Pacbrake PowerHalt PH2 Manuale utente

InstallationManual

www.powerhalt.com

AIR INTAKE EMERGENCY SHUT-OFF VALVE

PH2 AIR INTAKE EMERGENCY SHUT-OFF VALVE

AUTO / MANUAL / ELECTRIC WITH PULL CABLE

WITH POWERGUARD SMART OVERSPEED LIMITER*

*COMES WITH AUTOMATIC ACTUATION ONLY

L6372_REV6.17.04.2018

ECN 1-1859

PowerHalt is a registered trademark of Pacbrake Co. 1

PH2 - AUTO/MANUAL/ELECTRIC WITH PULL CABLE(S) L6372

L6372_REV6.17.04.2018

ECN 1-1859

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

• A 1" clearance is required from the valve to any other components. The valve can be in any orientation.

• Maximum air temperature at the valve should not exceed 120°C. On a turbo-charged engine,

‘Option B’ (see diagram below) should be the last option due to high temperatures. (There are special

options available for higher temperatures, contact Pacbrake).

• Allhoses,adapters,andttingsmustbesuitableforthevibrationoftheengineapplication,

and of reinforced type. *If unsure of your vibration requirement, contact Pacbrake.

• Flexible hose gaps should be kept to a minimum and the overall pipe quality and integrity

 fromtheshut-offvalvetotheintakemanifoldshouldbeconrmed.

NOTE: - Failure to ensure this may result in hose collapse during valve activation and

possible system leaks, preventing engine shutdown

- For excessive vibration applications, and installations with long pipe runs,

additional support brackets may be required.

• Ifanairintakeametrapisused,thevalvemustbeinstalledupstreamofthetrap.

• Crankcase breather connections in the intake system between the valve and engine

(or in engine intake parts) must be sealed and replaced by an external breather.

• If you need to cut the existing intake piping to allow for the shut-off valve installation, please make sure to

cut the pipe off of the engine and that it is cleaned thoroughly to ensure no shavings are present.

NOTE: Failure to do so may result in engine damage caused by foreign debris ingesting into the engine.

• Itishighlyrecommendedthatthepipeisrolledwithabeadtoensurehosettingretentiononboththeinlet

and outlet sides of the shut-off valve.

• If more than one shut-off valve is installed on one engine it is imperative that the control method is

consistent with this requirement, ensuring valve activation is simultaneous for both valves.

In order of preferred location to least preferred

st POST INTERCOOLER

■Low Plumbing Leakage Risk

■Moderate Charge Air Temperature

■Fast Shutdown Response Time

nd POST TURBO

■Moderate Plumbing Leakage Risk

■High Charge Air Temperature

■Moderate Shutdown Response Time

rd PRE TURBO

■High Plumbing Leakage Risk

■Low Charge Air Temperature

■Slow Shutdown Response Time

ACCEPTABLE

(Not recommended)

OPTIMAL

(Recommended)

PERFORMANCE

PowerHalt is a registered trademark of Pacbrake Co. 2

PH2 - AUTO/MANUAL/ELECTRIC WITH PULL CABLE(S) L6372

L6372_REV6.17.04.2018

ECN 1-1859

KIT LAYOUT

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

This Manual L6372 supersedes L6336.

REQUIRED TOOLS

• Drill

• 1⁄2" Unibit

• Ratchet with 7⁄16"& 1⁄2" Sockets

(a 14″extension is ideal)

• Hack Saw

• Utility Knife

• Torque Wrench

KIT CONTENTS

A (1) PH2 Manual / Electric with Pull Cable Shut-off Valve.

B (8) Tie Straps

C (4) Pre-Tension Clamps

D (2) Silicone hose

E (1) Wiring Harness (Automatic Actuation Harness Shown)

F (1) PH2 PowerGuard Controller (Automatic Actuation Only)

G (1) Mag Pick-up (Automatic Actuation Only)

H (1) Override Switch

I (1) Pull Cable with T- Handle (2 Supplied with Dual Pull Cable Kits)

J (1) Pull Cable Nameplate (2 Supplied with Dual Pull Cable Kits)

*NOTE: Complete kit contents shown above, contents may vary for custom applications

*Microswitch where applicable

PowerHalt is a registered trademark of Pacbrake Co. 3

PH2 - AUTO/MANUAL/ELECTRIC WITH PULL CABLE(S) L6372

L6372_REV6.17.04.2018

ECN 1-1859

Thank you for your purchase of a PowerHalt Air Intake Emergency Shut-Off Valve by Pacbrake.

