BD Diesel 1033115 Exhaust Brake Installation Instructions

BD Diesel 1033115 Exhaust Brake Installation Instructions
11 July 2005
BD Universal Remote Mount Vacuum Brake
1
BD Remote Mount Vacuum Exhaust Brake
I n s t a l l a t i o n
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Covering BD Part
Numbers#:
(Application Diagram
inside manual)
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M a n u a l
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1034133 / 1037135 / 1033115 /
1037115 / 1033141 / 1037142 /
1037143 / 1037144
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 # I1037135
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
2
TABLE OF CONTENTS
Welcome ................................................................................................... 3
Application List .......................................................................................... 3
Options ...................................................................................................... 3
Valve Assembly Installation....................................................................... 4
Control Valve Assembly ............................................................................ 5
Throttle Switch Installation ........................................................................ 6
Ford Pick-up 1983-94 (Non-PowerStroke)........................................ 6
Ford PowerStrokes (1994-2000)............................................... 7
DFIV Wiring Diagram ........................................................ 7
Chevrolet/GMC (1994-2000) 6.5L Trucks ......................................... 8
Chevrolet/GMC (1982-93) 6.2/6.5L and Generic Applications.......... 8
Dodge................................................................................................ 8
1988-1993 ................................................................................. 8
1994 to 1998 12V...................................................................... 8
1998 to 2002 24V...................................................................... 9
Dodge DFIV Wiring Diagram (1998½ - 2002)................. 10
On all throttle switch applications (except PowerStrokes): ............. 10
DFIV Calibration ...................................................................................... 11
Power and Toggle Switch........................................................................ 11
Cruise Control Disable ............................................................................ 12
Chevrolet/GMC Cruise Control Disable .......................................... 12
Ford Powerstroke............................................................................ 12
Dodge Cruise Disable ..................................................................... 13
Exhaust Brake Routing Diagram ............................................................. 14
Optional Manual Shifter (Push-Pull Style) ............................................... 15
Optional Brake Pressure Gauge ............................................................. 15
Testing..................................................................................................... 15
Maintenance & Trouble Shooting ............................................................ 16
Operating Guidelines............................................................................... 17
LIMITED WARRANTY STATEMENT...................................................... 20
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
3
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.
Application List
Part Number
1034133
1037135
1033115
1037115
1033141
1037142
1037144
1037143
Application
Year Range
Exhaust Size
Dodge Cummins
1989-1993
3.0”
Dodge Cummins
1994-2002
3.5”
Chevy/GMC 6.5L
1994-2000
3.0”
Chevy/GMC 6.5L
1994-2000
4.0”
Ford 6.9L/7.3L IDI
1983-1994
3.0”
Ford 6.9L/7.3L IDI
1983-1994
3.5”
Ford 7.3L Powerstroke
1994-2003
4.0”
Ford 7.3L Powerstroke Van
1994-2003
3.5”
Options
Description
Manual Transmission Shifter Switch Kit
Brake Pressure Gauge Kit
Pyrometer Gauge Kit
Boost Pressure Gauge Kit (30 lb.)
Cockpit Gauge Mount (Single)
Molded Gauge Clusters (2 & 3 gauges)
Performance Torque Convertor
Part #
1300210
CALL
1030512
1030570
1030600
CALL
CALL
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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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, flex pipe is okay after the valve. 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.
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.
Mount the exhaust valve assembly using the two supplied V-clamps, with the
vacuum cylinder pointing away from the engine, and tighten the nuts and bolts.
NOTE: The arrow on the Exhaust Valve casting indicates exhaust flow, which
should be pointed towards the rear of the vehicle (Figure 1).
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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Control Valve Assembly
The control valve assembly has two hoses
attached to it. Push the shorter piece onto
the barbed fitting on the front cap of the
vacuum cylinder on the exhaust valve
assembly (see Diagram 1) and push the
longer piece onto the barb fitting on the
back cap (Red).
With the hoses now attached, locate or
drill a new hole on the inner frame rail to
mount the control valve assembly within
reach of the hoses.
