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InstallationManual

www.powerhalt.com

AIR INTAKE EMERGENCY SHUT-OFF VALVEAIR INTAKE EMERGENCY SHUT-OFF VALVE

C50219 AIR INTAKE SHUT-OFF VALVES

T800 KENWORTH / ISX ENGINE

PowerHalt is a registered trademark of Pacbrake Co. 2

C50219: ELECTRIC ACTUATION L6311

INSTALLATION REQUIREMENTS & RECOMMENDATIONS:

Prior to the installation, please read through the requirements and recommendations listed below so you have a clear understanding of your system and the location you plan to install the shut-off valve.

If you cannot meet these requirements, or are unsure of your system, please contact your dealer or PowerHalt representative and we can work with you to overcome your installation constraints and challenges.

PowerHalt Technical Representative can be reached Monday-Friday 6:00-4:30 (PST) at 800.663.0096 • A1"clearanceisrequiredfromthevalvetoanyothercomponents.Thevalvecanbeinanyorientation.

• Maximumairtemperatureatthevalveshouldnotexceed120°C. • Allhoses,adapters,andfittingsmustbesuitableforthevibrationoftheengineapplication, and of reinforced type. *If unsure of your vibration requirement, contact Pacbrake.

• Flexiblehosegapsshouldbekepttoaminimumandtheoverallpipequalityandintegrity fromtheshut-offvalvetotheintakemanifoldshouldbeconfirmed. NOTE: -Failuretoensurethismayresultinhosecollapseduringvalveactivationand possible system leaks, preventing engine shutdown -Forexcessivevibrationapplications,andinstallationswithlongpiperuns, additional support brackets may be required. • Ifanairintakeflametrapisused,thevalvemustbeinstalledupstreamofthetrap.

• Crankcasebreatherconnectionsintheintakesystembetweenthevalveandengine (orinengineintakeparts)mustbesealedandreplacedbyanexternalbreather.

• Ifyouneedtocuttheexistingintakepipingtoallowfortheshut-offvalveinstallation,pleasemakesureto cut the pipe off of the engine and that it is cleaned thoroughly to ensure no shavings are present. NOTE:Failuretodosomayresultinenginedamagecausedbyforeigndebrisingestingintotheengine.

• Itishighlyrecommendedthatthepipeisrolledwithabeadtoensurehosefittingretentiononboththeinlet and outlet sides of the shut-off valve.

• Ifmorethanoneshut-offvalveisinstalledononeengineitisimperativethatthecontrolmethodis consistent with this requirement, ensuring valve activation is simultaneous for both valves.



• Drill• 1/2”Unibit•Ratchetwith7/16”&1/2”Sockets (a 14” extension is ideal)• WireStrippers&Crimpers• ElectricalTape• HackSaw• UtilityKnife

REQUIRED TOOLSKIT CONTENTS

ABCDEFGHIJKLMNO

Shut-OffValveTieStraps(8)Clamps(4)SiliconeHose(2)SelfTappingScrewValveHarnessFuse/BatteryHarnessToggleSwitchHarnessRelay HarnessWasherNutSwitchSwitchIdentificationPlateSwitchCoverRelay

KIT LAYOUT

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Please ensure that you have all the parts listed in this kit before you start the installation.

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ThankyouforyourpurchaseofaPowerHaltAirIntakeEmergencyShut-OffValvebyPacbrake. Please read the entire manual to ensure you can complete the installation once started.

Shouldyouhaveanyissuesduringtheinstallation,pleasecalltechnicalsupportat800.663.0096.

Open the hood of the vehicle. Loosen the stock clamps on both sides of the hump hose attached post intercooler.

Loosentheupperclamponthefirstchargeaircooler(CAC)pipe,thenremovetheCACpipeandhumphose.

CAUTION:Ensuretheintakesystemiscoveredandprotectedfromany foreign debris ingress during the installation process.

Install the provided silicone hose to the intercooler, along with 2clamps(keepingtheclampsloosesothatthehosecanbere- positioned if needed).

