit
1/2” Unibit
Battery Terminal Wrench
TABLE OF CONTENTS
Before you start ................................................................................................................ 5
Required tools .................................................................................................................. 5
Installation ........................................................................................................................ 5
Intake valve locations ....................................................................................................... 6
Crankshaft position sensor locations ................................................................................ 9
Electronic PAS system operation .................................................................................... 17
Troubleshooting .............................................................................................................. 18
Circuit board switch and LED functions........................................................................... 20
Wiring diagram ............................................................................................................... 21
Installation
VEHCILE SHOULD
INSTALLATION.
BE
SAFELY
SECURED
BEFORE
1. Locate the intake air valve on the motor and connect the supplied BD PAS wiring
harness inline by connecting the BD harness directly to the valve and to the vehicles
original electrical connector.
NOTE: If the vehicle has been re-tuned to no longer utilize the intake air valve and it is
currently disconnected, connect the BD harness only to the intake valve and leave the
OE connector disconnected.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
Intake valve locations
2007-2015 Dodge 6.7
Intake horn, pointing downwards on the driver side of the engine. The electrical
connector is on the bottom of the valve. 2007-2009 have a 4 pin gray connector; 20102015 have a 5 pin black connector.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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
6
12 January 2015
103675X – Electronic positive air shutdown (I-00336)
2008-2010 GMC 6.6
Passenger side of engine,
between the air box and the
alternator. The electrical
connector is on the bottom of
the valve.
2011-2015 GMC 6.6
Passenger top side of engine.
The electrical connector faces
the front of the vehicle.
NOTE: The red connector lock
tab must be engaged or
connector may come apart.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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
7
12 January 2015
103675X – Electronic positive air shutdown (I-00336)
2008-2010 Ford 6.4
Front top of engine, behind the
radiator fan shroud. The
electrical connector is located
on the back side of the valve.
2011-2014 Ford 6.7
Front top of engine, behind
the radiator fan shroud. The
light brown electrical
connector is located on the
bottom front side of the
valve.
TIP: Removing the plastic
charge air tube from the
valve makes for easier
access to the valves
electrical connector.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
9
2. Locate engine crankshaft position sensor on the motor. Connect the supplied BD PAS
wiring harness inline so that the BD harness connects to the crankshaft position
sensor and to the vehicles original wiring.
Crankshaft position sensor locations
2007-2015 Dodge 6.7
Driver side of engine just behind crankshaft drive belt pulley.
(Do not mistake for the camshaft position sensor located above)
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
10
2008-2015 GMC 6.6
Passenger side of engine beside crankshaft drive belt pulley.
(Do not mistake for the camshaft position sensor located beside the water pump pulley)
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
11
2008-2010 Ford 6.4
Passenger side of engine, bottom front. To gain better access, remove the bolt securing
the passenger side of the upper steering stabilizer shock absorber and swing out of the
way. A long handled screw driver or similar tool can help push the connector off once
released.
(Do not mistake for the camshaft position sensor on the opposite side of the block).
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
2011-2014 Ford 6.7
Driver side of engine block in
transmission to engine adapter
flange. Remove rubber plug
from access hole to reach the
electrical connector behind it.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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
12 January 2015
103675X – Electronic positive air shutdown (I-00336)
13
3. Remove the toggle switch from the supplied switch harness. Route the end of
the switch wiring harness from within the engine bay, through the driver’s side
of the firewall to below the dashboard. Suggested pass through location is
through a slit in the existing grommet for the engine to instrument panel wiring
harness, otherwise a new hole may be drilled and a new grommet installed if
necessary.
4. Route the battery connection ring terminals to the driver side battery. Connect
BLACK wire ring terminal to the driver side battery negative or to body ground if
desired. Leave the RED positive wire disconnected until end of installation.
5. Locate suitable location for BD PAS module so that it will reach both wiring
harnesses. Attach it with supplied adhesive hook and loop tape or wire ties.
Suggested mounting location is on top of the plastic fuse box cover on the
driver side of the engine bay. If using hook and loop tape, thoroughly clean the
mounting surface for good adhesion.
2007-2015 Dodge
Driver side front corner fuse box
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
2008-2015 GMC
Fuse box on driver side of the engine bay
2008-2014 Ford
Driver side rear of the engine bay behind or beside the coolant bottle
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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
14
12 January 2015
103675X – Electronic positive air shutdown (I-00336)
15
6. Carefully secure all wiring within the engine bay with supplied wire ties to that it is
away from moving parts, chafe hazards and heat sources. Use extra care with the
crankshaft position sensor wiring due to the close proximity to belts, fans and road
debris and potential consequences of a short or break in this wire.
7. Inside the cab, reconnect the toggle switch to the switch wiring harness in the same
way they were removed. See below for reference. Double check the connections here
as wiring the toggle switch incorrectly may damage the module.
8. Locate suitable spot to mount switch on the dashboard within reach of the driver and
in a highly visible location. Ensure there is sufficient space behind the dash to mount
the switch. Drill a 1/8” pilot hole, then using a stepper bit (unibit) drill a 1/2” hole in the
dashboard. Install switch with the groove in the thread boss facing down. Install with
either the supplied switch decal or with the supplied switch guard and apply decal to
the switch guard. Secure wire below the dashboard using supplied wire ties.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
Switch decal
9.
