17 August Cool Down Timer Page 1. Part# Application Chart --

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1 17 August Cool Down Timer Page 1 BD Cool Down Timer Part# Application Chart -- Dodge Cummins Ford F Series (7.3L) Ford F Series (6.0L) GMC/Chevy Duramax *** Please read this manual before starting installation. *** OWNER S MANUAL - LEAVE IN GLOVE BOX Install Manual Part # I Printed in Canada

2 17 August Cool Down Timer Page 2 TABLE OF CONTENTS KIT CONTENTS:...3 NOTES ON CONNECTORS...4 WHAT IS THE COOL DOWN TIMER (CDT)?...4 HOW DOES THE COOL DOWN TIMER WORK?...5 PRECAUTIONS...5 SAFETY FEATURES...5 VEHICLE WIRING...6 WASTEGATE SOLENOID POWER WIRING (2004½ & 05 Dodges Only)...7 FORD POWERSTROKE WIRING DIAGRAM...8 DODGE CUMMINS WIRING DIAGRAM...9 DURAMAX WIRING DIAGRAMS...10 THERMOCOUPLE WIRING...12 Direct Thermocouple Connection...12 Amplified Pyrometer Gauge Kit...12 Conventional Non-Amplified Pyrometer Kit...13 TEMPERATURE ADJUSTMENT...13 COMMUNICATION / OPERATION LIGHTS...13 MOUNTING...14 TECHNICAL ASSISTANCE...14

3 17 August Cool Down Timer Page 3 KIT CONTENTS: Please check to make sure that you have all the parts listed in this kit before you start dis-assembling your truck. BD COOL DOWN TIMER (BD# ) Wastegate Solenoid Back- Ring CDT Control Module CDT Wiring Harness Feeding Power Wiring Kit Connector (2004½+ Dodges Only) Qty: 1 Qty: 1 Qty: 1 Qty: Posi-Lock Connector Posi-Lock Connector Posi-Lock Connector (18-22ga - Gray) (12-18ga - Black) (10-12ga - Green) Qty: 5 Qty: 2 Qty: 1 Required Tools: Wire strippers Wire crimpers Small Flat Nose Screwdriver Pliers (Needle / Flat Nose) Soldering Gun (Optional) Heat Shrink / Liquid Tape (Optional) Options: Probe (Thermocouple) Kit Compatibility: This Cool Down Timer will work with virtually all K type of thermocouples offered by companies such as ISSPRO or EGT. ** Dodges will require extra wiring see page 6 **

4 17 August Cool Down Timer Page 4 NOTE: The ground terminals of the vehicle s batteries should be disconnected before performing any piercing/posi-tapping onto any ECM/PCM wire. NOTES ON CONNECTORS The kit includes a number of Posi-Tap connectors (Gray/Black/Green) to tap onto OEM wiring. It is important to select the correct color of connector so that it matches the gauge of the OEM wire that it is being installed on. Using the incorrect connector could cause an inadequate connection and/or the OEM wire could be severed. OEM Wire 18-22ga 12-18ga 10-12ga Posi-Tap Color Gray Black Green Though these connectors offer a quicker installation, the best option would be to solder the wires and isolate the joints with heat shrink or liquid electrical tape. Proper soldering techniques should be used to ensure adequate connections. Posi-Tap Connector Usage Diagram Insert Hot Wire Tighten Strip Leads Insert & Tighten Make sure to center the wire when tightening the pierced portion of the hot wire to make a solid connection. WHAT IS THE COOL DOWN TIMER (CDT)? The CDT is designed to keep the engine running when ignition key is turned off and the exhaust temperature is above a set point (between 250 and 550 degrees Fahrenheit) to prevent turbocharger bearing failure that could occur when the engine is shut down too quickly. A typical turbocharger can spin in excess of 100,000rpm under load, which will continue spinning when the engine is turned off. The turbocharger is lubricated and cooled by the engine oil and when the engine is turned off, that oil supply is cut off. If a turbocharger is still spinning at a high RPM when the oil supply is cut off, the internal bearings will utilize what remaining oil is around them then start to heat up, essentially cooking the oil which causes premature bearing failure. By allowing the turbocharger to slow down to a safe RPM, this bearing failure can be prevented, and, a very efficient means of gauging a safe time to turn the engine off is by the exhaust temperature.

