BD Diesel 1027145 Exhaust Brake Installation Instructions

BD Diesel 1027145 Exhaust Brake Installation Instructions
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
1
2003-2007 Ford 6.0L Powerstroke
BD Remote Mount Exhaust Brake
Part Number
1027145
1027145AP
1027146
1027146AP
Application
Ford 6.0L Powerstroke with 3.5” Exhaust (Manual Trans)
Ford 6.0L Powerstroke with 3.5” Exhaust (Auto Trans)
Ford 6.0L Powerstroke with 4.0” Exhaust (Manual Trans)
Ford 6.0L Powerstroke with 4.0” Exhaust (Auto Trans)
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
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
2
TABLE OF CONTENTS
Kit Contents ..............................................................................................................3
Welcome....................................................................................................................4
Options......................................................................................................................4
Battery Disconnect & Removal ...............................................................................5
Installation ................................................................................................................5
Vacuum Pump & Reservoir Removal................................................................5
Air Compressor & Reservoir Installation ...........................................................6
Regulator Installation ........................................................................................6
Valve Installation ...............................................................................................7
Air Solenoid Installation ....................................................................................8
Pump Relay Harness and Under-hood Wiring ..................................................9
Exhaust Brake Wiring .....................................................................................11
Cab Wiring ......................................................................................................12
Optional Shifter Switch (Push-Pull Style) ........................................................15
Optional Shifter Switch (Rocker Switch Style) ................................................16
PCM Wiring .....................................................................................................17
Cruise Control Wiring ......................................................................................18
Control Wiring .................................................................................................19
Battery Reinstall ..............................................................................................19
Brake Controller Calibration .................................................................................19
Exhaust Brake Testing...........................................................................................20
Maintenance & Troubleshooting...........................................................................21
Common Problems ................................................................................................22
Exhaust Brake Adjustments..................................................................................22
Operating Guidelines .............................................................................................23
LIMITED WARRANTY STATEMENT ......................................................................25
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
Kit Contents
Base Kit
All kits receive these parts – see below for the separate items for each kit.
1
1
1
1
1
1
1
1
2
2
1
1
1030125
1030124
1330440
1127038
1220047
1220048
1220113
1331045
1100350
1100404
1100735
1321045
Air Pump Kit (w/ mounting bracket)
Vacuum Pump Relocation kit
Vacuum Pump/Relay wiring harness
Exhaust Brake
Regulator Assembly
Solenoid Assembly
Air Snorkel Kit
Control Kit
3.5” Pipe Adapter
4.0” Marmon clamp
3.5” Lap Exhaust Clamp
Application Kit (w/ brake module)
Additional Kit Components – 1027145
2
2
1
1100350
1100404
1100735
3.5” Pipe Adapter
4.0” Marmon clamp
3.5” Lap Exhaust Clamp
Additional Kit Components – 1027146
2
2
1
1100400
1100404
1100740
4.0” Pipe Adapter
4.0” Marmon clamp
4.0” Lap Exhaust Clamp
Additional Kit Components – 1027145AP
2
2
1
1
1100350
1100404
1100735
1031300
3.5” Pipe Adapter
4.0” Marmon clamp
3.5” Lap Exhaust Clamp
Ford 6.0L Auto/PressureLoc
Additional Kit Components – 1027146AP
2
2
1
1
1100400
1100404
1100740
1031300
4.0” Pipe Adapter
4.0” Marmon clamp
4.0” Lap Exhaust Clamp
Ford 6.0L Auto/PressureLoc
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
3
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
4
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 installation information
and retain this manual for any future reference.
Options
Description
Manual Transmission Shifter Switch Kit
Transmission Gauge Kit (Auto Trans)
X Monitor (3 in 1 Digital Gauge)
Performance Torque Convertor
Part #
1300210
1030584
1087210
Call
Attention:
On vehicles with automatic transmissions it is absolutely necessary to
install a 6.0L AutoLoc/PressureLoc (#1031300) to utilize the full
performance of the BD exhaust brake.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
5
Battery Disconnect & Removal
Disconnect the negative terminals on both of the vehicle’s batteries, and then
disconnect the positive terminals. The passenger side battery will have to be
temporarily removed for the installation of some of the components of this kit.
