BD X-MONITOR, Installation Manual

Page 1: ... 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 ...

Page 2: ...g Diagram 13 Lift Pump Fuel Pressure 1998 2002 14 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 Operation 22 Recommended Alarm Settings 22 X Monitor Display Settin...

Page 3: ... control module 6ft of 1 8 air tubing and a fused power wire with ground wire 1300837 1 8 Boost Fitting 1820210 Control Module Display Kit Side Button 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: ...ents can be displayed by themselves or you can add one of these options along with them Description Value BD P N Transmission Temperature TRANS INCLUDED Remote Oil Temp OIL 1080125 Exhaust Brake Back Pressure B PSI 1080135 Fuel Pressure F PSI 1080156 Auxiliary Tank Level FUEL 1080160 The fuel tank level accessory kit interfaces with an aftermarket level sender with a range of 240ohms Empty to 33oh...

Page 5: ...e to locate the thermocouple is in the turbocharger down pipe If you have a TURBO MOUNT EXHAUST BRAKE or an after market down pipe installed there may be a 1 4 NPT plug already in the system Remove this plug and install the supplied thermocouple into the 1 4 NPT hole and tighten with an open ended wrench We recommend using an anti seize compound on the threads of the thermocouple BD Engine Brake I...

Page 6: ...stallation Thermocouple Wiring Route the thermocouple wire towards the firewall taking precaution to keep it away from hot and moving parts and then pass it through the firewall by piercing a large rubber grommet in the firewall beside the brake booster canister NOTE Do NOT cut or splice the thermocouple lead wire as it is special wire that provides correct reading to the gauge Simply coil any exc...

Page 7: ...he supplied 6 piece of 1 8 plastic air hose onto the open fitting and route it through the firewall by piercing a large rubber grommet beside the brake booster canister Route the hose into the cab under the dash taking care not to kink the tubing and to keep it away from hot and moving parts Push this end into the supplied fitting see diagram below and connect the rubber hose to the pressure senso...

Page 8: ...or 8 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: ... model years 1996 2003 PCM C2 Center Block Pin 1 Violet Wire Pin 1 Transmission Temperature Sensor Signal Violet 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 2004 2007 ECM C2 50 pin block closest to the firewall Pin 29 Dark green w orange tracer wire Ph 604 853 6096 Fax 604 853 8749 Internet www bd power co...

Page 10: ...998 2003 model years To ensure that the proper program is being used measure the voltage on the violet wire on Pin 1 of plug C2 on the PCM at an ambient temperature of 40 100 F 2 2 75 Volts Conventional Sender Use Program 1085010 1 1 75 Volts Low Voltage Sender Use Program 1085012 Programming is explained in the Programming and Set up section later in this install manual BD Engine Brake Inc A10 33...

Page 11: ...the temperature of your manual transmission locate the appropriate location for the sender to fit NOTE Not all locations will accommodate the size of the sender or the bushings supplied in the kit An alternative location sender or bushing may have to be purchased to be installed in the desired location Remote Temp Wiring Diagram BD Engine Brake Inc A10 33733 King Rd Abbotsford BC Canada V2S 7M9 Sh...

Page 12: ... the RPS module to the X Monitor module as per diagrams and secure all wires and tubing keeping them away from heated or moving components The plastic filter housing will need to be changed out after 6 12 months of use The replacement time is dependant on air humidity and the amount of moisture that is trapped in the actual filter The replacement filter part is 1800135 This filter should be mounte...

Page 13: ...e X Monitor 13 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 ack Pressure Wiring Diagram B Ph 604 853 6096 Fax 604 853 8749 Internet www bd power com ...

Page 14: ... rear of the filter housing is a fuel inlet line and pressure test fitting Remove the test fitting and then remove the washers CAUTION Fuel will escape from this line ensure a small drip pan or some rags are in place to prevent excessive fuel from leaking Install one of the new washers supplied in the kit onto the supplied banjo bolt fitting BD Engine Brake Inc A10 33733 King Rd Abbotsford BC Cana...

Page 15: ...ump located on the driver s side of the engine top front section There are two different styles of throttle linkages on the 2003 2007 Dodge Ram pick ups If the throttle linkage is located near the top of the engine remove the throttle linkage plastic cover before proceeding Once the fuel pressure port is located remove the existing factory banjo bolt and install supplied banjo bolt in X Monitor ki...

Page 16: ...ewall near to the control box and connect the wiring as per the Lift Pump Pressure wiring diagram 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: ... green wire from the control module connects to the output of the auxiliary fuel tank s fuel sender Consult the literature for the sender for the correct terminal or wire for the output 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: ...The ground connection can be routed back towards and connected to the battery 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 5 Volt Supply Located at the MAP Sensor Model Year Wire Color Pin 1998 2001 Orange A 2002 Violet w White tracer 3 2003 Dark Green w Orange tracer C 2004 2007 Pink w Yellow tracer C X Mo...

Page 19: ...nt and through the A pillar Drill a hole through the A pillar large enough for the display control wiring connector to pass through Optional This hole is NOT required if you decide to run wiring along the outside of the A pillar Install the telephone type communication cable into the back of the display circuit board and route the wiring through the drilled hole or along the outside of the pillar ...

Page 20: ... PART on the top line and 1080000 on the bottom line 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 ...

Page 21: ...ge X Monitor 21 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: ...are approximate and may vary due to the characteristics of the sensor sender or probe and certain conditions can cause interference or sway the reading The alarm settings for fuel pressure F PSI oil pressure O PSI and fuel level FUEL will display an alarm when the measurement drops below the set value all other measurements will alarm when the value is above the set value The history value also wo...

Page 23: ...M9 Ship 88 446 Harrison St Sumas WA 98295 Mail PO Box 231 Sumas WA 98295 X Monitor Display Settings IN DISPLAY SHUTDOWN MODE Counts down from 9 to shut off display only All functions continue to work in the background Press MENU lower button to turn display on Ph 604 853 6096 Fax 604 853 8749 Internet www bd power com ...

Page 24: ...connected should solve any problems that may arise NOTE Analog signals are naturally affected by RF radio frequency noise To eliminate any possible chance of an erratic signal please choose a clean ground signal for the 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 ...

Page 25: ...duct 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 writt...