BD Diesel Performance 1036703 User manual

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

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 2
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
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
Air Shutoff Valve
Wiring Harness
3”-3 ¼” Silicone Boot
Qty: 1
Qty: 1
Qty: 2
1302280
1302282
1407030
1405211
3” PAS Bead Ring
PAS Drill Template
0350 Clamps
0325 Clamps
Qty: 2
Qty: 2
Qty: 2
Qty: 2
1800060
1301381
1306710
1302285

Velcro strips
Heat Shrink
Ford Electronic Module
Solder
Qty: 2 x 4”
Qty: 3”
Qty: 1
Qty: 5”

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 3
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
1036703-M Kit Contents
1302300
1302249
1302274
Air Shutoff Valve
Wiring Harness
3”-3 ¼” Silicone Boot
Qty: 1
Qty: 1
Qty: 2
1302280
1405211
1407030
1302282
3” PAS Bead Ring
0325 Clamps
0350 Clamps
PAS Drill Template
Qty: 2
Qty: 2
Qty: 2
Qty: 2

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 4
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
WELCOME
Thank you for purchasing a BD positive air shutoff. This manual is divided into different
areas to assist you with your installation and operation of your positive Air shutoff.
This product is a safety product and should be tested often.
Installation should occur on a vehicle properly secured to prevent rolling.
TABLE OF CONTENTS
1036703 Kit Contents.......................................................................................................2
1036703-M Kit Contents...................................................................................................3
REQUIRED TOOLS..........................................................................................................4
MAINTENANCE................................................................................................................5
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...............33
Automatic Mode (Pre Configured RPM)......................................................................33
Manual Mode (User Configured RPM) ........................................................................35
TESTING FLOW CHART with OVER SPEED ELECTRONICS......................................38
TESTING FLOW CHART without OVER SPEED ELECTRONICS.................................39
LED OPERATION...........................................................................................................40
REQUIRED TOOLS
Frequency/Voltmeter (Optional)
Drill
11/32” Drill Bit
1/8” Drill Bit
1/2” Unibit
Electrical Tape
Heat Gun
Needle Nose Pliers
Reciprocating saw
Soldering Iron
Air or Manual Ratchet
7/16”, 1/2” Sockets
Wire Strippers
Wire Cutters
Flat Screw Driver
Center Punch
Band Saw/ Cut Off Wheel
Center Punch

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 5
BD Engine Brake Inc.
Plant Address: 33541 MacLure Rd. Abbotsford, BC, Canada V2S 7W2
U.S. Shipping Address: 88-446 Harrison St, Sumas, WA 98295 U.S. Mailing Address: P.O. Box 231, Sumas, WA 98295
Phone: [phone] | Fax: [phone] | Internet: www.bd-power.com
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 BE 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 cooler
pipe using a flat screwdriver to
release the spring clips on both
sides of the turbo intake, and a
7/16” socket and ratchet to
loosen both T clamps to release
the pipe from the water to air
cooler.
NOTE: Keep all spring clamps
as you will be reusing them.

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 6
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: [phone] Fax: [phone] Internet: www.bd-power.com
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.
4. Then make the second cut from the grip start at 1 1/4”.
GRIP START
CAC SIDE

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 7
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: [phone] Fax: [phone] Internet: www.bd-power.com
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.
For the 3” pipe the sticker
should wrap perfectly around
the pipe, the start of the sticker
should meet the end of the
sticker.
NOTE: Refer to the Bead Ring
and Drill Jig Installation section
on page 29 in this manual if you
require more information.
Sticker edge and pipe
edge inline

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 8
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: [phone] Fax: [phone] Internet: www.bd-power.com
6. With the sticker in place use
a center punch and then use
a Ø1/8” drill bit and drill a
hole in the center of the
holes marked “For 3Ø”.
There will be two holes and they
should be perfectly 180° inline
with each other through the pipe.
DO NOT DRILL COMPLETELY
THROUGH THE PIPE AND
OUT THE OTHER END. YOU
WILL NEED TO DRILL ONE
SIDE THEN ROTATE, AND
THEN DRILL THE OTHER
SIDE.
7. Once the pilot holes are
drilled you will need to drill
an Ø11/32” hole through the
pilot holes.
You can now remove the sticker.
You must deburr the inside of
the drilled holes.
Now drill the pilot
holes using 11/32
drill bit.
Drill two 1/8” holes;
they should be 180°
apart in line.