Installation
Vacuum Pump & Reservoir Removal
Locate the small electric vacuum pump and reservoir on the passenger side fender
well. Remove the reservoir by removing the bolts on the underside of the fender
well, and disconnecting all air hoses. Remove the small electric vacuum pump by
removing the screws, unplugging the electrical plug and pulling off the supply tube
to the reservoir.
Relocate the factory vacuum
pump to the radiator support
bracket.
Remove the electric vacuum pump from the stock mount and re-install onto the new
relocation mount provided. Trim the rubber ends on the three vibration dampers to
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
6
clear when reinstalling. Install on the right hand side of the radiator support bracket
with the two bolts and washers provided.
Cut the power supply wires for the electric vacuum pump approximately 4” from the
connector and splice in the black and blue wires supplied using the butt connectors
and shrink tubing. Route the relocation loom along the fender and towards the front
up to the new vacuum pump location. Inside of the loom should be the supplied
black and blue wires, along with the 1/8” plastic vacuum tube. Shrink tubing as
been provided to securely seal this connection.
Air Compressor & Reservoir Installation
Install the supplied air compressor mounting bracket in the same location that the
small electric vacuum pump was removed from. Secure it to the side of the engine
compartment with supplied fender screws.
Install the BD Air Compressor onto the mounting bracket with the nuts supplied and
reinstall the reservoir back into its original location. Once this has been completed,
re-attach all air hoses.
You may now re-install the battery, but do not connect the positive or negative
terminals at this time.
Regulator Installation
Install the Air Regulator assembly just above the AC dryer onto the MAP sensor
bracket. You will need to remove two 10mm nuts to secure the regulator bracket to
the mounting bolts. Install the bracket in a way that the regulator is easily adjusted
and re-tighten the nuts to finish the installation. Install the relay wiring assembly on
one of the existing screws or bolts and route the harness over to fender and secure.
Make wire connections as per 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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
7
Brake Relay
Air Inlet Snorkel
Air Regulator
Bracket
BD Air Compressor
Valve Installation
*SAFETY*: Raise the vehicle to a good working height and support with jack stands
or axle stands to prevent injury or damage.
Locate the catalytic converter. About 8” from the rear of the catalytic converter you
will need to remove an 8” section of the exhaust.
Slide the supplied flanges over the each side of the cut exhaust. The flange closest
to the front of the vehicle will need to be welded. A good clean weld is needed to
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
8
seal the high backpressure that the exhaust brake will create. The rear flange
should be mounted with the supplied stainless band clamp.
Insert the valve assembly in between the two flanges and ensure that there is ample
room when welding and tightening the two flanges. Also take note that there is an
exhaust flow direction arrow cast into the exhaust brake. This arrow should be
pointing towards the rear of the vehicle. Once you have finalized the fit by
welding the front flange and securing the rear the flange, tighten the two supplied V
clamps around both flanges on either side of the exhaust brake. The exhaust brake
should now be held securely in place.
Rear of Truck
Weld
Here
Use V
Clamp
Use SS
Band Clamp
Note: This kit can be purchased for 4” exhaust or the factory 3.5” exhaust.
Air Solenoid Installation
Just across from the exhaust
brake on the passenger side
frame rail you will notice a
number of factory holes in
the frame. You will need to
mount the air solenoid
assembly on the inside of the
frame rail utilizing one of
these holes. Make sure that
the air solenoid assembly is
as close as possible to the
exhaust brake to ensure a
quick
engagement
and
disengagement of the valve.
Install Feedback
Diode here.
