BD Diesel Performance 1036703 Instructions Manual
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BD Diesel Performance 1036703 Instructions Manual

2011-2012 ford 6.7l powerstroke positive air shutoff
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21 October 2011
2011-2012 Ford 6.7L Powerstroke
P LEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION
U
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295
Phone: 604-853-6096 | Fax: 604-853-8749 | Internet: www.bd-power.com
Ford 6.7L 2011-2012 Positive Air Shutoff
Positive Air Shutoff
1036703
P/N#
1036703-M
P/N#
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
1

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  • Page 1 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 2011-2012 Ford 6.7L Powerstroke Positive Air Shutoff 1036703 P/N# 1036703-M P/N# P LEASE READ ALL INSTRUCTIONS BEFORE INSTALLATION BD Engine Brake Inc. Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2 U.S.

  • Page 2: 1036703 Kit Contents

    K I T C O N T E N T S : Please check to make sure that you have all the parts listed in this kit before you start the disassembly of your truck. 1036703 Kit Contents 1302300 1302258 1302274 3”-3 ¼”...

  • Page 3: 1036703-M Kit Contents

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 1036703-M Kit Contents 1302300 1302249 1302274 3”-3 ¼” Silicone Boot Air Shutoff Valve Wiring Harness Qty: 1 Qty: 1 Qty: 2 1302280 1405211 1407030 1302282 3” PAS Bead Ring 0325 Clamps...

  • Page 4: Table Of Contents

    INSTALLATION with OVER SPEED ELECTRONICS (1036703) ........5 INSTALLATION without OVER SPEED ELECTRONICS (1036703-M) ......18 BEAD RING AND DRILL JIG INSTALLATION ..............29 WIRING DIAGRAM with OVER SPEED ELECTRONICS (1036703) ......30 WIRING DIAGRAM without OVER SPEED ELECTRONICS (1036703-M) ..... 31 RESETTING THE VALVE ....................32 SETUP, TESTING AND VERIFICATION with OVER SPEED ELECTRONICS ....

  • Page 5: Maintenance

    Ford 6.7L 2011-2012 Positive Air Shutoff MAINTENANCE No maintenance is needed other then check to make sure the valve is acting correctly. Please see the testing section later in the manual for the correct procedure. INSTALLATION with OVER SPEED ELECTRONICS (1036703) VEHICLE SHOULD SAFELY...
  • Page 6 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 3. Once the pipe is removed from the truck, you can make your first cut at 4 1/2” from the factory pipe benders grip start on the C.A.C. side. *IMPORTANT* Ensure all cuts are straight. GRIP START CAC SIDE 4.
  • Page 7 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff When both pipes are cut they should look like this. WATER TO AIR PIPE TURBO PIPE 5. Remove backing from drill Jig sticker and wrap around pipe. The edge of the sticker should line up with the edge of the pipe.
  • Page 8 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 6. With the sticker in place use a center punch and then use a Ø1/8” drill bit and drill a Drill two 1/8” holes; they should be 180° hole in the center of the apart in line.
  • Page 9 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 8. Once the holes are drilled, install the ring bead around the pipe. Lock each end of the ring bead into each hole. You can use needle nose pliers to tweak or adjust the ring fit slightly.
  • Page 10 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 9. Once the bead rings are on the pipes install boots (1302274) onto the valve using the supplied spring clamps 0350 (1407030), then connect the pipes to the valve assembly ensuring the arrow on the valve points away from the pipe that connects to the turbo.
  • Page 11 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff Install the assembly into the truck, clock pipe sections and valve for clearance. Tighten all clamps until spring is bound. supplied harness over top of the driver’s side of the engine. You will then need to route the switch wires through the firewall on the driver’s side (note you...
  • Page 12 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff Using a 1/8” drill, drill a pilot hole in the location you have selected for the switch to be mounted. Finally using a 1/2” UNIBIT drill bit, drill an exact 1/2” round hole.
  • Page 13 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff Mount the switch so that the groove on thread boss is facing down. Adjust the HEX washer/nut so that the switch threads do not protrude an unsightly amount. Then apply the supplied sticker and finally install the round plastic nut.
  • Page 14 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff You will now need to locate the crankshaft position sensor wire (pin 33) at the connector passenger side firewall. Year Wire Color 2011 Yellow/Orange 2012 Yellow/Orange 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...
  • Page 15 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff Being that the RPM signal is critical you will need to solder the connection. Using wire strippers create a 1” window/gap in insulation of the wire. Then strip about 1” of insulation of the RPM signal wire of the BLUE wire from the PAS wiring harness.
  • Page 16 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff For the last connection will need locate ignition power. This will power the automatic over speed control switch. Note that the unit still activated manually with the switch at any time. Locate the fuse box under the hood (driver’s side in front of firewall).
  • Page 17 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff Mount electronic control unit on to the junction box. Be sure to clean the mounting surface with alcohol before applying the supplied Velcro. Connect the wiring harness to the electronic control unit. Mount electronics control unit on fuse box using Velcro.

