Bully Dog PMT, 40300 Installation Manual
INSTALLATION MANUAL
Vehicle Application Part #
Ford (6.0L) ‘03-’07 40300
GM (6.6.0 L) ‘01-’07 40300
Dodge (5.9 L) ‘03-’07 40300
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Parts Description PMT Installation Operating Instructions Internet Updates Appendix
TROUBLESHOOTING:
If you have questions during the installation of this product,
please visit www.bullydog.com/Product_Updates.php.
The latest version of these instructions can be found at the
same location. Please review the Troubleshooting section on
page 66 before calling technical support to cover most common issues.Technical support is available by calling 866bullydog (866-285-5936).
TABLE OF CONTENTS
INTRODUCTION ..........................................................................................................PG. 3
BILL OF MATERIALS.....................................................................................................PG. 4
PARTS DESCRIPTIONS ..............................................................................................PG. 57
PMT INSTALLATION ..............................................................................................PGS. 827
Installation Overview .............................................................................................pg. 8-9
Section 1: Mounting the Cradle........................................................................... pg. 10-18
Custom A-Pillar mounting........................................................................................................................11-13
Dash mounting .........................................................................................................................................14-17
Windshield mounting .................................................................................................................................... 18
Section 2: Pyrometer and Pyrometer Connection Head ........................................ pg. 19-23
Installing the pyrometer ...........................................................................................................................20-22
Installing the PCH .......................................................................................................................................... 23
Section 3: OBDII Adapter Plug ............................................................................. pg. 24-25
Section 4: Power Wire .............................................................................................. pg. 26
Section 5: Proper PMT Docking into the Cradle ......................................................... pg. 27
OPERATING INSTRUCTIONS ................................................................................ PGS. 2844
Section 1: Button Navigation ................................................................................... pg. 28
Section 2: PMT Setup Wizard .............................................................................. pg. 29-31
Section 3: Exploring the Main Screen .................................................................. pg. 32-34
Main screen navigation ................................................................................................................................. 32
Main screen parts description ....................................................................................................................... 33
Large gauge display types ............................................................................................................................. 34
INTRODUCTION
Introduction
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INTRODUCTION
Introduction
OPERATING INSTRUCTIONS (continued) ................................................................ PGS. 2844
Section 4: Exploring the Menu System................................................................ pg. 35-58
Main menu description/navigation .............................................................................................................. 35
Change vehicle ............................................................................................................................................... 36
Install download .......................................................................................................................................37-41
Gauge setup ................................................................................................................................................... 44
Vehicle parameters ...................................................................................................................................43-44
User Options .....................................................................................................pgs. 45-50
Adjust backlight ............................................................................................................................................. 46
Adjust background color ................................................................................................................................ 47
Adjust volume ................................................................................................................................................ 48
Adjust time/date ............................................................................................................................................ 49
Reset to default .............................................................................................................................................. 50
Defueling Parameters .......................................................................................pgs. 51-52
Set defuel levels ............................................................................................................................................. 52
Transmission Tune (6.0L Only) .................................................................................pgs. 53
Adjust Tire Size .......................................................................................................pgs. 54
Diagnostics ............................................................................................................pgs. 55
Show Settings ........................................................................................................ pgs. 56
Update PMT Software........................................................................................pgs. 57-58
PMT INTERNET UPDATE INSTRUCTIONS .............................................................. PGS. 5962
Section 1: PMT Version Information ......................................................................... pg. 60
Section 2: The Update Agent ..................................................................................... pg.61
Section 3: The Update Process ...................................................................................pg.62
APPENDIX ......................................................................................................... PGS. 6367
Section 1: Pyrometer Calibration ............................................................................. pg. 63
Section 2: Transmission Relearn Procedure............................................................... pg. 64
GM Duramax 6.6L .......................................................................................................................................... 64
Ford Power Stroke 6.0L .................................................................................................................................. 64
Section 3: Custom A-Pillar Information .................................................................... pg. 65
Section 4: Troubleshooting/Error Codes .................................................................... pg. 66
Section 5: Formatting SD Card ...........................................................................pgs. 67-68
Section 6: Warranty and Disclaimer ......................................................................... pg. 67
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Parts Description PMT Installation Operating Instructions Internet Updates Appendix
Be sure to update the PMT through
the Update Agent before installing
on your vehicle.