At the same time it is a good
idea to install the feedback
diode harness. Connect the
connectors together matching Black to Black (Ground) and Red to power.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
9
Pump Relay Harness and Under-hood Wiring
Consult the diagram on pages 10-12 for proper connections.
Starting first at the relay loom assembly, you’ll need to connect both the positive and
negative leads to the respective battery terminals (The battery leads should not be
yet connected at this time).
Connect the male and female blue bullet connectors from the Relay loom assembly
to the BD Air compressor leads.
Connect the male spade connector (blue wire) and the female bullet connector (blue
wire) to the corresponding connectors (blue wire) on the small pressure switch loom.
Route the pressure switch loom near the top of the engine firewall. Connect the two
female spade connectors (blue wires) to the pressure switch. Note that it does not
matter which connection goes where.
Route and connect the ground eyelet to a bolt on the firewall that will provide a good
solid ground.
Note: You do not need to connect the spare male bullet connector. It should
be taped off.
Connect the female bullet connector to the long Air Solenoid loom assembly. This
loom assembly will contain one black wire and two airlines. You will need to crimp
the corresponding male bullet connector on this black wire, once you have routed
the loom and trimmed the assembly to fit your specific application. You will need to
route this loom assembly to Air Solenoid unit that you mounted on the frame rail
across from the brake. Connect the female bullet connector to the red wire of the
feedback diode assembly. The other red wire end of the feedback diode assembly
should then be connected to the air solenoid. Connect the ground of the air
solenoid to the black wire of the feedback diode assembly, and finally connect the
remaining black wire to ground. Be sure that this connection is very tight. Sealing
this connection with dielectric grease or shrink tubing is preferred.
It is highly recommended that you route this loom away from any moving parts or
heat sources (i.e. exhaust). A good path is on the outside of the frame rail.
The next step is to connect all the airlines. Use a small piece of the provided plastic
airline to make a connection between the pressure switch and the BD air
compressor.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
10
Connect the long airline to the 90° connector on the pressure regulator to the air
solenoid mounted on the frame rail. You will need to connect this line to the input of
the air solenoid. “IN” is marked on the input for easy reference.
Use a small section of line to connect the output of the air solenoid (90° fitting) to the
input of the exhaust brake. The Air Cylinder has a quick release air valve attached
to the top of it.
Air Inlet
Snorkel
You must next run the snorkel line from the exhaust brake cylinder to underneath
the hood of the vehicle in a dry clean area. You should see this connection on the
front end of the exhaust brake air cylinder.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
Exhaust Brake Wiring
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
12
Cab Wiring
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.
For 2005-07 trucks that are equipped with the up fitter switches, you may wire these
12V inputs into the toggle switch input of the brake controller.
Consult the diagram on the next page for proper connections.
BD ENGINE BRAKE, INC.
Plant Address: A10-33733 King Rd, Abbotsford, BC, Canada V2S 7M9
US Shipping Address: 88-446 Harrison St, Sumas, WA 98295 US Mailing Address: PO Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
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
13
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
14
Remove the lower section of dash, under the steering column, and mount the 6.0L
Brake Control module to the cross member. Connect the black wire from the 6.0L
Brake Control module to a good clean ground using the round eyelet. You will also
use this ground point for the on/off switch (black 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 PosiTap connector to it (green for 10/12ga and black for the 14/16ga wire). Also note
that fuse #29 in the central junction box underneath the dash will also work.
Connect the red wire from the 12V (Switched power) input of the brake controller to
this Posi-Tap. You should also use this connection to power the on/off switch (red
wire).
When wiring the on/off switch be sure to leave yourself enough wire length when
mounting the switch in the dash. You will need to drill a ½” hole in the dash to
accommodate the toggle switch. Connect the ground (black) and power (red) wires
to the switch using the supplied female blade connectors. The ground wire must be
connected to the terminal labeled “AMBER”. The provided tan wire should go to the
TOGGLE SWITCH terminal on the brake controller and be connected to the output
of the switch.