Please read the entire manual before beginning to ensure you can complete the installation once started.

Should you have any issues during the installation, please call technical support at 800.663.0096.

CORRECT

INCORRECT

1VALVE INSTALLATION

Disconnect the battery.

Remove the engine panels or covers to gain access to

the intake hose location where the shut-off valve will be

installed.

2Remove the stock clamps and hoses from the air cleaner

and intake manifold.

Take the provided silicone hoses, install them on the air

cleaner outlet and intake manifold.

NOTE: Ensure the hoses are fully sealed onto the valve

(see photo 2B).

3Install the provided pre-tension clamps on the hoses and

leave them loose.

4Install the PH2 valve into the hoses openings. After the

installation, rotate the valve accordingly; ensuring the pull

cable armature is in the upright position.

5Torque all 4 clamps to 70- 80 in-lbs (7.9 - 9 N•m).

PowerHalt is a registered trademark of Pacbrake Co. 4

PH2 - AUTO/MANUAL/ELECTRIC WITH PULL CABLE(S) L6372

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31 4

FIGURE 6A

1 T- Handle Bulk Head Fitting

2 M10 Nuts

3 M10 Flat Washers

4 M5 Nut

5 T- Handle

FIGURE 6B

1 Threadedendtting

2 M8 Pretention adjusting nuts

3 M8 Flat washers

4 Cable Ball End

FIGURE 6C

1 Coupling Sleeve

FIGURE 6D

1 Activation Pin

1334

225

6 PULL CABLE PARTS IDENTIFICATION

COUNTERBORE

PowerHalt is a registered trademark of Pacbrake Co. 5

PH2 - AUTO/MANUAL/ELECTRIC WITH PULL CABLE(S) L6372

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INCORRECT

CORRECT

7Insert the Cable ball end into the activation pin. (See photo 7A)

Install the Coupling sleeve over the activation pin, align the slot

to allow the cable to pass through the coupling sleeve.

NOTE: One end of the coupling sleeve has a counter bore, this

end must go towards the activation pin. (See photo 7B)

Rotatethecable90°,andinsertthethreadedendttingintothe

slot on the attaching bracket, with one M10 nut and washer on

either side of the bracket. (see photo 7C)

For valves with dual pull cables, repeat steps 7.

8 Cable pretension is achieved when the T-handle M5 jamb nut is

justbeingpulledagainstthreadedendofthebulkheadtting.

Adjustthethreadedendtting,M8adjustingnut,withatwoM14

wrenches to ensure the cable pretension is correct.

NOTE: The Coupling sleeve must be held from moving, this is

achieved with proper adjustment of the threaded end tting.

Torque adjusting nuts to 11 +/- 1 ft-lbs (15 +/- 1.3 N•m).

Torquethenutsofthethreadedendttingtothevalvebracketto

9 +/- 1 ft-lbs (12 +/- 1.3 N•m). Installed in step 7.

NOTE: Secure the pull cable with the provided tie straps, away

from any moving parts or high heat sources.

NOTE: A MINIMUM BEND RADIUS OF 4" MUST BE MAINTAINED.

PowerHalt is a registered trademark of Pacbrake Co. 6

PH2 - AUTO/MANUAL/ELECTRIC WITH PULL CABLE(S) L6372

L6372_REV6.17.04.2018

ECN 1-1859

MANUAL KIT INSTALLATION

9SWITCH INSTALLATION

Locate the desired location for the activation switch in your cab

or control panel.

NOTE:

• Activation switch should be as close to driver’s side door as

possible to allow for shutdown when standing outside of the

vehicle

• Consider the dash construction, as the switch requires a single

dash wall for install unless the double wall is modied

• DO NOT ACTIVATE THE MANUAL SWITCH FOR

MORE THAN 10 SECONDS.

Damage to the solenoid may occur

10 Drill a ½" hole in the desired location.

11 Install the toggle switch through the backside of the dash and

thenremovethenameplatecoverlmandinstallthenameplate,

toggle cover, and lock washer as shown in picture.

Tightenlockwasherrmly.

NOTE: If the dash cannot accept the switch nameplate, use the

toggle sticker and install onto the switch cover as shown.

12 ELECTRICAL WIRING (MANUAL ACTIVATION)

Connect the relay, toggle switch, power source and valve

solenoid as per schematic on page 11.