INTRODUCTION
INTRODUCTION
The PMT is the most advanced vehicle downloader, controller, monitor and gauge in a single unit. This
product is engineered to provide the most benets and the greatest features of any combination of engine performance and monitoring enhancements in the automotive aftermarket. This product is easy
to install on any applicable vehicle; all operations of the PMT take place in-cab and feature on-the-y
adjustments. This owners manual comes with both installation instructions and operating instructions.
For free technical support and all product related questions call: 866-285-5936.
This instruction set outlines how to install and operate the PMT on the following:
Dodge 5.9L Cummins
‘03-’07
Ford 6.0L Power Stroke
‘03-’07
GM 6.6L Duramax
‘01-’07
Introduction
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Parts Description PMT Installation Operating Instructions Internet Updates Appendix
BILL OF MATERIALS
The PMT Head Unit
PMT Cradle w/ Cradle Cable & Power Wire
OBDII Adapter Plug
Dash Mount Assembly
Custom A-Pillar Mount Assembly
PCH Assembly w/PCH Cable
Pyrometer Cable
SD Card Reader
TOOLS NEEDED
• Flat Head Screwdriver
• Phillips Head Screwdriver
• Wire Strippers
• Electric Drill
• 5/16” Drill Bit
• 1/8” Pipe Tap
• 9/16” Wrench
• 5/8” Wrench
• Fuse Puller
BILL OF MATERIALS
The list below includes by name the major parts included in your PMT package. The tools list indicates all of
the tools necessary to complete the PMT install.
BILL OF MATERIALS
Introduction
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PARTS DESCRIPTION
Parts Description
PARTS DESCRIPTION
This section describes each of the parts in the Bill of Materials, the descriptions provide a physical set of
attributes and a purpose for each part. The parts descriptions also list everything that is included in each
assembly.
The PMT Head Unit
The main component is the PMT Head Unit. The Head Unit is
the interface in which you control vehicle performance parameters. It is also the brains that will save vehicle activity
and defuel a vehicle. Notice that the head unit has: seven total buttons, ve on the left side and two on the right, a large
color screen, an electronic plug for docking on the bottom and
a snap hinge on the top also used for docking. Note that this is
the last piece that you will install.
Note: PMT includes a SD card inserted in the side of
the
Head Unit.
PMT Cradle with Cradle Cable and Power Wire
The cradle itself is the docking station for the PMT Head
Unit. It acts as the means of communication for the PMT.
Notice that two wires come out of the bottom back side of
the cradle, the Cradle Cable and the Power Wire. During the
installation, the Cradle Cable runs to the OBDII Adapter Plug
and the Power Wire runs to the vehicle fuse box.
OBDI
I Adapter Plug
The OBDII Adapter is rectangular and has a total of four
electronic ports. The largest port on the top of the adapter
plugs into the vehicle OBDII port. The three smaller ports on
the sides include: a Cradle Cable port on one side, and on the
opposite side a 4 Pin PCH Cable port and a 5 Pin Peripheral
port. The main purpose of the OBDII Adapter Plug is to act
as a hub for all communication lines between the PMT and
the vehicle.
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Pyrometer Connection Head (PCH) Board Assembly
The PCH Board or Pyrometer Connection Head serves as a dock to connect the pyrometers into the PMT
system. The PCH Board includes the ability to connect two pyrometers. Attached to the PCH Board housing
is a cable with four pin plug which connects to the OBDII Adapter Plug. The list below includes all separate
parts that make up the entire PCH Board Assembly.
• PCH Board
• Velcro
• (2) Self-tapping Sheet Metal Screws
• Pyrometer Cable
Dash
/Windshield Mounting Assembly
This mounting assembly is recommended mainly for use on the dash of the vehicle, but can also be used in
the same manner on the windshield of the vehicle. The assembly includes all parts and pieces necessary to
mount the cradle, along with the PMT to the vehicle dash or windshield. The list below includes all parts and
pieces of this assembly (must be assembled by installer):
• Mounting Base
• Top Cradle Arm
• Bottom Cradle Arm
• Top Aluminum Plate
• Bottom Steel Plate (threaded)
• (2) Flat-head Screws
• Double Stick Foam Tape.
PARTS DESCRIPTION
Parts Description
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Custom A-Pillar Mount Assembly
This mounting assembly enables the PMT to be mounted on the Custom A-Pillar Pod on the driver’s side of
the vehicle. Using this mounting style does require that a Custom A-Pillar Pod be purchased from Bully Dog,
but it also oers the cleanest install.
