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6 November 2006
1085200/5210/5220 Dodge X-Monitor
1
BD X-MONITOR
1994-2007 Dodge Ram 5.9L Cummins
I n s t a l l a t i o n
M a n u a l
Date Purchased
Purchased from
Installed by
READ THIS MANUAL COMPLETELY BEFORE INSTALLING THIS PRODUCT.
OWNER'S MANUAL - LEAVE IN GLOVE BOX
Installation Manual Part # I1085200
Printed in Canada
BD Engine Brake Inc
A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9
Ship: 88 – 446 Harrison St, Sumas, WA 98295
Mail: PO Box 231, Sumas, WA 98295
Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com
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Table of Contents
Summary of Contents for BD X-MONITOR
- Page 1 Installation Manual Part # I1085200 Printed in Canada BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com...
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Page 2: Table Of Contents
Lift Pump Fuel Pressure (2003-2007) .............15 Wiring Diagram – Lift Pump Pressure............16 Auxiliary Fuel Tank Level ................17 Fuel Pressure Sensor Power and Ground ............18 X-Monitor Power and Ground .................18 Display Assembly Installation................19 A-Pillar Mounts ..................19 Programming and Set Up ..................20 X-Monitor Programming Chart................21... -
Page 3: Kit Contents
1830010 Sensor Wire Kit BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 4: Welcome
OEM sensor) - all other applications will require one of the accessories above to install. Once the components have been installed, the X-Monitor will have to be programmed to match the application and the measurements being monitored. This will be done via the buttons on the display and will be explained further in this manual. -
Page 5: Installation
BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 6: Thermocouple Wiring
Simply coil any excess wire out of the way. If the thermocouple wire is too short, call factory for longer leads. From under the dash, route the thermocouple to the X-Monitor Control Module. Install the wires onto the Control Module as shown in the diagram. -
Page 7: Boost Pressure Sender Assembly
NOTE: The module should be mounted with the boost fitting pointed down. BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 8: Basic Installation With Transmission Temperature
Basic Installation with Transmission Temperature BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 9: Automatic Transmission Temperature Sensor
Dark green w/ orange tracer wire BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 10: Note For 1999 Model Year
* Programming is explained in the “Programming and Set-up” section later in this install manual. BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 11: Remote Oil Temperature (Diff / Manual Trans / Etc)
Remote Temp Wiring Diagram BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 12: Brake Back Pressure
1085200/5210/5220 Dodge X-Monitor Brake Back Pressure On the BD Exhaust Brake valve there is a 1/8” NPT plug used for measuring brake back pressure. Remove this plug and install the tube fitting with 1/8” NPT male threads. One end of the formed piece of stainless tube has a fitting attached and other end is bare - Insert the bare end into the fitting on the brake valve. -
Page 13: Back Pressure Wiring Diagram
Pressure Wiring Diagram BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 14: Lift Pump Fuel Pressure (1998½-2002)
BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 15: Lift Pump Fuel Pressure (2003-2007)
Once the fuel pressure port is located, remove the existing factory banjo bolt and install supplied banjo bolt in X-Monitor kit. When installation complete, engine and check for leaks. BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 –... -
Page 16: Wiring Diagram - Lift Pump Pressure
Wiring Diagram – Lift Pump Pressure BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 17: Auxiliary Fuel Tank Level
BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 18: Fuel Pressure Sensor Power And Ground
Ground connector of the control box. BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 19: Display Assembly Installation
Insert the supplied ratchet fasteners through the drilled holes and into the A-pillar securing the X-Monitor display assembly to the A-pillar. Install the A-pillar into place and route the control wiring down to the control box. Insert the telephone type connector in the socket of the control box. Once all connections are made, secure the box in place under the dash and away from any moving parts. -
Page 20: Programming And Set Up
Using the programming chart located on the next page, find the program number that matches the application and measurements you are going to program the X-Monitor for. Press the top button until the program number appears, then press the bottom button to activate that program (see diagram below). The display will now cycle through the normal start-up screens that will appear every time the truck is started. -
Page 21: X-Monitor Programming Chart
1085200/5210/5220 Dodge X-Monitor X-Monitor Programming Chart BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 22: Operation
(F-PSI), (O-PSI) and (FUEL) and the highest value on all others. The X-Monitor is calibrated to the thermocouple that is supplied with the kit and may not register accurately if an existing or different thermocouple is used. If the thermocouple was installed post-turbo (in the exhaust pipe), then all temperatures will indicate to be lower, and the maximum safe temperature would be 900°F. -
Page 23: X-Monitor Display Settings
-Press MENU (lower) button to turn display on. BD Engine Brake Inc A10 – 33733 King Rd, Abbotsford, BC, Canada V2S 7M9 Ship: 88 – 446 Harrison St, Sumas, WA 98295 Mail: PO Box 231, Sumas, WA 98295 Ph: 604.853.6096 Fax: 604.853.8749 Internet: www.bd-power.com... -
Page 24: Maintenance & Troubleshooting
X-Monitor, that is clearly mounted away from the alternator wires or any other voltage sources (positive battery cables, etc.). If for some reason you still have erratic sensor readings try a direct ground connection to the battery. -
Page 25: Limited Warranty Statement
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.