Locate the Throttle Position Sensor at the throttle pedal and, using a Posi-Tap
connector, attach the Yellow wire from the brake controller module to the correct
APPS/TPS wire. If this wire does not exist, you will need to locate a wire that varies
its voltage according to how much the throttle is depressed (0.5V to 4.5V). This wire
should be connected to the APPS/TPS terminal of the brake controller.
Vehicle Year
2003-2004
2005-2007
APPS/TPS Wire Color
Yellow w/white
White w/Red
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
15
Optional Shifter Switch (Push-Pull Style)
Mount the shifter switch onto the shift
lever using the clamp supplied (either
5/8” or 3/4”). Run the electrical cable
down the shifter shaft, securing the
cable with zip-ties or electrical tape,
and run it under the carpet to the
firewall and under the dash to the
relays, leaving enough slack for proper
shifting of the transmission lever and
to prevent any rubbing of wire.
At the end of the cable, cut off any
excess and strip away about 1 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 6.0L Brake 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 from the toggle switch.
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 PosiTap 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: 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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
16
Optional Shifter Switch (Rocker Switch Style)
Mount the shifter switch onto the shift lever using the clamp supplied (either 5/8” or
3/4”). Run the electrical cable down the shifter shaft, securing the cable with zip-ties
or electrical tape, and run it under the
carpet to the firewall and under the dash
to the relays, leaving enough slack for
proper shifting of the transmission lever
and to prevent any rubbing of wire.
At the end of the cable, cut off any excess
and strip away about 1-2” of the black
rubber insulation exposing the black,
white and green wires, then strip the
insulation from the ends of the three
wires.
Connect the green 12V output green wire
to the “Switch” input terminal on the 6.0L
Brake Module.
Attach the 5/16” ring connector to the
black ground wire and attach it to a good
ground nearby.
Locate one of the ignition switched power
fuses in the fuse panel underneath the
steering column. Use the supplied fuse
tap and female flag connector to supply
ignition switched power to the “Keyed 12
Volts” (white) wire of the rocker switch
assembly.
Also provided in the kit is a Posi-Tap
connector as an alternative to the fuse tap
and flag connector. If you want to use the
Posi-Tap instead of using the fuse tap in
the fuse panel, then you will need to
locate a 12V switched ignition wire to
power the switch. You could also use the
12V Switched Power source that powers
the 6.0L Brake Module.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
17
PCM Wiring
You will now need to connect three wires to the vehicle’s PCM. Push the white,
grey and purple wires through the firewall from the underneath the hood. Run the
pink wire through the firewall as well (this will be used later on). Connect the grey
wire to the VSS terminal, the white wire into the EBP INPUT terminal and the purple
wire to the EBP OUTPUT terminal of the brake controller.
Note: To access the PCM you will need to remove the battery cover on the
driver side of the vehicle.
VSS Wire
Wire Color
Grey w/Black
Pin
35
Remove the locking plugs from the ECM for easier access.
Use the supplied Posi-tap to connect the grey wire to the Vehicle Speed Sensor
(VSS) wire. This wire is grey w/black tracer and is located on connector A (closest
to the driver), pin 35. This wire should be connected to the VSS terminal on the
brake controller.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
18
Locate the exhaust back pressure sensor (EBP) at the front of the engine on the
driver side. Disconnect the factory plugs from the EBP sensor and use the provided
connectors to connect to the EBP sensor. Reconnect the factory plug into the
provided female plug. When installing the plugs, be sure that no pins get pressed
out the backside when inserting the plugs together.
The supplied violet wire
should be connected to
the
EBP
OUTPUT
terminal,
while
the
supplied
white
wire
should be connected to
the EBP INPUT terminal
of the exhaust brake
controller.
Please
reference
the
wiring diagram to remove
any discrepancies that
you may have.
You may now reinstall the
PCM connectors and the
battery cover.
Cruise Control Wiring
NOTE: If the vehicle does not have Cruise Control, remove the Green and Blue wire
from the install and discard.
