BD Diesel 1040193 Fuel Control Plate Installation Instructions

BD Diesel 1040193 Fuel Control Plate Installation Instructions
26 August 2005
1040192-7 - BD Camplate Installation
-1-
BD POWER CAMPLATE KIT
Installation Instructions
PLEASE READ ALL INSTRUCTIONS CAREFULLY BEFORE INSTALLATION.
NOTE: Unless this product has been identified with a CARB # it is only legal in
California for racing vehicles which may never be used upon a highway.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
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Required Tools
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•
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Fender Covers (To protect paint)
7/16” deep socket - 3/8” drive with 3” ratchet
10mm six point socket - 3/8” drive with extensions
Tape or clean towels (To cover openings)
7mm and ¼” six point sockets - ¼” drive with 3” extensions
19mm socket - 3/8” or ½” drive
Center punch 8-10” long
Hammer to strike punch and hand impact tool
Hand impact tool - 3/8” or ½” drive
T15 & T20 TORX bits – ¼” drive with ¼” extension 6” long
¼” to 3/8” and/or ½” adapter to hand impact tool
8mm, 6-point ¼” drive socket
Large standard screwdriver bit with 6” adapter for impact tool
Large screwdriver or small pry bar
Pliers
7/16” open-ended wrench
5/8” open-ended wrench
Torque wrench (Capable of at least 30 ft. lbs.)
RTV silicone sealant
8mm Allen wrench
-- BD CAMPLATE APPLICATION RATINGS -CUMMINS PICKUP TRUCK
Torque Plate#
#12 –
1040195
#11 –
1040194
#10 –
1040197
#8 –
1040193
#6 –
1040192
#5 –
1040196
Stock Ratings
BHP/lbs-ft BHP/lbs-ft BHP/lbs-ft BHP/lbs-ft BHP/lbs-ft BHP/lbs-ft
1994-95 Automatic
160hp 400 lbs. Ft
165/440
185/500
200/550
210/570
230/605
255/650 †
--CPL#’s 1549, 1815, 1959,
1968
1994-95 Manual
190/500
210/550
220/570
230/605
250/635
270/675 †
175hp 420 lbs. Ft
1996-98 Automatic
180hp 420 lbs. Ft
190/500
210/550
220/570
230/605
250/635
270/675 †
--CPL#’s CA, 1863 **
Stock injector orifice: .0095
1996-98 Manual
215hp 440 lbs. Ft
230/605
280/680
330/750†‡
NR
NR
NR
CPL#’s 2023, 2175
Stock injector orifice: .0105
** - The California 96-98 manual and automatic are both EGR engines – 180hp & 420 lbs-ft, which may not be to CPL# 1553
† - Stock automatic transmission or manual clutch (whichever applicable) will not handle this rating
‡ - Exhaust temperatures will run hot and may cause damage without airflow improvements
NR – Not Recommended
CUMMINS MOTORHOME
Torque Plate#
#12 –
1040195
#11 –
1040194
#10 –
1040197
#8 –
1040193
#6 –
1040192
#5 –
1040196
Stock Ratings
1992-97 Automatic
5.9L 6BTA 239HP/605 lbs-ft
1991-96 Automatic
5.9L 6BTA 190HP
1996-99 Automatic
5.9L 6BTA 210HP
1993-96 Automatic
8.3L 6CTA 250hp
BHP/lbs-ft
BHP/lbs-ft
BHP/lbs-ft
BHP/lbs-ft
BHP/lbs-ft
BHP/lbs-ft
250/635
270/690
290/710
NR
NR
NR
NR
220/570
230/605
240/645
260/660
NR
325/310
NR
NR
350/360
375/410
400/460
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
-3-
Installation
1) Park your vehicle in a suitable work location. Set your transmission in park (if
automatic), manual transmissions into neutral and set your parking brake.
2) Take a note of your radio settings if you wish, as you will lose all stored
memory in your stereo unit. Open your hood and disconnect both negative
battery cables.
3) Clean the engine if necessary
to keep debris and foreign
objects from entering the
engine.
4) Place fender covers or other
protective covering to protect
your paint and batteries.