The Custom A-Pillar Mount Assembly includes:
• Front Mounting Plate
• Back Mounting Plate
• (4) Mounting Screws
USB
to
SD Card Adapter
This Card Reader is used to update the PMT’s SD memory card . It is used primarily for internet updates.
PARTS DESCRIPTION
Parts Description
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Introduction Parts Description Operating Instructions Internet Updates Appendix
Installation Overview
PMT & Cradle
OBDII Adapter Plug
OBDII Port
Pyrometer Connection Head
Pyrometer Probe
Cradle Cable
Power Wire
PCH Cable
Fuse Box
Fire wall grommet
(to exhaust manifold)
DODGE CUMMINS ‘03’07
INSTALLATION OVERVIEW
The installation overview illustrates a totally installed and functional PMT system. This overview is meant
to help reference the general location of installed parts and pieces of the PMT. Notice that there are three
dierent overview diagrams. Each diagram is vehicle specic; one for Dodge, Ford and GM. The rest of the
installation instructions will instruct how to install the PMT in detail.
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OBDII Port
OBDII Adapter Plug
Cradle Cable
Power Wire
PCH Cable
PMT & Cradle
Pyrometer Connection
Head
fuse box
Pyrometer Probe
(to exhaust manifold)
Fire wall grommet
FORD POWER STROKE ‘0307
OBDII Port
OBDII Adapter Plug
Cradle Cable
PCH Cable
(to exhaust manifold)
Fire wall grommet
fuse box
Pyrometer Probe
Pyrometer Connection
Head
PMT & Cradle
Power Wire
GM DURAMAX ‘02’07
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PMT INSTALLATION INSTRUCTIONS
These installation instructions are split into ve sections. Each section provides a comprehensive description
of installation for all vehicle applications. The ve sections are:
• SECTION 1: Mounting the Cradle
•
SECTION 2: Installing the Pyrometer and the PCH Board
•
SECTION 3: Installing the OBDII Adapter
•
SECTION 4: Installing the Power Wire
•
SECTION 5: Proper docking and removal of the PMT from the Cradle
SEC
TION 1: MOUNTING THE CRADLE
In this section you will decide where to mount the PMT Cradle, so you are essentially choosing the location
for the PMT inside the vehicle cab. First, decide which mounting style you will choose for the PMT; we oer
three dierent styles of mounting:
1. Cus
tom A-Pillar mounting (most recommended)
2. Dash mounting
3. Windshield mounting
The following mounting instructions outline how to mount the PMT, explaining each mounting style
individually.
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CUSTOM APILLAR MOUNTING
We recommend the Custom A-Pillar mounting style, because it makes for the best looking, most convenient and least intrusive mounting style. The Custom A-Pillar mounting style does require that a Custom
A-Pillar Pod be purchased from Bully Dog; see part numbers and vehicle applications for a Custom A-Pillar Pod in the appendix. The Custom A-Pillar mounting assembly comes in separate pieces and rst needs
to be assembled before it is installed.
TO ASSEMBLE:
1. Gather the following parts to begin assembly:
• PMT Cradle with Cradle Cable and Power Wire
• Four Mounting Screws
• Front Mounting Plate
• Back Mounting Plate
• Vehicle Specic A-Pillar Pod
PMT Cradle
Front Mounting Plate
Back Mounting Plate
(Threaded Screw Holes)
Mounting Screws
Custom A-Pillar Pod
(Not Included)
Custom A-Pillar Pod Mount Assembly Diagram
(To OBDII Adapter Plug)
(To Vehicle Fuse Box)
Cradle Cable
Ignition Fuse Wire
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2. With all assembly pieces gathered, refer to the Pillar Pod Mount Assembly Diagram for a visual
reference on how the assembly ts together. Steps 3 through 6 explain how to assemble the pieces,
the A Pillar Mount Diagram shows what the assembled mounting style looks like.
Note that installation instructions for each vehicle specic Custom A-Pillar Pod are included
with the Custom A-Pillar Pod, and are not described here.
3. Insert the ball that is on the back of the cradle into the lower hole on the front of the Front Mounting Plate and then shift the ball into the center of the Front Mounting Plate. Make sure that the
extruded part of the Front Mounting Plate is facing the cradle when inserting the ball.
4. Run the Cradle Cable and Power Wire through the lower hole on the front of the Front Mounting
Plate and then through the hole on the front side of the Custom A-Pillar Pod. Pull all of the slack in
the Cradle Cable and Power Wire through the Front Mounting Plate and the Custom A-Pillar Pod.