Existing holes or new holes will have to be drilled out to 5/16”. Mount the control
valve assembly to the frame using the long bolt, spacer and nut provided (Dia. 2). A
good ground must be made when bolting bracket to frame rail.
Advise the driver not to operate the exhaust brake if the vehicle is driven through
large amounts of water, as the water can be sucked through the venting filter, which
would reach the control valve assembly.
On the free 3/8” barbed fitting on the Control Valve Assembly, push one end of the
long piece of hose supplied in the kit. Connect the long piece of 1/4" plastic tubing
(supplied in kit) to the free compression fitting next to the 3/8" barbed fitting you just
pushed the hose onto. At the other end of the plastic tubing, screw in the supplied
brass filter fitting so that it is snug and secure. Uncoil the long wire attached to the
control valve, insert the wire into the loom and push it up to the control valve. Run
the wire, tubing and hose along the frame rail and up into the engine compartment,
securing with tie wraps and keeping them clear of moving or heated parts.
NOTE: The end of the plastic tubing w/brass filter will not be connected to anything.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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NOTE: If the vehicle has a vacuum assisted hydraulic brake booster or the vacuum
pump is located on the driver side, then run the hose and wire along a cross
member and up the driver’s side frame rail.
In the engine compartment, locate the hose coming from the vacuum pump on the
engine or to the vacuum assisted hydraulic Brake Booster. (On newer Chevrolets,
the Air Conditioner Pump will have to be unbolted from its bracket and pushed off to
one side.) Push the plastic tee (supplied in Application Kit) onto the hose coming
from the Control Valve Assembly, and run hose to Vacuum Pump or Brake Booster.
Cut the outlet hose of the vacuum pump or brake booster, no closer than 1” from the
outlet fitting. Push both ends of the hose onto the plastic tee. Secure the hose with
tie wraps and keep it clear of moving or heated parts.
Throttle Switch Installation
Ford Pick-up 1983-94 (Non-PowerStroke)
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. Loosen the two lower nuts holding the Accelerator Pedal
Assembly to the floorboard, slide the bracket all the way left under the nuts, using
the two large groves, and tighten (Dia. 3).
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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Ford PowerStrokes (1994-2000)
DFIV 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 vehicles ECU and/or installed components may result.
NOTE: If the vehicle does not have Cruise Control, remove the green and blue wire
from the install and discard.
Remove the lower section of the drivers side dash, under the steering column, and
mount the DFIV module to the cross member. Connect the black wire from the DFIV
module to a good ground.
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). Connect the
fused red wire from the toggle switch to this Posi-Tap and mount the switch in a
convenient spot on the dash.
Locate the Throttle Position Sensor (TPS) at the throttle pedal. Use a Posi-Tap
connector to attach the yellow wire from the DFIV module to the grey w/white tracer
wire (1999-2003 trucks) or the red wire w/gray tracer wire (1994-1997 trucks) to 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.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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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. Go to page 11
and follow the instructions to calibrate the DFIV module.
Chevrolet/GMC (1994-2000) 6.5L Trucks
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. (Similar to Dia. 3)
Chevrolet/GMC (1982-93) 6.2/6.5L and Generic Applications
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 it’s resting/idle position, the pedal arm presses against the flexible
arm of the switch.
Dodge
1988-1993
The Throttle Switch Bracket mounts behind
the throttle linkage using the two bolts
used for mounting the throttle linkage to
the engine (Diagram 6). On all years, if
throttle return spring(s) are weak, another
spring may have to be installed.
1994 to 1998 12V
Place the Throttle Switch on the bracket by
using the two bolts of the engine front cover by
the injection pump throttle linkage (Diagram 5).
Every time the throttle is released the linkage
should actuation the micro switch by slightly
touching it.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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1998 to 2002 24V
These models of Cummins trucks have been upgraded to use the DFIV
(Dodge/Ford Idle Verifier) system. This system electronically senses the throttle
position via the APPS (Accelerator Pedal Position Sensor) output circuit.
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!
***DANGER***
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.
Go to page 11 for the DFIV calibration instructions.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
10
Dodge DFIV Wiring Diagram (1998½ - 2002)
On all throttle switch applications (except PowerStrokes):
Manually move the linkage back and forth to make sure the proper activation to the
throttle switch is occurring. 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 brake will not be activated during these
occurrences.