5) Using a 7/16” deep socket,
loosen the lower clamp on the
upper intake connection hose
and slide the lower clamp off of
the hose and down the steel
tube, out of the way. (See figure 1)
6) Remove the six bolts holding the air intake connection and dipstick tube in
place using a 10mm six-point socket. Take note of the bolt locations as
they are different lengths and need to be re-installed in the proper
location during re-assembly.
7) Remove the intake manifold connection and hose as a unit, taking care not to
damage the gasket. This gasket can normally be re-used, however if it is torn,
replace it while lifting the air
connection so that the gasket joint
under the grid heater is not
disturbed.
8) Cover the air tube and manifold
openings with tape or towels to keep
out any debris.
9) Determine where your vehicle
obtains its wastegate pressure
signal. Some vehicles pick up this
signal at an elbow on the front of the
turbo (see figure 2) while others get
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
-4-
the signal at a tee connected to the rear of the injection pump (see figures 3 &
4). If your vehicle is the system shown in figure 2, skip to step 11. If your
vehicle gets its wastegate signal from the tee at the rear injection pump,
loosen the hose clamps on the AFC housing to the turbo wastegate tube air
hose using a 7mm socket. Disconnect the hose from the barbed fitting on the
top of the fuel pump Air Fuel Control (AFC) housing. Slide the hose as far
down as possible onto the steel turbo wastegate tube.
10) Remove the barbed fitting from the AFC housing using a 7/16” deep barrel
socket.
NOTE: Save this barbed fitting in case you want to convert your engine back to
stock; This fitting is not used with the Camplate Kit.
11) Remove the injection pump
fuel supply tube banjo bolt
using a 19mm socket. A few
ounces of fuel will drain out
which could wash the
sealing washers away. Do
not to lose the sealing
washers, as they need to
be re-used. In the event that
you lose or damage them,
re-order
Cummins
part
number 3918192. NOTE:
The fuel supply tube is not
removed; loosening it on the
injection pump end allows
access to get to the AFC
housing screws. You can
avoid removing the
banjo bolt if you bend
the fuel supply line
slightly
to
make
access to the breakoff screw. (See figure
4) This option saves
some
time,
eliminates breaking
into the fuel line, and
starts the engine
quicker at the end of
the install.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
-5-
12) Remove the front passenger side AFC housing break-off screw. This screw is
a factory break-off screw with a rounded head and no screwdriver, Allen head
or TORX slot (tamper proof). Use a hand impact tool with a 6” long ¼”
extension and a T15 TORX bit to remove this screw. A center punch may be
required to start a hole in the center of the screw. Set the hand impact tool in
the removal position (counter-clockwise) and use light hammer taps on the
impact tool to loosen the screw. Tap progressively harder allowing it to be reinstalled later with the T15 TORX bit. In some cases, the hole in the top of the
screw is too large for the T15 bit; In this case, use the T20 TORX bit. There is
usually a lock washer and flat washer under each of these screws. As another
option, you can use a sharp chisel to remove the break-off screw, chiseling in
a counter-clockwise direction.
13) Use the hand impact tool and a 8mm socket to remove the two drivers side
AFC screws.
14) Use the hand impact tool with a large standard screwdriver bit to remove the
rear passenger side AFC screw.
15) Pry the fuel shutdown solenoid bracket away from the AFC housing using a
larger screwdriver in the pry slot
shown in FIGURE 4. This
bracket only needs to move
about 3/8” for clearance.
16) Lift the AFC housing and move it
out of the way towards the rear
of the engine. If your boost line is
a plastic line, then it does not
need to be disconnected.
However, some engines have a
metal boost line rather than a
plastic line between the engine
intake and the AFC housing. In
this case, the boost line should
be disconnected.
17) Place the black installation guide provided with the camplate kit over the
torque curve plate (see Figure 5 & 6). This guide plate prevents objects from
entering the open fuel pump and helps position the new torque curve plate.
18) Leave one of the torque plate screws tight while removing the other screw
using the hand impact tool with a large screwdriver bit.
19) Move the removed screw and re-install it to one corner of the guide plate.
Slide the installation guide as far towards the rear of the engine as possible so
that there is zero clearance between the front edge of the torque curve plate
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
-6-
flange and the installation guide (See Figure 6). Once zero clearance is
achieved, hand-tighten the screw so that the guide does not move during the
next four steps.
20) Remove the other torque
plate screw and install it in
another corner to help hold
the guide in place.