PowerHalt is a registered trademark of Pacbrake Co. 7

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AUTOMATIC KIT INSTALLATION

13 POWERGUARD INSTALLATION

Locate a suitable location for the PowerGuard controller. It is

recommended that the controller be within a compartment and in

alocationthatisprotectedfrommechanicaldamage.Aat

(7" x 7") space is required to mount the controller.

Use 2 self-tapping screws or 2 cap screws (not provided) to

fastenthecontrollerrmlyinplace.

Connect the wiring harness’ grey and black connectors as per

the wiring schematic provided at the back of this manual to the

PowerGuard controller (see page 11).

NOTE: Ensure the PowerGuard controller is not mounted in

locations that are exposed to high pressure water or locations

which can exceed ambient temperatures of 80°C

14 SWITCH INSTALLATION

Locate a convenient location on the control panel (see photo

14A) to install the PowerHalt shutdown switch. Drill a ½” hole in

the control panel for the switch installation.

Install the toggle switch through the backside of the control

panelandthenremovethenameplatecoverlmandinstallthe

nameplate, the switch cover, the washer, and the nut (see photo

14Band14C).Torquethenutrmly.Connectthewiringharness

lead with the 2 blue spade connectors to the override switch.

15 POWER INSTALLATION

Route the harness leg with the 15 AMP fuse and Ground wire to

the Engine battery location as per the wiring schematic provided

(see page 11).

Connect to the Power and ground lugs.

NOTE: Secure the wiring harness with the provided tie straps

away from any moving parts or high heat sources.

14A

14B

14C

13A

PowerHalt is a registered trademark of Pacbrake Co. 8

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L6372_REV6.17.04.2018

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16 MAGNETIC PICK UP INSTALLATION

Inspect the engine for a suitable location on the Bell Housing

for a magnetic pick-up. Ensure this location is accessible and

centeredovertheywheelringgears.

NOTE: If a ywheel inspection chamber is present then use this

to determine the center position for drilling.

Drill and tap as required based on your magnetic pick-up

SuggestedTorquespecicationsbelow.

Suggested Torque:

Magnetic pick-up diameter 3⁄8 - 24 is 4 ft-lbs

Magnetic pick-up diameter 5⁄8 -18 is 20 ft-lbs

Magnetic pick-up diameter 3⁄4 - 16 is 62 ft-lbs

Install the provided magnetic pick-up (mag) into the new tapped

hole on the Bell Housing. Thread in all the way until the mag

contacts the ring gear. Once this happens back off a ½ turn. Use

hand tap to clean port threads if necessary. Tighten the jam nut

securely as per the suggested torque.

Route the mag pick-up wiring to the mag location on your engine

and connect the weather-pack connector.

NOTE: Secure the wiring harness with the provided tie straps.

Away from any moving parts or high heat sources.

17 VALVE WIRING INSTALLATION

Route the harness leg with 2 pin Metri-Pak to the PowerHalt

valve. Connect the connector to the mating connector on

the valve.

NOTE: Secure the wiring harness with the provided tie straps

away from any moving parts or high heat sources.

PowerHalt is a registered trademark of Pacbrake Co. 9

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ECN 1-1859

VALVE CLOSED

(TRIPPED)

VALVE OPEN

(RUN POSITION)

POST INSTALLATION TESTING OF YOUR POWERHALT SHUT-OFF VALVE

Once the installation is complete, ensuring that all the steps, schematics and recommendations have been

followed, it is time to test your system.

1. Activate the manual switch (no engine running).

NOTE: DO NOT ACTIVATE THE MANUAL SWITCH FOR MORE THAN 10 SECONDS.

Damage to the solenoid may occur

2.Viewvalveandconrmvalvehastripped.Theresetknobshouldbeinthetrippedposition

Thiswillhavethelinedirectionontheresetknob,perpendicularfromtheairowdirection.

3. Reset the valve.

4. Activate both pull cable stations.

5. Reset valve.

6. Start the engine and run.

7. Activate the PowerHalt shut-off valve by pushing the test button on the PowerGuard Controller for

at least 3 seconds. The engine should stop within a few seconds.

•Iftheenginedoesnotshutdowninthespeciedtimepleasecheckallintakepipingandhoses

for leaks between the valve and intake system.

• If the system is leak-free and your valve still does not shutdown the engine, please consult a

PowerHalt Service Representative for support.

8. Once the engine stops, wait 30 seconds, then reset the valve by turning the red reset knob

clockwisetotheopen“Run”positionwithknoblineinlinewiththeairowdirection.

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