Run the wire coming from the Control Valve Assembly though the fire wall (except
Dodge and Cummins Trucks & Motorhomes) and to the Throttle Switch; using an
electrical connector, hook up wire to the top screw on switch, or on Ford
PowerStrokes, free terminal (#87a) on relay.
For Dodge and Cummins Trucks & Motorhomes, run wire over to Throttle Switch,
cut wire and connect to the top terminal with an electrical connector.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
11
DFIV Calibration
-- For 1999-2002 Ford Powerstrokes and 1998-2002 Dodge Cummins model trucks.
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.
Power and Toggle Switch
Mount the toggle switch in a convenient
and secure location on the dash. Locate a
12v ignition switched source (fuse panel or
wire), then connect the in-line fuse holder to
the source line or use the fuse tapper
(Diagram 7).
This power line should be connected to the
middle terminal of the toggle switch.
Ground the black wire from the upper
switch terminal marked amber. Connect
the lower switch output terminal to the
middle position on the micro switch
mounted to throttle. Connect the reaming
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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terminal on the micro switch to the exhaust brake control valve you mounted earlier.
Route this wire away from any heat sources or moving parts.
For Powerstroke applications the toggle switch and the manual shifter switch should
control power to the DFIV. When the brake is engaged 12V should be provide to
the switched input of the DFIV. See previous drawing.
Cruise Control Disable
Chevrolet/GMC Cruise Control Disable
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 illuminated, but no light when you press on the brake pedal. Cut
this wire and connect both ends (see Diagram 9) to the purple (or blue) wires
coming from the supplied relay using non-insulated butt connectors and shrink wrap.
The yellow wire from the relay connects to the same terminal on the Throttle Switch
as the wire coming from the toggle/shifter switch. Mount the relay under the dash
and ground the Black wire.
Ford Powerstroke
Locate the black w/yellow tracer wire at the cruise control disable (Brake Applied)
switch located on the brake master cylinder and expose the wiring approximately 46 inches from the switch to allow for a good length to work with. This wire may be a
different color in various applications. If there is no black w/yellow wire going to this
switch, then use a test light to check which wire changes state (power to no power)
when the brake pedal is applied.
Cut the black w/yellow tracer wire (BK/Y), then strip both ends and attach a
separate blue Posi-Lock connector on each end of the cut wire. Run the green and
blue wires that were brought through the firewall to the Brake Applied Switch at the
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
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brake booster and cut off any excess. Attach these wires to the two blue Posi-Lock
connectors that you have just installed to the Black wire w/Yellow tracer.
Dodge Cruise Disable
You will only need to disable cruise control on 2001+ 245HO standard transmission
trucks. Please order part #1321039 (DFIV Application 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
11 July 2005
BD Universal Remote Mount Vacuum Brake
Exhaust Brake Routing 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
14
11 July 2005
BD Universal Remote Mount Vacuum Brake
15
Optional Manual Shifter (Push-Pull Style)
Mount the push/pull switch on the shifter lever
(Diagram 10), using the switch clamp, and
secure the cable on to the lever.
NOTE: Keep cable away from spots where it
could get pinched during shifting. Strip the
ends of the wires and attach male blade
connectors to each.
Slip off the Red wire from Toggle Switch and
attach to Black wire of Manual Shifter Switch
cable, and, slip off the Yellow wire from Toggle
Switch and attach to White wire of cable. Discard Toggle Switch and its black wire.
Attach the Yellow wire to the middle terminal of Throttle pedal Switch or the 12V
Switched input of the DFIV.
Optional Brake Pressure Gauge
For the optional Brake Pressure Gauge, push tubing through firewall. 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 switch by the head light
switch, and connect a ground wire to the mount screws of the gauge. Mount the
gauge in the desired location.
Testing
Start up the engine and turn the toggle switch on to make sure the brake activates.
Depress the throttle pedal and let up on it to check that operation of the throttle
switch, allowing the brake to engage when the throttle is in the resting/idle position.
Using a standard pressure gauge, follow the list below for proper setting, with the
engine running at idle and brake turned on.