Install the PowerHalt valve onto the silicone hose opening from theintercooler,ensuringtheflowdirectiononthevalveispointingtowards the intake manifold (as shown).

If the Pacbrake replacement CAC pipe is purchased, skip steps 5 & 6

TaketheremovedfactoryCACpipeandmeasurefromthe PH2valvetotheupperhumphoseandmarkthepipe.

Have the factory pipe cut and beaded accordingly, to ensure a minimumof½”clearanceisprovidedfromthevalvetothepipe.

CAUTION:Ensureabead(orbeadkit)isutilizedashighboost pressures may cause the hose to blow off it no bead is used.

InstalltheprovidedsiliconehosetotheoutletsideofthePH2valve andtheninstallthe2providedclampslooselytothesiliconehose.

Ensurethatboththeinletandoutlethosesarefullyseatedon thePH2valveasshown.

InstallthefactorycutandbeadedCACpipe(orthecustompipe provided by Pacbrake) and clamps.

RotatethePH2valvetoobtaintherequiredvalveclearance, asshown,thentorqueallclampsto70-80in-lbs(7.9-9N•m)

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CORRECTINCORRECT



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Relay InstallationMounttherelayharnessonthedriver’ssideofthevehicleusingthe provided self-tapping screw.

Switch InstallationLocate the desired location for the activation switch in your cab.

NOTE: •Activationswitchshouldbeasclosetodriver’ssidedooras possible to allow for shutdown when standing outside of the vehicle

•Considerthedashconstruction,astheswitchrequiresasingledashwallforinstallunlessthedoublewallismodified

• DO NOT ACTIVATE THE MANUAL SWITCH FOR MORE THAN 10 SECONDS. Damage to the solenoid may occur

Drilla½”holeinthedesiredlocation.Takethetoggleswitch harnessandroutethe2bluewiresfromswitchlocationto the relay location and ground location as shown in the wiring schematiconpage8.Usetheprovidedheatshrinkablebutt connectors and ring terminal to make the connections.

Install the toggle switch through the backside of the dash, then remove thenameplateprotectivefilmandinstallthenameplate,switchcover,washer,andnut-asshown.Tightennutfirmly.

NOTE: If the dash cannot accept the switch nameplate, use the toggle sticker and install onto the switch cover as shown.

Battery ConnectionTaketheprovidedfuseharnessandconnectthepositivewireto thevehiclebatterypostusingtheringterminal.Ensureagood clean battery connection is provided.

Route the positive battery wire to the relay location and connect to battery positive wires using the provided heat shrinkable butt connector.

NOTE:Securethecableroutingwiththeprovidedtiestrapsaway from any moving parts or high heat sources.

Air Intake Valve WiringTaketheprovideharnesskitandconnecttheMetri-PackconnectoroftheharnesstothematingconnectoronthePowerhaltvalve.Thenroute the harness to the relay, and connect the red with white stripe wire to the corresponding coloured wire of the relay using the provided heat shrinkable butt connector. Route the black wire to a suitable ground location using the provided ground ring terminal.

NOTE:Securethecableroutingwiththeprovidedtiestrapsaway from any moving parts or high heat sources.



VALVE CLOSED (TRIPPED) VALVE OPEN (RUN POSITION)

POST INSTALLATION TESTING OF YOUR POWERHALT SHUT-OFF VALVE

Once the installation is complete, ensuring all the steps, schematics and recommendations have been followed, it is time to test your system.

1. Activatethemanualswitch(noenginerunning). NOTE: DO NOT ACTIVATE THE MANUAL SWITCH FOR MORE THAN 10 SECONDS. Damage to the solenoid may occur

2. Viewvalveandconfirmvalvehastripped.Theresetknobshouldbeinthetrippedposition. Thiswillhavethelinedirectionontheresetknobfacing90°fromairflowdirection.