21) Remove the stock curve
plate using pliers or a
magnet. Save the stock
torque curve plate to
permit
converting
the
engine back to stock in the
future.
22) Place the new torque curve
plate in the same position
that the stock plate was in,
sliding it as far forward as
possible so that there is nearly zero clearance between the front of the torque
plate and the installation guide.
23) Install one of the two torque plate screws and hand tighten as tight as possible
with a normal large screwdriver. Install the second screw. Using the hand
impact tool and a large standard bit, tighten each screw another 1/8” to ¼”
turn.
24) Remove the installation guide and save it in case you want to convert the
engine power back to stock.
25) Be sure that the AFC housing seal is in its groove (it may require a small
amount of grease or silicone sealant to hold it in place), and then carefully reinstall the AFC housing. Do NOT force the housing into the plate; rather
ensure that the tang on the bottom of the housing fits into the slot in the torque
curve plate. Wiring harnesses, hoses and the shut-off solenoid bracket may
need to be moved to get the housing to drop into its proper location.
26) Move the shut-off solenoid bracket back to its original position so that the AFC
housing mounting screws will pass through the proper holes in the bracket and
housing.
27) Install the AFC housing hold down screws loosely into their original locations
(see Figure 4).
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
-7-
28) Tighten three of the AFC mounting screws (not the break-off screw) as tight as
possible with a normal screwdriver. Use the hand impact tool to turn each
screw an additional 1/8” to ¼” turn. It is suggested that you successfully
complete the test drive before breaking off the head of the break-off screw;
Only tighten it slightly to keep it from falling out during the test drive. You can
re-use the original break-off screw by installing it with a TORX bit.
29) Install the turbo boost control (the small brass elbow supplied) into the 1/8”
pipe port for wastegate control (see Figure 4) in place of the barbed hose
fitting removed in step 10. If your vehicle senses manifold pressure at the
turbo (see Figure 2), remove the crimp type clamp with pliers, remove the
stock elbow and install the boost control elbow from the camplate kit in its
place. Do NOT disturb the Allen head set screw in the brass elbow, as it will
affect boost levels. Lightly tighten this fitting using a 7/16” open-ended wrench,
and then continue to tighten until the barbed end aligns with the turbo
wastegate tube.
30) Install the hose removed in step 9 onto the brass barb of the turbo boost
control. The AFC housing to boost pressure line fitting may need to be
loosened slightly using a 5/8” open-ended wrench for good alignment of the
hose. Tighten the two hose clamps loosened in step 8 using a 7mm socket. If
your vehicle uses the system shown in Figure 2, use the new hose clamp
supplied in the camplate kit, re-attach the hose and tighten the clamp using a
¼” socket. For vehicles with the metal boost line that was removed, re-install it
now.
31) Remove the duct tape or towels from the previously covered openings. Reinstall the air connection gadget and the air intake connection, starting with the
rubber hose on the air intake tube first, then rotating the connection into
position.
32) Clean any debris from the threads of the air connection bolts, then place a
small amount of RTV sealer sparsely on the first ¾” of the threads, re-install
the bolts to their original position and tighten to 18 lbs. Ft. using a 10mm six
point socket and suitable torque wrench.
33) Re-install the lower air connection hose clamp and tighten it hand tight. Do
NOT strip the threads on the clamp bolt. Check the other seven air circuit
clamps, ensuring the four hoses and eight clamps are not leaking air.
34) Remove fender and battery cover, lights, tools, etc., and re-connect the battery
cables.
35) Start the engine and check for any leaks. Since there was an amount of fuel
drained from the injection pump fuel supply tube, it is normal to take several
seconds of cranking before the engine will start. Don’t panic, this is normal.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
-8-
Depress the throttle to about half throttle position and crank the engine no
more than 30 seconds. Let the starter motor cool for 2 minutes before
attempting to crank for another 30 seconds. The engine will normally start
during the first 10 seconds of cranking. If after four 30-second attempts the
engine has not started, check to make sure the fuel shutoff solenoid and
shutoff level are moving when the key is turned from off to start. When the
engine starts, release the throttle back to the idle position and check under the
hood for leaks.
36) Test-drive the vehicle
- It should now have
much more power
and
quicker
acceleration
than
before. Observe the
acceleration rate and
smoke level. If the
vehicle is still slow to
accelerate or has too
much smoke, adjust
the AFC setting by
removing the large
plug on top of the
AFC housing (see
Figure 7) using an
8mm Allen wrench.