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 9
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: [phone] Fax: [phone] Internet: www.bd-power.com
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.
Be careful not to bend the ring
bead to much as you will
weaken it.
Note the ring bead does not
have to be perfectly tight or
snug around the pipe, as we will
be installing a silicone boot over
top of it.
With the ring bead in place, you
should not be able to pull the
ring bead off axially from the
tube.

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 10
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: [phone] Fax: [phone] Internet: www.bd-power.com
9. Once the bead rings are on the
pipes install the 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.
Secure the boot with the
provided 0325 clamps
(1405211). Note that there
should be about 3/4”-1” of
silicone material after the bead
ring.
Note: leave clamps loose to
allow for movement.
1302300
STOCK BOOT &
CLAMPS
0350
STOCK PIPE
0350
STOCK PIPE
STOCK BOOT & CLAMPS
0325
0325

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 11
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: [phone] Fax: [phone] Internet: www.bd-power.com
10. Install the assembly into
the truck, clock pipe sections
and valve for clearance.
Tighten all clamps until spring is
bound.
11. Lay out 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
will need to remove the switch
from the harness to accomplish
this). See wiring diagram on
page 30
Choose a highly visible location
for the switch and mount it to
the dash.
Suggested switch
mounting location

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 12
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: [phone] Fax: [phone] Internet: www.bd-power.com
12. 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.
13. Once you have the
mounting hole drilled, insert
the switch from the backside.
Reinstall the correct wires to the
correct switch terminals.

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 13
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: [phone] Fax: [phone] Internet: www.bd-power.com
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 the supplied sticker
and finally install the round
plastic nut.
15. Now underneath the
hood locate and connect the
weather pack connector on
the wiring harness to the
solenoid on the PAS valve.
See page 30 for more info.

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 14
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: [phone] Fax: [phone] Internet: www.bd-power.com
16. You will now need to
locate the crankshaft position
sensor wire (pin 33) at the
PCM connector on the
passenger side of the
firewall.
Year
PCM
Pin
Wire Color
2011
33
Yellow/Orange
2012
33
Yellow/Orange

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 15
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: [phone] Fax: [phone] Internet: www.bd-power.com
17. 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.
Wrap the copper wire around the
factory RPM signal wire and
solder this connection.
Then use electrical tape to wrap
this connection so that it is water
tight.
You can also cut the factory
crank signal wire and use heat
shrink tubing if you would like.
18. Next on the wiring
harness, connect the BLACK
and RED wires to the
respective battery
connections.
(Driver’s Side Battery).
Solder the connection and then wrap
and seal with electrical tape

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 16
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: [phone] Fax: [phone] Internet: www.bd-power.com
19. For the last connection
you will need to locate
ignition power. This will
power the automatic over
speed control box LED
switch. Note that the unit
can still be activated
manually with the switch at
any time.
Locate the fuse box under the
hood (driver’s side in front of
firewall). Remove junction box
cover and locate the appropriate
fused ignition power circuit (See
table below). Install fuse tapper
onto fuse #49 and reinstall fuse.
Connect the yellow lead wire
with flag connector to this new
connection. Route wire out of
the fuse box and close lid.
Fuse #49 (10 AMP)

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 17
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: [phone] Fax: [phone] Internet: www.bd-power.com
20. Mount the 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.
Double check all wiring connections and ensure wires are routed away from any heat
sources and moving parts, and continue to the Setup, Testing and Verification section in
this manual.
Mount electronics control unit on fuse
box using Velcro.

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 18
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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
INSTALLATION without OVER SPEED ELECTRONICS (1036703-M)
VEHICLE SHOULD BE 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
cooler pipe using a flat
screwdriver to release the
spring clips on both sides
of the turbo intake, and a
7/16” socket and ratchet to
loosen both T clamps and
release the pipe from the
water to air cooler.
NOTE: Keep all spring
clamps as you will be
reusing them.

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 19
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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
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.
4. Then make the second cut from the grip start at 1 1/4”.
GRIP START
CAC SIDE

21 October 2011 Ford 6.7L 2011-2012 Positive Air Shutoff 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: [phone] Fax: [phone] Internet: www.bd-power.com
INSTALLATION without OVER SPEED ELECTRONICS
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.
For the 3” pipe the sticker
should wrap perfectly around
the pipe, the start of the
sticker should meet the end of
the sticker.
NOTE: Refer to the Bead Ring
and Drill Jig Installation
section on page 29 in this
manual if you require more
information.
Sticker edge and pipe
edge inline