3. Resetthevalve.

4. StarttheengineandrunatlowRPM(preferablyatidle).

5. ActivatethePowerHaltshut-offvalvebypushingthemanualswitchinanupwarddirection. Theengineshouldstopwithinafewseconds.

-Iftheenginedoesnotshutdowninthespecifiedtimepleasecheckallintakepipingandhoses for leaks between the valve and intake system. - If the system is leak-free and your valve still does not shut down the engine, please consult a PowerHaltServiceRepresentativeforsupport.

6. Oncetheenginestops,wait30seconds,thenresetthevalvebyturningtheredresetknob clockwisetotheopen“Run”positionwithknobarrowinlinewithairflowdirection.

WINDOW DECALInstall the window decal included in your kit to the lower corner of the inside of your windshield so that it is legible to those on the outside.



VALVE OPERATIONPrior to running your system you must ensure that the valve is latched (clockwise) into its open position and that the above installation procedure was completed as described. It is recommended that the engine be shippedwiththeshut-offvalvesysteminitsactive/openandready-to-usestate.

Tocarryouttheemergencyshutdownprocedure,thepullcablehandlemustbepulledasthiswillshutthevalve and stop the engine.

CAUTION: No attempt to restart the engine should happen until the activation information/details are understood and the valve is confi rmed to be returned back to the open “Run” position.

NOTE: Please reference your specifi c operation procedures defi ned by your organization for additional operation specifi cs / details. If you require additional recommendations on the steps to operate your shut-off valve, please reference PowerHalt’s operation manual based on your application.

VALVE MAINTENANCEToensureatrouble-freelonglifeofyourPowerHaltshut-offvalveascheduledmaintenanceprocedureismandatory.Itisrecommendedthatyoufollowtherequirements&proceduresstatedbelow:

MONTHLY REQUIREMENTS● Inspectallclamps,pullcablesandsupportbracketstoensuretheyareingoodconditionandtothe

required torque.● Inspectallwiring&cablerunstoensurethereisnocorrosionorwear.● Inspectallhosestoensuretherearenocracksordamage.● Activatethevalvetoensureitisexercised.

Seeprocedurebelow.

3 MONTH REQUIREMENT (or at oil change interval’s whichever comes fi rst)● LubricatethePH2,flapO-ring,withParker®SuperO-Lube,Part#SLUBE884-2,orequivalent.

VALVE ACTIVATION PROCEDURE:1 RunengineatlowRPM(preferablyatidle).

2 ActivatethePowerHaltshut-offvalvebypullingthecablehandle.Theengineshouldstopwithinafewseconds.

NOTE: ● If the engine does not shutdown in the specifi ed time, please check all intake piping and hoses

for leaks between the valve and the intake system.● If the system is leak free and your valve still does not shut down the engine, please consult

PowerHalt’s service representative for support.

3 Oncetheenginestops,wait30seconds,thenresetthevalvebyturningtheredresetknobclockwisetotheopen“Run”positionwithknobarrowinlinewithairflowdirection.

CAUTION: The #1 failure mode of any valve in the market is seizing due to lack of use. As this is a safety device, it is imperative that you employ safety activation testing at a minimum of once per month.



CUSTOMER SERVICE HOURSMONDAYTOFRIDAYFROM6:00AMTO4:30PMPST

BUSINESS HOURS OF OPERATIONMONDAYTOFRIDAYFROM7:30AMTO4:00PMPST

CORPORATE HEADQUARTERS / R&D CENTER 1959496THAVENUESURREY,BRITISHCOLUMBIA

WIRING SCHEMATIC

85 86

3087

RELAY

SWITCH

BATTERY

15 AMPFUSE

PH2 POWERHALTSHUT-OFF VALVE

+

electric manualelectric pneumaticelectric manual pull

Patentspending.PacbrakeisaregisteredtrademarkofPacbrakeCompany.Othertrademarksusedhereinarepropertyoftheirrespectiveholders. PrintedinCanadaL6311_rev3_22.06.2016

manualpacbrakeoem.com/wp-content/uploads/l6311.pdf · 2016-10-28 · installation manual air intake...

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