5. With the Cradle still attached, put the Front Mounting Plate up to the hole on the Custom A-Pillar
Pod, then place the Back Mounting Plate up to the backside of the of the hole on the Custom A-Pillar
Pod. Make sure that the slot on the Back Mounting Plate is pointing downward like in the Custom
A-Pillar Pod Mount Assembly Diagram so the Cradle Cable and Power Wire can get through the
mount and down to the OBDII Adapter Plug and vehicle fuse box.
6
. Use
the four mounting screws to secure the connection of all pieces in the assembly. Tighten the
screws all the way down. See the Custom A-Pillar Pod mount diagram, nished assembly should
look identical.
7. To install the A-Pillar Pod Mount assembly on a vehicle refer to the instructions included with the
Cus
tom A-Pillar Pod.
8. Run the end of the Cradle Cable and Power Wire down through the driver’s side of the vehicle
dash and pull
all of the extra slack in the cable down also. The Cradle Cable plug will need to be
connected to the OBDII Adapter Plug and the Power Wire will need to be hooked to a fuse in the
vehicle fuse box.
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(To OBDII Adapter Plug)
(To Vehicle Fuse Box)
Cradle Cable
Custom A-Pillar Mount
with Cradle
Custom A-Pillar Pod Mount Diagram
Power Wire
Custom A-Pillar Pod
(Not Included)
TIGHTENING THE CUSTOM APILLAR MOUNT SCREWS TIP
The four screws included with the Custom A-Pillar Mount work in pairs to perform two dierent
functions in securing the cradle to the Custom A-Pillar Mount. See the diagram below for details in
tightening the screws properly.
These two screw locations
tighten the mount to the APillar itself. Only completely
tighten these screws down
when the mount is in the
A-pillar and the A-pillar is
installed on the vehicle.
These two screw locations
tighten the front and back
mounting plates together
to create a tight t over the
cradle ball. Use these two
screws to adjust the tightness of the swivel eect of
the cradle in the mount.
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DASH MOUNTING
Dash mounting is a quick and easy way to mount the PMT. The dash mounting pieces do require some assembly. Dash mounting requires all parts in the dash mount assembly diagram (pg. 15).
TO ASSEMBLE:
1. Gather the Dash Mounting assembly pieces:
• Top Mounting Arm
• Bottom Mounting Arm
• The Cradle with Cradle Cable
• Dash Mounting Base with Foam Tape
• Top Plate
• Bottom plate (with threads)
• (2) Flat-Head Screws
2. Insert the metal top plate into the recessed area on top of the top mounting arm and hold it in place
while inserting the bottom plate into the bottom mounting arm (note: the bottom plate has threaded
screw holes).
3. Bring the arms together with the ends of the arms covering the ball on the cradle back and the ball on
the mounting base. When together they will form two ball joints connected by a single arm.
4. Insert the two Flat-Head screws in the two holes in the top plate and then thread them into the bottom
plate through both arm pieces. Hand tighten the screws just enough so that the assembly stays in one
piece. You will fully tighten the screws once a mounting location on the dash has been located and a
desired angle for mounting is chosen.
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Flat Head Screws
Top Plate
Top Mounting Arm
Mounting Base
Double Stick Foam Tape
Cradle
Bottom Mounting Arm
Bottom Plate
(Threaded Screw Holes)
Dash Mount Assembly Diagram
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TO MOUNT THE DASH ASSEMBLY:
1. Use the PMT to gauge where on the dash of the vehicle you want the PMT to sit. See the dash mounting
diagram for a quick example of the two recommended dash mounting locations.
PMT Dash Mount Recommended Locations
PMT and Cradle
PMT and Cradle
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TO MOUNT THE DASH ASSEMBLY: CONTINUED
2. Once a mounting location is chosen, determine the position of the PMT and direction the PMT will
face by moving the ball and socket joints of the dash mount assembly. Once you nd the right position
tighten down the two Flat-Head screws to secure that position, the screws must be tightened sufciently to hold the PMT in position.
3. Make sure that the mounting location on the dash is cleaned, preferably with isopropyl alcohol. Peal
the backing o of the double stick foam tape on the bottom of the dash mounting base and stick the
dash mount assembly along with the cradle to the dash. Press down rmly to ensure that the adhesive
reaches full contact with the dash.
