Ford 6.7L Installation of the Guardian Safety System

Transcription

1 Ford 6.7L Installation of the Guardian Safety System Diesel Tech Industries Ltd Avenue Edmonton, Alberta, Canada T5L 2R8 Phone: (780) DTI /13

2 The following are the steps involved to properly install a DTI3000-Pro on a 6.7L Ford: 1. Installation of the Wiring Harnesses 2. Installation of the VCU (Valve Control Unit) 3. Installation of the Dash Controller 4. Installation of the Power Supply 5. Installation of the RPM Sensing Cable 6. Installation of the Valve to the Air Intake 7. Programming the System 8. Testing the System * 3 Valve Nozzle Hose 9ft Valve Cable Clamps Dash Controller Connectors Fuse Main Harness VCU Fuse 9ft VR Cable *Core charge for the nozzle Holder

3 Before the following procedure is carried out, the ensuing warning and precautions must be observed: Pre-Installation Before beginning the installation make sure you have received all necessary components (verify with the provided checklist). Once verified open the DTI Guardian software then connect the VCU (Valve Control Unit) to your computer via USB. Lastly, fill out the registration section (see images below) to set up the Bluetooth connection for your unit. Once completed you may begin the installation. Begin by clicking the M to register the valve

4 Next, click File at the top left side of the page followed by clicking System. Lastly, click Config Bluetooth module. Type the VIN of the vehicle/machine and press the Update button to complete the preinstallation.

5 Step 1 Installation of the Wiring Harnesses The first step required for running the cables is to locate a route through the firewall on the driver s side of the truck. There are usually rubber grommets or factory auxiliary passages that can be used to run the cables through. It is often required to poke a hole through the rubber grommets with a probe or a sharp screwdriver. If none of the above is available then it will be necessary to drill a hole in the firewall to pass the cables through. The route through the firewall is located on the driver s side, here In order to run the valve cable through the firewall you must remove the wedge from the connector by using a standard flat blade Connector screwdriver. Next, use the screwdriver to push Wedge Grommet the tabs away from the pins on the inside of the connector followed by pulling each of the four wires out individually (colour code the connector to remember the location of each wire). Lastly, remove the grommet. Valve cable with the wedge, connector, and grommet removed Afterwards, tape the four wire valve cable and the power cable, and in certain applications, the rpm cable together. Then, begin to pass the cable through the firewall and pull it through while leaving enough cable to run the wires beneath the dash without disrupting any stock steering, brake or fuel controls. Ensure that all wires are pushed back into the connectors along with the wedges and grommets. After tie strapping the components check for damaged cables, burns and moving parts that may cause malfunction. If there are no matters to address continue with the installation. Step 2 Installation of the VCU (Valve Control Unit) Locate a spot behind the dash to mount the VCU. Ensure there is ample room for stock parts to move without rubbing. Zip tie the VCU to a solid mounting area, or, if necessary, a wiring harness. Avoid placing the VCU and its terminals anywhere water or excessive dirt can come into contact with, or where it might interfere with the driver s feet. Also, don t install it where it might touch a heater pipe or conduct.

6 Proceed by plugging the main grey harness plug into the corresponding grey VCU terminal. Plug the black valve cable terminal into the corresponding VCU terminal. Step 3 Installation of the Dash Controller Start off by ensuring that the dash controller cable is long enough to reach the desired dash mounting location. When selecting the location to mount the dash controller use the provided template (check figure below) and choose a location where the dash controller will not obstruct the driver's knees. Drill out 3/16 Drill out 3/16 We recommend that you place the dash controller on the left side of the steering column as it provides ease of access on the outside and inside of the truck.

7 (*The screw mount template on the previous page is included in your installation kit, copy is not actual size.) After choosing a location in which to mount the controller, take a marker, and using the template, mark where you will drill the hole for the wires to pass through. Make sure to not drill the hole too large. After cleaning the surface thoroughly, pass the dash controller wire through the back of the hole and plug it into the back of the dash controller. Step 4 Installation of the Power Supply Direct to batteries (make sure to disconnect both batteries) Installing the power cable, first, requires you to have run the cable properly through the firewall. This step should have been completed earlier with the valve cable and the possible RPM sensing cable. Make sure that when you run the wires that you have given yourself enough slack at the end of the battery to work. If you have excess wire at the end you can always pull it through the cab afterwards. Now that you have run the wire, you can start the procedure to attach it to the battery. Before you can attach the cable directly to the battery, the valve system requires that you have a power inline fuse connector. If you have the provided fuse kit it will include one fuse holder, two eyelets, one butt connector and one fuse. If you do not have the fuse kit then you will need to provide the above listed items for yourself. Power (+) Fuse Ground (-)