Take care not to lose the sealing washer under the plug. Removing the plug
exposes a star wheel, which changes the quickness of fueling response to
boost. If the acceleration is weak with minimal smoke, rotate the top of the star
wheel towards the engine a few revolutions. If the vehicle has heavy black
smoke on initial acceleration, rotate the top of the star wheel away from the
engine a few revolutions. Re-install the large plug with the sealing washer and
test-drive the vehicle again. It may take a few repeated attempts to get this
adjustment set. If the heavy smoke is still encountered with the star wheel
moved completely to the rear position, go back to step 26, loosen the AFC
housing and slide it rearward a 1/16” inch, re-tighten and test again. Repeat
until desired results occur.
37) To make your installation look more professional, paint the new parts and
chips on the screws and bolts with matching engine paint. Cummins paint part
number 3822975 “blue” matches earlier engines that appear grayish-bluishblack. Later engines are painted with a glossy black 3824514 “titanium black”.
If you have any technical questions about this or other products, call the BD
Sales & Technical Support Line at (800) 887-5030, Monday to Friday, 8:30am
– 5:00pm PST.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
26 August 2005
1040192-7 - BD Camplate Installation
-9-
BD ENGINE BRAKE
DISCLAIMER OF LIABILITY
Other than as expressly set forth herein, BD ENGINE BRAKE, Inc. (hereafter collectively, "SELLER"),
together with its distributors, jobbers and dealers shall in no way be responsible for the PRODUCT’S
proper use and service. In no event shall SELLER be liable for any special, incidental, indirect or
consequential damages of any kind or nature, whether or not BUYER was advised of the possibility of
damage, arising or resulting from the use or performance of the PRODUCT, and BUYER hereby
waives any and all such claims.
BUYER acknowledges that he/she/it is not relying on SELLER’S skill or judgment to select or furnish
goods suitable for any particular purpose and that SELLER has no liability that will extend beyond the
scope of the limited warranty contained herein, and BUYER hereby waives all remedies or liabilities,
expressed or implied, arising by operation of law or otherwise, (including, without limitation, any
obligations of SELLER with respect to fitness for any particular purpose; merchantability; and special,
incidental, indirect or consequential damages) or whether or not occasioned by SELLER'S negligence.
SELLER disclaims any warranty and expressly disclaims any liability for personal injury or damages
related to BUYER’S use of the PRODUCT. BUYER acknowledges and agrees that the disclaimer of
any liability for personal injury is a material term for this agreement and BUYER agrees to indemnify
SELLER and hold SELLER harmless from any claim related to the PRODUCT and its use or
performance. Under no circumstances will SELLER be liable for any damages, liabilities, costs or
expenses incurred as a result of by reason of the use, performance or sale of the PRODUCT,
including, without limitation, any damages, liabilities, costs or expenses incurred by reason of
BUYER’S negligence related to those uses of the PRODUCT as a result of the removal of the
PRODUCT.
SELLER assumes no liability regarding the improper installation or misapplication of the PRODUCT. It
is the installer's responsibility to check for proper installation, and, if in doubt, contact the manufacturer.
LIMITATION OF WARRANTY
SELLER hereby provides the following limited warranty as to description, quality, merchantability,
fitness for any product’s purpose, productiveness, or any other matter of SELLER'S product sold
herewith. The SELLER 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 SELLER and BUYER.
The Warranty is Limited to one (1) year from the date of sale and limited solely to the parts contained
within the product's kit. All products that are in question of Warranty must be returned shipping prepaid
to the SELLER and must be accompanied by a dated proof of purchase receipt. All Warranty claims
are subject to approval by BD ENGINE BRAKE, Inc.
Under no circumstances shall the SELLER be liable for any labor charged or travel time incurred in
diagnosis for defects, removal, or reinstallation of this product, or any other contingent expenses.
Under no circumstances will the SELLER be liable for any damage or expenses insured by reason of
the use or sale of any such equipment.
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. THE INSTALLATION OF THIS PRODUCT
INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND
ACCEPTS ITS TERMS AND CONDITIONS.
BD Engine Brake Inc.
Plant Address: Unit A10, 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: 604-853-6096 Fax: 604-853-8749 Internet: www.bd-power.com
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