5 17 August Cool Down Timer Page 5 A good temperature range to go by is when a turbocharger is below 400 degrees (with the thermocouple mounted post-turbo), then it is safe to turn off the engine. The further away the probe is away from the turbocharger, the lower the shut-off temperature should be. If the thermocouple is mounted pre-turbo, then the shutoff temperature can be higher. HOW DOES THE COOL DOWN TIMER WORK? The CDT module utilizes the signal from the thermocouple that is measuring the exhaust gas temperature. The thermocouple may already be connected to a gauge or it can be connected to the CDT module on its own. When the key is turned off and the exhaust gas temperature is above the shutdown setting, the CDT module will keep power supplied to the ECM/PCM, which in turn will keep the engine running until the temperature falls below the setting. PRECAUTIONS The CDT will not lock the doors or set the alarm. With most vehicles, once you shut the door you can use the keyless remote or key to lock the doors. Most OEM and aftermarket alarms will have to be activated after the CDT has shutdown the engine. Due to the wide variety of the alarms and immobilizers, it is best to test the system(s) thoroughly to ensure proper procedures of activation or use in conjunctions with the CDT. Proper parking procedures should be adhered to before leaving the vehicle including the engagement of the parking brake. Children or animals should not be left unattended in the vehicle while the CDT is keeping the vehicle running. SAFETY FEATURES The CDT module has a few safety features built-in that the driver should be aware of. If for some reason the exhaust gas temperature does not fall below of shutdown setting within five (5) minutes from the key being turned off, the CDT will automatically shutdown the engine. The CDT module is also designed to monitor the vehicle s hydraulic brakes when it is connected to the brake pedal switch via the Brake Pedal terminal on the module. While the CDT module is keeping the engine alive (ignition key turned off and exhaust gas temperature above the shutdown setting), if the brake pedal is depressed the CDT will shutdown the engine. This was implemented to protect the vehicle from being stolen when the engine is in cool down mode; eventually the brake pedal would have to be pressed which will shutdown the engine

6 17 August Cool Down Timer Page 6 preventing the thief from easily driving away with the vehicle. This is also useful in situations where the engine needs to be shutdown immediately or is desired to be shutdown sooner. VEHICLE WIRING Using the following diagrams applicable to your vehicle, tap onto the vehicles wires using the appropriate sized Posi-Tap connector (not necessary if soldering the connections). All the vehicle wires are located under the dash where the module will be located. Excess wire can be trimmed but please keep in mind that the module may have to be accessed to adjust the shutdown temperature so we suggest leaving enough slack to perform this function. Connect to the appropriate terminals on the 7-terminal connector as per the charts and diagrams. Tighten each terminal by turning the terminal screws clockwise until the wire is secure. When connecting the wires to the module, leave enough slack to so that the module can be accessed to temperature adjustments.

7 17 August Cool Down Timer Page 7 WASTEGATE SOLENOID POWER WIRING (2004½ & 05 Dodges Only) Dodge trucks starting in the year 2004½ have a waste gate solenoid that requires power when the CDT keeps the ECM alive in cool down mode. You may notice that the check engine light comes on (with codes P0480 & P0243) approximately 30 seconds after the key is turned off. To avoid this requires some extra wiring with a diode to prevent back feeding power. The codes being sent do not affect performance or drivability in any way but only causes the annoyance of the engine light coming on. See the diagram below and on the next page for reference Wastegate Solenoid Power Back-Feed Harness 2004½ Dodge additional wiring

8 17 August Cool Down Timer Page 8 FORD POWERSTROKE WIRING DIAGRAM Ford Connector Fords Fords Connect the black wire to a good grounding point. Model Location OEM Wire Pin Brake Pedal (Blue Wire) L Brake Pedal Switch GN L Brake Pedal Switch RD/GN Key (Green Wire) L Ignition Connector C269 BK/LG 297 A L Ignition Connector C269 RD/BK 1040 A L Ignition Connector C250 RD/BK 1040 A L Ignition Connector C250 RD/BK Keep Alive (Tan Wire) L Ignition Switch Harness RD/LG 16 I L Ignition Switch Harness RD/BK 1000 I L Ignition Switch Harness RD/LG 16 I L Ignition Connector C250 WH/YL 1044 I L Ignition Connector C250 RD/LG 16 1 Constant (Pink Wire) L Ignition Switch Harness YE 37 B1 or B L Ignition Connector C250 YE 37 B1 or B L Ignition Connector C250 YE 37 7

9 17 August Cool Down Timer Page 9 DODGE CUMMINS WIRING DIAGRAM Dodge Connector Connect the black wire to a good grounding point. Model Location OEM Wire Pin Brake Pedal (Blue Wire) Brake Pedal Switch WT/TN L Brake Pedal Switch WT/TN L50 2 Key (Green Wire) Ignition Switch Harness BK/OR A Ignition Switch Harness BK/WT A Ignition Switch Harness PK/YL F982 9 Keep Alive (Tan Wire) Ignition Switch Harness DB A Ignition Switch Harness DB A Ignition Switch Harness PK/LG F951 3 Constant (Pink Wire) Ignition Switch Harness RD A Ignition Switch Harness RD A Ignition Switch Harness RD A951 4