  • Page 18: Installation Without Over Speed Electronics (1036703-M)

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff INSTALLATION without OVER SPEED ELECTRONICS (1036703-M) VEHICLE SHOULD SAFELY SECURED BEFORE INSTALLATION. 1. Block the wheels of the vehicle to prevent the vehicle from rolling. Open the hood. 2. Remove the charge air...
  • Page 19 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 3. Once the pipe is removed from the truck, you can make your first cut at 4 1/2” from the factory pipe benders grip start on the C.A.C. side. *IMPORTANT* Ensure all cuts are straight. GRIP START CAC SIDE 4.
  • Page 20 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff When both pipes are cut they should look like this. WATER TO AIR PIPE TURBO PIPE 5. Remove backing from drill Jig sticker and wrap around pipe. The edge of the sticker should line up with the edge of the pipe.
  • Page 21 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 6. With the sticker in place use a center punch and then use a Ø1/8” drill bit and drill a hole in Drill two 1/8” holes; they should be 180° the center of the holes marked apart in line.
  • Page 22 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 8. Once the holes are drilled, install the ring bead around the pipe. Lock each end of the ring bead into each hole. You can use needle nose pliers to tweak or adjust the ring fit slightly.
  • Page 23 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 10. Once the bead rings are on the pipes install the boots (1302274) onto valve using supplied spring clamps 0350 (1407030), then connect the pipes to the valve assembly ensuring the arrow on the valve points away from the pipe that connects to the turbo.
  • Page 24 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 11. Install assembly into the truck, clock pipe sections and valve for clearance. Tighten all clamps until spring is bound. Lay out supplied harness over top of the driver’s side of the engine.
  • Page 25 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff Using a 1/8” drill, drill a pilot hole in the location you have selected for the switch to be mounted. Finally using a 1/2” UNIBIT drill bit, drill an exact 1/2” round hole.
  • Page 26 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 14. Mount the switch so that the groove on thread boss is facing down. Adjust the HEX washer/nut so that the switch threads do not protrude an unsightly amount. Then apply supplied sticker and finally install the round plastic nut.
  • Page 27 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff For the last connection you will need to locate ignition power. Locate the fuse box under the hood (driver’s side in front of firewall). Remove junction box cover locate appropriate fused ignition power circuit (See table below).
  • Page 28 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 18. Double check all wiring connections and ensure wires are routed away from any heat sources and moving parts. Then install the loom with the supplied tee connector and clips for the loom ends and continue to the testing flow chart without over speed electronics in this manual.

  • Page 29: Bead Ring And Drill Jig Installation

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff BEAD RING AND DRILL JIG INSTALLATION 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...

  • Page 30: Wiring Diagram With Over Speed Electronics (1036703)

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff WIRING DIAGRAM with OVER SPEED ELECTRONICS (1036703) 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...

  • Page 31: Wiring Diagram Without Over Speed Electronics (1036703-M)

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff WIRING DIAGRAM without OVER SPEED ELECTRONICS (1036703-M) 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...

  • Page 32: Resetting The Valve

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff RESETTING THE VALVE Valve Activated (Closed) Valve Reset (Open) Rotate lever and lock in position to reset 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...

  • Page 33: Setup, Testing And Verification With Over Speed Electronics

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff SETUP, TESTING AND VERIFICATION with OVER SPEED ELECTRONICS Engine Idle Speed Frequency Each unit is specifically configured for each model of 2011-2012 Ford 6.7L truck. As in the case of different model years and 600-800 Hz makes the engine RPM frequency is different.
  • Page 34 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 5. With the valve reset, remove the outer enclosure from the control module. There are two locking tabs on the sides of the enclosure. 6. Change the position selection switch to position #2 (Auto Test). Slide enclosure cover over circuit board.

  • Page 35: Manual Mode (User Configured Rpm)

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff toggle switch should flash. board, it should flash proportionally to the engine RPM. 8. Reset the valve and reset the mode position switch to position #1 You are now complete and the unit should function correctly. This test cycle should be completed once a year.
  • Page 36 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff PRESS & 3. Start the engine. HOLD Button 4. Press and hold the RPM SET button. When you push the SET RPM button will see the “RPM Set” LED illuminate. RPM Set 5.
  • Page 37 21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff them step on the accelerator with the PRESS & HOLD vehicle in park. Raise the engine RPM Button to MAXIMUM engine RPM. 11. Release the SET RPM button. RPM Set Upon releasing the button the unit will RELEASE TO store the RPM + 25%.

  • Page 38: Testing Flow Chart With Over Speed Electronics

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff TESTING FLOW CHART with OVER SPEED ELECTRONICS Manual Mode Automatic Mode Start Vehicle Start Vehicle Activate PAS valve using manual switch Activate PAS valve using manual switch Did Valve Activate Check Wiring Check Did Valve Activate Wiring...

  • Page 39: Testing Flow Chart Without Over Speed Electronics

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff TESTING FLOW CHART without OVER SPEED ELECTRONICS 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...

  • Page 40: Led Operation

    21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff LED OPERATION Description POWER Illuminates when unit is POWERED RPM SET Illuminates when SET Button is Pressed RPM Signal Flashes proportional to Engine RPM Ground Sense Illuminates when a GROUND signal is sensed on the activation line or the solenoid is disconnected.

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1036703-m

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