You will now need to locate the 8 pin connector located just underneath the steering
column on the passenger’s side. In this connector will be the speed control switch
input Light Blue/ Black wire Attach the supplied red scotch-lok connector to this
wire. Attach the male spade connector to the supplied green wire and connect it to
the fore mentioned scotch-lok. This green wire should then be wired into the
“CRUISE IN” input of the brake controller. The supplied blue wire should then be
wired to ground and then into the “CRUISE OUT”.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
19
NOTE: For this change, the firmware loaded inside the Exhaust Brake Controller
will have to be at least version 1.30. There is a version identifier sticker on the back
of the module if you are unsure which version you have.
Control Wiring
Connect the pink brake activation wire that was brought through the firewall to the
BRAKE OUTPUT of the brake controller. This wire should be routed along the top
of the firewall, under the hood. You must keep this wire away from the
turbocharger, as exposed heat will melt this wire. You will need to connect a female
bullet connector to the end of the pink wire, which then should be connected to
yellow wire located in the pressure switch loom.
Battery Reinstall
Re-install the passenger side battery. Reconnect the positive terminals on both
batteries then reconnect the negative terminals.
Brake Controller Calibration
Ensure the connections of the corresponding wires to the Brake Controller 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 Brake Controller Module must be calibrated for your vehicle.
The Brake Controller has an LED inside of the case that should be visible through
the case indicating brake activation.
With the throttle at idle, start the engine and turn on the brake switch. Using a small
flat bladed screwdriver, turn the small adjusting screw (potentiometer) on the right
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
20
side of the Brake Control Module counterclockwise or clockwise until the brake
engages and the LED JUST turns on.
Hold the small test button on the side of the Brake Controller during this process.
This button must be pressed to calibrate the engagement/disengagement point of
the exhaust brake, as normally the exhaust brake disengages at 15mph.
CAUTION: THE ADJUSTING SCREW IS A MICRO-SWITCH WHICH IS VERY
DELICATE, SO TURN USING SMALL ADJUSTMENTS.
Test by revving up the engine to approximately 1000 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 Brake Controller Module with
the TPS. Remember to keep the test button depressed.
The exhaust brake and LED should activate again when the throttle pedal returned
to idle. If not, readjust the Brake Control Module so that it does. Reinstall lower
dash cover.
Exhaust Brake Testing
Start the vehicle and check for idle pressure.
The idle pressure should be preset at 10–15 lbs from the factory, so it should not
need to be adjusted. If an adjustment is thought to be necessary, please go to the
exhaust brake adjustment section.
NOTE: The butterfly valve has been preset at the factory and should not be
adjusted.
Start the vehicle and take it for a test drive. The brake will only engage above 15
mph - it will not operate below this speed. Take the vehicle above this set speed,
turn on the brake activation switch and let off of the throttle. The brake should apply
and you should feel the vehicle slow down. Once 15 mph is reached, the brake will
disengage automatically. Accelerate past the threshold speed once more, and let
off the throttle once again. Re-apply the throttle and make sure the brake quickly
disengages.
The brake must quickly disengage, if it does not, a PCM error code may be
generated. Some common reasons for a slow reacting brake would be from the
brake controller not being adjusted correctly, or the air solenoid valve being too far
away from the brake.
Next you will need to test the brake for maximum retarding pressure. You can either
do this under load from a large hill or perhaps from letting off the throttle at a high
RPM.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
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The regulated pressure is adjusted with the regulator on the control assembly and
has been preset to allow a MAXIMUM of 45psi of exhaust back pressure. Note that
you should try to attain this maximum pressure.
CAUTION: Do NOT exceed 45 psi of back pressure.
If for some reason you do not have a back pressure gauge, you can measure the
voltage at the “EBP IN” pin of the 6.0L Brake Controller. Under peak exhaust brake
use (High Load & High RPM) you should see just below 4.0 Volts.