4. Run
the end of the Cradle Cable down through the driver’s side of the vehicle dash and pull all of the
extra slack in the cable down also. The Cradle Cable Plug will need to be connected to the OBDII Adapter
Plug and the Power Wire will need to be hooked to a fuse in the vehicle fuse box.
Dash Mount Diagram
Dash Mount Assembly
with Cradle
Cradle Cable
(To OBDll Adapter Plug)
(To Vehicle Fuse Box)
Power Wire
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WINDSHIELD MOUNTING
Follow the same instructions for the dash mount procedure; apply the same instructions to the windshield
of the vehicle rather than the dash.
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SECTION 2: INSTALLING THE PYROMETER AND THE PYROMETER CONNECTION HEAD PCH
The PCH Assembly Diagram provides a quick visual description of all parts and pieces needed to acquire
pyrometer temperatures. The parts described in the diagram below will be referred to in this section of the
installation instructions.
Pyrometer Lead (Red)
(Longest of the two leads)
Pyrometer Lead Terminals (Pyro 1)
(Red on right, Yellow on left)
Pyrometer Lead Terminals (Pyro 2)
(Red on right, Yellow on left)
PCH Cable
(To OBDll Adapter Plug)
Pyrometer Lead (Yellow)
(Shortest of the two leads)
Pyrometer Cable
(To Pyrometer Probe)
Velcro Strip
(Mounting Option)
Jumper
(Connects to Pyro 2)
Sheet Metal Screw
(Mounting Option)
PCH Assembly Diagram
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INSTALLING THE PYROMETER PROBE
In this section you will drill and tap the Pyrometer Probe in the exhaust, either pre-turbo or
post-turbo as a means to collect exhaust gas temperatures (EGT). Exhaust gas temperatures
indicate how hot the motor is getting and can be used to set safety defueling parameters (see
Operating Instructions Set Pyrometer defuel Level on pgs. 51-52).
POSTTURBO VS. PRETURBO
You must decide between mounting the Pyro Probe either post-turbo or pre-turbo. The dierence
in location determines what temperatures will read on your PMT. Pre-turbo mounting is generally
recommended because it provides more accurate EGT readings; the PMT is also capable of running
both pre and post-turbo pyrometers simultaneously.
It is recommended that you mount both a pre-turbo and a post-turbo Pyrometer Probe if a vehicle
is running more than 50 horsepower over stock. On screen, the PMT can display Pyro 1 and Pyro 2
which correspond to the Pyro 1 and 2 locations on the PCH board. It is very important to note if Pyro
1 is displaying pre or post-turbo exhaust gas temperatures, and the same for Pyro 2.
If installing a single Pyrometer Probe it is recommended that you install the probe pre-turbo on the
Ford Power Stroke and GM Duramax, and post-turbo on the Dodge Cummins.
Whether you mount post-turbo or pre-turbo, you need to monitor your temperatures; know what
is safe and when to back o. Use the Pyrometer Calibration Procedure in the Appendix for these
instructions to gure out what your safety limits are.
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PRETURBO MOUNT:
1. Drill a 5/16” hole into the exhaust manifold where
all the exhaust runners of the manifold come together, just before the turbo exhaust inlet. Then
tap the hole with a 1/8” pipe tap and mount the
Pyrometer Probe in the hole. Use a 9/16” wrench
to tighten the probe holder or tube tting to the
down tube. Then tighten the Pyro Probe Cap to
the holder using a 5/8” wrench.
2. Run the Pyro Cable up to engine bay; let the end
of the cable sit while installing the PCH Board.
WARNING: If any debris such as drill bits and
metal
shavings drop inside the manifold, we
advise that the manifold be removed from the
vehicle so that the debris can be removed before
starting the vehicle again.
Ford Pre-turbo Mount
GM Pre-turbo Mount
TOOL TIP, PRETURBO MOUNT
When drilling into the exhaust manifold, metal spews, shavings, and broken drill bits can fall inside. This
can be hazardous to your turbo when the engine starts. Try doing four things to avoid this possible problem. One, use a high quality twist bit and a slow speed drill, about 500-800 rpm. Two, start with a small
pilot bit about 1/8”, then use the full 5/16” bit after the smaller one has punched through. Three, grease your
drill bit in addition to the normal lubricant, this will catch ying spews as they are cut. Four, just prior to
punching through into the inside of the manifold, start the engine and build up exhaust pressure on the
inside of the manifold (blows spews outside the manifold instead of letting them fall inside).
PMT Installation
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