10.
16
Switch Guard with decal applied.
Connect RED positive feed wire to the battery.
Test and verify system functionality.
Manual Activation Test: With the engine running at idle, momentarily toggle the PAS
switch on the dashboard. The engine should stop within a few seconds. Wait at least 10
seconds before restart.
Automatic Activation Test: With engine not running, remove the cover from the module to
access the circuit board. Keep away from metal objects that may cause a short circuit.
Set the bottom switch to “1500 RPM TEST” mode. This will cause the module to shut the
engine down if it exceeds 1500 RPM. Start the vehicle and slowly accelerate the engine,
verify that it shuts down over 1500 RPM. Wait at least 10 seconds before restart.
NOTE: The BD E-PAS module is connected to constant battery power unless the
harness fuse is removed. Use care when opening module to avoid short circuiting it
against metal objects in engine bay.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
17
11. Set the operation mode switch on the circuit board back to AUTOMATIC and Set
the automatic RPM shutdown speed on the module according to the engine it is
installed with. This must be above the normal engine redline to avoid accidentally
setting it off during driving. Reinstall module cover and re-secure module.
Year/Make
2008-2015 Dodge 6.7L
2008-2015 GM 6.6
2008-2010 Ford 6.4L
2011-2014 Ford 6.7L
RPM
4200 RPM
4600 RPM
5000 RPM
4600 RPM
Electronic PAS system operation
The BD Electronic PAS module constantly keeps track of engine speed and will
automatically stop the engine if it exceeds the preset maximum RPM. The air valve can
be shut at any time even if the engine is not running by toggling the switch on the dash
manually.
When the engine is off, the BD E-PAS module will go into a low power consumption state
and the toggle switch on the dash will not be lit. Once the engine is started, the module
will automatically begin monitoring engine RPM and the toggle switch on the dash will
light up to show the system is ready.
If the system is triggered automatically or manually by the switch, the intake air valve will
close and remain closed until the engine RPM has dropped to zero and for an additional
5 seconds afterward. During this time the toggle switch will flash to indicate a closed
valve position. DO NOT ATTEMPT TO RESTART ENGINE WHILE VALVE IS CLOSED.
The valve will automatically reset itself to the open position and the toggle switch light will
turn off once shutdown process is complete.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
18
Troubleshooting
Valve does
not close by
manual toggle
switch
activation
No power to module. Check fuse at battery. If fuse is blown,
inspect harnesses for short circuits or other problems.
Remove cover from module and check that the POWER
lamp is flashing every two seconds with engine off indicating
it is powered and in standby.
Incorrect switch wiring. Carefully check the toggle switch wire
connection is correct, incorrect connection may damage the
module.
Intake air valve connectors not fully seated. An audible click
should be heard when the connector is fully mated together.
Tug on connector to ensure it does not come apart.
Valve closes
by manual
toggle, not
automatically
Incorrect module mode setting. If conducting low speed
system test, verify that the lower switch on the module circuit
board is set to the middle position, “1500 RPM TEST”. For
normal automatic operation, the switch should be fully
counter clockwise, “AUTOMATIC” and RPM selector switch
is set to the correct speed.
Harness connected to camshaft position sensor rather than
crankshaft position sensor. Verify against pictures in
installation section of this manual.
No RPM signal to module. Open module cover and start
engine. Verify that RPM light is flashing when engine is
running and POWER light is on solid. If it is not on or is
intermittent, carefully check blue wire from the modules black
connector (pin 7) to the crankshaft position sensor is not
severed.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
103675X – Electronic positive air shutdown (I-00336)
19
Code set during installation. If the ignition switch was on or
ECM had not powered down during installation, fault codes
may be set by disconnecting air valve. Clear codes and
recheck.
Engine light
on / fault
codes set
Intake air valve connectors not fully seated. An audible click
should be heard when the connector is fully mated together.
Tug on connector to ensure it does not come apart.
Black connector disconnected from BD E-PAS module. If the
module is not currently being used, the black connector must
still be plugged into the module or the valve connected back
to stock configuration.
Connectors not mated. Inspect crankshaft position sensor
connector is correctly installed; an audible click should be
heard when connected. Tug on connectors to verify they are
correctly mated.
Engine does
not start
Shorted crankshaft position sensor wire. Inspect the blue
wire from the modules black connector (pin 7) to the
crankshaft position sensor; if this wire is chaffed or broken it
may short out the crankshaft position sensor signal.
Intake air valve jammed shut or defective. Toggle the system
manually while listening for valve movement. If suspect,
remove the intake air tube from the valve and visually verify
the intake air flap is not closed.
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
20
103675X – Electronic positive air shutdown (I-00336)
Circuit board switch and LED functions
Maximum engine
RPM for automatic
mode
Operation Mode:
Automatic, test or
manual only.
Power light on
when engine
running. Flashes
every 2 seconds
when in standby.
RPM light flashes
when the engine
is running.
Active light on
when the valve is
controlled by the
module.
If you have any technical difficulties, concerns, comments, or complaints,
please phone our Technical Support hotline at (800) 887-5030 between
8:30am-5:00pm PST (Pacific Standard Time) Monday to Friday
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
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 January 2015
94-02 Dodge 2wd Steering Box Support (SBS)
Wiring diagram
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
21
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