8 The first step towards completing the wire connection is to begin with the negative end. After stripping the wire for the eyelet, insert the wire into one eyelet and crimp and shrink correctly making sure not to burn the wire. These are all the steps required for the negative end of the wire connection. Next is the positive wire, this will require the rest of the kit including the fuse holder, eyelet and butt connector. Begin by stripping the end of the positive wire. The next step is to take the fuse holder, strip one end of it and feed it into the other end of the butt connector. After crimping the connector correctly, take a heat gun and shrink the connection for a waterproof seal. The next step is to attach the eyelet to the other end of the fuse holder. Strip the wire and feed it into the eyelet. Crimp and shrink to make the eyelet waterproof. After everything has been crimped and shrunk you may now attach both ends to the battery. It is often necessary to attach a direct power source behind the dash. To complete this part it is first required that you find a viable power source that won t disrupt any other function on the truck (all time power). Step 5 Installation of the RPM Sensing Cable In order to install the RPM sensing cable on the Ford you must first solder a wire to a terminal on the back of the alternator. To do so you must remove the primary alternator. Once the alternator is removed you must then detach the back plastic cover to expose the terminals, then take the provided RPM wire and pass it through the vent slots on the plastic cover. Place the alternator with the top facing up, followed by soldering the RPM wire to the top diode (see picture for reference), then replace the plastic cover. Place the alternator back in the engine

9 and run the wire from the alternator, following the electrical routes used by Ford harnesses, through the firewall and to the VCU. Next, plug the wire into terminal one of the two pin DT Deutsch connector, place the provided wedge into the connector and plug it into the main harness. Top of alternator You must use the top diode to solder the wire Bottom of alternator Before the following procedure is carried out, the ensuing warning and precautions must be observed:

10 Step 6 Installation of the Valve to the Air Intake The initial steps towards installing the valve are locating the stock air intake system followed by removing it. On the 6.7L you only need to remove the charged air intake pipe on the driver's side of the engine. To remove this pipe, there is a clip on the clamp at the top of the pipe. Remove it with a flat blade screw driver. Then twist and pull the pipe off the flange. Then, follow the pipe to the air to air cooler and loosen the clamp. Afterwards, slowly wiggle the pipe off. Next, using a cutting tool, cut the metal band that clamps the hose to the lower part of the pipe. There is a metal band on the inside of the top piece of the pipe that has to be removed; the best way to take it out is by using a puller. The metal band has to be removed in order for the nozzle to fit in the pipe. Securely place the puller in a vise and pull on the pipe until the metal is removed. Then, on the same piece of pipe cut the lip mark (as shown on the picture below). In order to remove the lip you can either cut it off with a pipe cutter or, alternatively, you can use a bench sander to sand it away, ensure that the cut is even and that the sand edges are smooth. Afterwards, ensure there are no plastic particles in the pipe.

11 Shown here is how the system fits together. The bottom half of the hose attaches to the right side of the valve that has a 3" nozzle. It requires two clamps, one on the side of the valve and one on the bottom pipe. Now place the pipe into the truck with the bottom piece of the pipe first; attach the valve first, then add the top piece and attach it to the valve. Before tightening the clamps attach the pipe to the engine, once it is attached, align then tighten both clamps on the valve. Then tighten the clamp on the bottom piece of the pipe and replace the clip on the top of the pipe. Step 7 Programming the System Verify with your vehicle that the appropriate RPM setting is set up. Rev the engine to 1000, 1500, and 2000 RPM to ensure that DTI s Guardian Configuration software and your vehicle s RPM odometers match. Adjust the Pulses per Revolution box on DTI s software (by either increasing or decreasing the preset number) to correct any discrepancies between your vehicle and DTI s software RPM reading. For assistance on how to program the system click the Help button on the DTI Guardian Configuration software. Step 8 Testing the System It is recommended that the operator open and close the valve every day before starting the vehicle to ensure the system is functioning properly as well as to prevent the valve from ceasing. Before closing the dash and tie strapping the system, please make sure the system is functioning properly by doing an RPM Test.

12 To test the system have the engine at idle (below 900 rpm), press the Open button for a minimum of 4 seconds (remain pressing the button for the duration of the test) then rev the engine to the dealer s preset test RPM (1500 RPM). At this point the truck will shut down. Push the Open button to re-open the valve. The VCU (Valve Control Unit) will automatically reset to the original High REV Shutdown RPM configuration. The Ford 6.7L is set to have a test shutdown at 1500 RPM and the regular shutdown rate is set to 2500 RPM. The pulse/flywheel teeth count needs to be set to 25 (see picture below for reference).

13 Have any questions or concerns? If you have any questions or concerns regarding this Ford 6.7 L Installation manual, please feel free to contact us in any of the following ways: * support@dtiguardian.com Diesel Tech Industries Ltd Ave. Edmonton, Alberta Canada, T5L 2R8 Toll Free: 1 (888) Phone: (780) Fax: (780) *If you decide to contact us via please include your contact information as well as the company you represent and the DTI unit (shutdown valve) serial number in your .