While driving, turn on the cruise control, and then activate the brake. The activation
of the brake should disconnect the cruise control. Turn the brake off and activate
cruise control again, this time pressing down on the hydraulic brake pedal to ensure
that the cruise control disconnects when the brake pedal is applied.
You may also notice that every time the vehicle is started, the exhaust brake is
cycled for a 1/10th of second. This should help everything stay free and clear and
reduce the possibility of the valve being contaminated.
NOTE: Over the next two weeks, the backpressure at idle may rise due to the initial
carbon build up and the brake valve will need to be adjusted again.
Check for any exhaust leaks and re-check all connections and hoses for security
and interference from moving or heated items. After about 100 miles (160 km), retorque the turbo exhaust clamp and flange bolts.
Maintenance & Troubleshooting
Your exhaust brake has been designed so that every time the vehicle is started the
exhaust brake will cycle for 1/10th of a second. This will extend the operating life of
the brake substantially.
On a twice-yearly interval, check and adjust the brake pressure to 10-15 lbs while
the engine is at idle. The hoses, wires, fittings and clamps should be inspected on a
regular basis for any deterioration, damage, or leaks.
By following the diagrams in this manual, trace hoses and wiring, check continuity
through electric components, and check for any lines that are disconnected.
This should solve any problems that may arise but if you should need any
assistance or need replacement parts, call our Technical Service department at 1800-887-5030, between 8:30am and 4:30pm Pacific Time.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
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Common Problems
Brake cycles ON/OFF upon disengagement speed – To cure this problem, a new
ground should be found for the Brake Controller. Electrical noise on the ground and
the VSS line cause this symptom.
Brake does not activate – Check all the wire connections and make sure that
when the brake is supposed to be energized that 12V exists on the Brake output of
the Brake Controller. Whenever the brake is supposed to be energized, a red LED
should be lit inside of the brake controller. You can check this operation by pressing
the test button on the side of the controller. Check to make sure that the idle
verification potentiometer has been adjusted correctly and that the activation switch
is in the ON position and is providing 12V to the switch input.
Upon disengagement of brake, Vehicle bogs down – Make sure that the
feedback diode wiring assembly is installed at the solenoid valve. Without this,
sporadic operations will result.
Exhaust Brake Adjustments
As mentioned in these installation instructions, the backpressure must be measured
and adjusted when the vehicle is at idle. There is a 1/8” NPT port on the side of the
exhaust brake casting designed for a pressure gauge.
It is required that a standard pressure gauge be used to make the necessary
adjustments to the brake valve. Adjust the brake to reach approximately 10-15 lbs
while the engine is at idle.
You will need to loosen the stop bolt on the top of the exhaust brake. To do this,
first loosen the locknut and then turn the stop bolt in (clockwise) into the exhaust
brake frame. Activate the brake. At this time the brake will stroke until it hits the side
of the valve casting. Re-adjust the stop bolt until it touches the actuator arm, then
turn it another 60° so that the stop bolt pushes the valve just off the side of the
casting. Tighten the locknut and the check the back pressure gauge for the 10-15
psi idle pressure. If you are still having problems, please contact BD Technical
Support.
DO NOT SET THE VALVE TO STROKE AGAINST THE VALVE CASTING WALLS
AS WARRANTY WILL BE VOIDED.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
23
Operating Guidelines
Thank you for taking interest in the BD Engine Exhaust Brake. As a driver, you
probably already know the need for extra braking power that your vehicle requires
on the hills and long grades. With loads being towed behind you, the extra push
when slowing down or maintaining speed on downward grades can prove to be a
great strain on the vehicle hydraulic braking system, even to point of “burn-up”.
These guidelines were designed to offer a better understanding of the benefits of
using exhaust brakes and are based on material developed by the US Department
of Transportation National Highway Traffic Safety Administration.