10 17 August Cool Down Timer Page 10 DURAMAX WIRING DIAGRAMS Duramax Connector Connect the black wire to a good grounding point. Model Location OEM Wire Pin Brake Pedal (Blue Wire) Ignition Connector C201 WT 17 A Brake Pedal Connector WT Key (Green Wire) Ignition Connector C201 BRN 41 A Ignition Connector C201 BRN 41 B18 Keep Alive (Tan Wire) Ignition Connector C201 PNK 139 A2 Constant (Pink Wire) Ignition Connector C201 RD 242 B Ignition Connector C201 RD 342 C1

11 17 August Cool Down Timer Page 11 DURAMAX WIRING DIAGRAMS (cont d) Duramax Trucks Duramax Trucks

12 17 August Cool Down Timer Page 12 THERMOCOUPLE WIRING On most common K type thermocouples and wiring, a yellow wire is connected to the positive (+) side and a red wire is connected to the negative (-) side. The following are three common ways to connect the thermocouple to the CDT module. In all cases, the positive side of the thermocouple will be connected to the Thermocouple + terminal as indicated on the CDT module drawings and the negative side will be connected to the Thermocouple - terminal. Direct Thermocouple Connection If there is no pyrometer gauge in the vehicle and a thermocouple is being installed to connect to the CDT module, follow this diagram: Amplified Pyrometer Gauge Kit Some pyrometer gauge kits utilize a powered amplifier in between the pyrometer gauge head and the thermocouple. If the vehicle has one of these systems installed, use the following diagram:

13 17 August Cool Down Timer Page 13 Conventional Non-Amplified Pyrometer Kit A conventional pyrometer gauge kit will have the thermocouple connected to the pyrometer gauge head via a lead wire. If the vehicle has one of these systems installed, use the following diagram: TEMPERATURE ADJUSTMENT The shutdown temperature can be set by using a small flat-head screwdriver to adjust the potentiometer that can be accessed through the hole on side of the CDT module. By turning the screw clockwise until the potentiometer stops the CDT will shutdown at approximately 550 degrees F; by turning all the way counter clockwise the CDT will shutdown at approximately 250 degrees F. The CDT may have to be adjusted a few times until the desired shutdown temperature is achieved. NOTE: Be careful not to apply too much pressure due to the adjuster is plastic and can break. COMMUNICATION / OPERATION LIGHTS Through the translucent red case of the CDT module, there will be a red lightemitting diode (LED) visible during the operation of the CDT. The red LED will light up when the exhaust temperature is above the shutdown temperature setting. The LED will flash if there is a problem with the thermocouple.

14 17 August Cool Down Timer Page 14 MOUNTING Once all the wiring and adjusting has been performed, secure or mount the CDT module so that it is not interfering with feet and moving parts or near direct heat. Some examples are to use Velcro to mount to the firewall or to the back of the X Monitor module. Being that the CDT module is light, it can be suspended if the wiring is secure. TECHNICAL ASSISTANCE If you required technical assistance with the installation or operation of this kit, please contact us at , Monday to Friday, 8:00am to 5:00 Pacific Time. We can also be contacted via at techline@bd-power.com or visit our discussion forum site at

15 17 August Cool Down Timer Page 15 BD ENGINE BRAKE, INC. LIMITED WARRANTY STATEMENT THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS. DISCLAIMER OF LIABILITY, its successors, distributors, jobbers, and dealers (hereafter BD ) shall in no way be responsible for the product's proper use and service. THE BUYER HEREBY WAIVES ALL LIABILITY CLAIMS. BD disclaims any warranty and expressly disclaims any liability for personal injury or damages. BD also disclaims any liability for incidental or consequential damages including, but not limited to, repair labor, rental vehicles, hotel costs, or any other inconvenience costs by reason of use or sale of any such equipment. 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. This warranty shall not apply to any unit that has been improperly stored or installed, or to misapplication, improper operation conditions, accidents, neglect, or which has been improperly repaired or altered or otherwise mistreated by the BUYER or his agent. BD also assumes no liability regarding the improper installation or misapplication of its products. It is the installer's responsibility to check for proper installation and if in doubt, contact the manufacturer. LIMITATION OF WARRANTY (hereafter "BD") warrants to the BUYER that any parts purchased shall be free from defects in material workmanship. A defect is defined as a condition within the product that would render the product 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 written instrument signed by BD and the BUYER. The Warranty is Limited to one (1) year from the date of sale and labor costs incurred by the removal and replacement of the BD product, while performing warranty work, will be covered for 1 (one) year, payable at BD rates, at authorized centers and with prior approval. Until BD has approved the claim, the consumer may be responsible for these costs. A Return Authorization (WA) number, obtained in advance from BD, must accompany all products returned for warranty consideration. All products must be returned, shipping prepaid, to BD and must be accompanied by a dated proof of purchase receipt. All Warranty claims are subject to approval by BD and repaired or replaced product will be returned to the customer freight collect. Accepted warranty units, which have been replaced, become the sole property of BD. This warranty is in lieu of all other warranties or guaranties, either expressed or implied, and shall not extend to any consumer or to any person other than the original purchaser residing within the boundaries of the continental U.S. or Canada. 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.

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