Vehicle
Lbs.
Pressure @ Idle
Chevy 6.2/6.5L & Ford 6.9/7.3L 32lbs. 8-10 lbs.
Ford Powerstroke & Dodge Cummins 40lbs. 10-12 lbs.
Dodge Cummins w/ 60lb. exhaust springs 60lbs. 18-20 lbs.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
16
If the brake pressure does not fall within these limits, please call the BD
Engine Brake technical hotline at (800) 887-5030.
Be sure to test the cruise control disconnect system while test-driving the 1994 and
newer Ford PowerStrokes and Chevrolet 6.5L engines. Set the cruise at a safe
speed and then turn the exhaust brake on, which should turn the Cruise Control off
right away.
If the cruise control does not disengage right away, then turn the exhaust brake off
immediately.
If the cruise control did disengage, then turn the exhaust brake off and hit the
resume function on the cruise control switch to see if the cruise will re-engage.
Maintenance & Trouble Shooting
To prevent premature service or seizing of the valve, we suggest continual use of
the brake and to restrain from extended periods of non-usage. If problems do occur
with operation of the unit, then consult the following list and the diagrams on the
previous pages for the most common problems.
Complaint
Braking Performance
not effective
Brake quit operating
Gauge not reading, but
brake working
Cause
Check/Correction
Valve set too low or drive
train problem
Check effect in lower gear.
Check auto trans stall
speed. Adjust valve to
close more to increase
pressure at idle.
Electrical or Vacuum
problem
Check fused at in-line fuse
holder.
Check throttle
switch
for
activation.
Check
power
at
connections between line
tap and Control Valve.
Check vacuum pump and
hose.
Plugged pressure line
Disconnect pressure line
from gauge and blow air
through pressure line.
If problems still occur, then please call our BD Technical Department Monday to
Friday, 8:00am to 5:00pm Pacific Standard Time (PST) at (800) 887-5030, or we
can be reached by fax at (604) 853-8749.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
17
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 your vehicles chassis’s braking system, even to the point of “burnup”. 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 for
increasing the driveline drag of the vehicle without the use of the chassis’s brakes.
A tool, which with maximum or even occasional use can reduce wear on chassis’
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 chassis’s 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’s brakes will
increase. This is because of the decreased use of the chassis’s brakes in situations
like hills, the wear factor is reduced and there is less opportunity for your chassis’s
brakes to heat up which would reduce the efficiency.
When you ride your chassis’s 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 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 throttle switch is deactivated and the valve opens
again.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
18
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.
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.
For Ford IDI and Chevy vehicles adjust the brake pressure to
8-10lb at idle; and Ford PowerStrokes, adjust to 10-12lb at idle.
On Dodge 6BTA (1989-98) with the stock exhaust valve springs, adjust the idle
pressure to 10-12lb at idle, and if the heavy duty valve springs have been installed,
adjust idle pressure to 18-20lb at idle. Dodge ISB (1998-up), adjust idle pressure to
18-20lb at idle.
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 adjust the brake pressure to 20-25lb at idle.
Never adjust the brake to the 60 lb. setting on an engine that has not had the heavyduty engine exhaust valve springs installed first.
With the normal mounting position of the Control Valve Assembly being on the
frame rail, it would make it exposed to water if driven through rivers, creeks, or deep
bodies of water. If the Exhaust Brake is being used during these situations, water
could be sucked through the venting filter and eventually into the Vacuum Cylinder,
damaging booth. For the best prevention of this damage, do not operate the brake
during these occurrences.
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’s 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.
So, in summary, by using the BD Exhaust Brake, you reduce the need for use of
your chassis’s brakes in situations where you need to slow down or maintain (i.e.
hills, off ramps, approaching speed changes or traffic lights). By reducing the use
of your chassis’ brakes, in these situations, the heat build up is reduced, as well as
wear and damage to linings and drums. And, when you reduce these factors, you
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
19
save your chassis’s brakes for when you really need them (i.e. for stopping or
emergencies).
The BD Exhaust Brake is not a substitute for your chassis’s 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 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.
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
11 July 2005
BD Universal Remote Mount Vacuum Brake
20
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: 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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