The emphasis on today’s vehicles is to give the consumer a product that can give
them usable power with fuel efficiency. But, in the transition, the vehicles have lost
their natural braking power, making it more easy for the vehicle to continue to roll
and harder to stop. Of course, this gets more noticeable with the increase of weight,
on or behind the vehicle. This is where an exhaust brake becomes a useful tool in
increasing the driveline drag of the vehicle without the use of the hydraulic brakes.
A tool, with maximum use or even occasional use, that can reduce wear on
hydraulic braking parts and at the same time increase safety. The BD Exhaust
Brake can be used to help maintain a controlled vehicle speed on a downward
grade, as well as slowing the vehicle down for such times as turns or exit ramps,
without you using your hydraulic brakes.
However, the exhaust brake cannot be used as a parking brake or a service
brake to bring your vehicle to a complete stop.
By using a BD Exhaust Brake, the life and effectiveness of your hydraulic brakes will
increase. This is because of the decreased use of the hydraulic brakes in situations
like hills, the wear factor is reduced and there is less opportunity for your hydraulic
brakes to heat up which would reduce the efficiency.
When you ride your hydraulic brakes, make hard stops or have poorly adjusted
brakes, this creates high temperatures and as your brakes get hotter, the more
chance there is for fading or failure. With terrain that is a series of up and down
grades, the BD Exhaust Brake will aid in reducing exhaust valve warpage. Because
of the power needed to pull your vehicle and load up a hill, this generates a lot of
heat.
When you have reached the crest of the hill and are now coasting down the other
side, the heated valves are too quickly cooled. With the exhaust brake engaged,
the heat loss to the valves will be reduced, which can prevent valve warpage. When
the toggle switch is turned to the “On” position, the valve is activated every time the
driver takes his foot off of the throttle pedal. When the driver puts pressure back on
the throttle pedal, the relay is activated and the valve opens again.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
24
Exhaust brakes are designed to operate with the throttle at idle, not to be used in
conjunction with cruise controls, and not designed to aid in gear shifting. Such
cases could cause damage to engine and/or the exhaust brake. Vehicles may
require downshifting to obtain the necessary retarding force.
Automatic transmissions with lock-up clutches in the converters can achieve the
best retarding force with the use of a clutch control device (i.e. AutoLoc).
Incorporated with the BD Exhaust Brake, there is a pressure regulating system that
will control the created backpressure. If the backpressure reaches the set limit, the
exhaust valve will open slightly to relieve the excess pressure.
The brake pressure at idle is required to be checked and adjusted at time of
installed, two weeks after installed, and on a regular twice a year interval.
Using a standard pressure gauge and the pressure port on the exhaust valve, the
brake pressure at idle must be set between 10 and 15 psi. The best scenario for
exhaust braking is when going down hill, select a gear that lets you maintain a
constant speed with little or no use of the hydraulic brakes, or, the same gear that
would be used to go up the same grade of hill. This also depends on the weight,
load or road conditions that the vehicle will come upon.
Therefore, in summary, by using the BD Exhaust Brake, you reduce the need for
use of your hydraulic brakes in situations where you need to slow down or maintain
(i.e. hills, off ramps, corners, approaching speed changes or traffic lights). By
reducing the use of your hydraulic brakes in these situations, this reduces the heat
build up, as well as wear and damage to linings and drums. And, when you reduce
these factors, you save your hydraulic brakes for when you really need them (i.e. for
stopping or emergencies).
The BD Exhaust Brake is not a substitute for your hydraulic brakes and, cannot
correct or compensate for poorly maintained or misadjusted brakes. But, when you
need to slow down or maintain a constant speed, the BD Exhaust Brake will be a
valuable and effective tool. Exhaust Brakes are more efficient at preventing than
correcting an over-speed condition.
You may also notice that every time the vehicle is started the exhaust brake is
cycled for a 1/10th of second. This should help everything stay free and clear and
reduce the possibility of the valve being contaminated.
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
1 February 2007
Ford 6.0L Exhaust Brake P/N#1027145 / 1027146 / AP
25
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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