Digital Propane Injection® for Ford 7.3L
Contents
1. Notes FLE Ox Ford 7 3L 99 up Powerstroke Default data and menu for Diesel Engine Propane Fumigator 4810705 Uses menu 4810405 7 J start Inbox Microsoft Out MSD Graphview FILE 4 untitled Paint R JK DMs 3 33 4m Figure 10 Pro Data Screen and Program Windows SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 INSTALLATION INSTRUCTIONS 9 DATA MONITOR LIST Note List will be blank if there is no product communication User Notes Data Editor RPM Meter Alert List Allows you to enter notes and save with each program Programmable items Graphical display of RPM Propane Operating Pressure and Manifold Pressure Engine Boost Displays notifications of alerts Only visible when Alert is active Maintenance Log Lists the last nine alerts recorded MONITORED ITEMS Pwm RPM LpPsia TPS In TPS Fuel Temp Mapln AcqRun Lp Sys Liquid Sol PwrLevel Baro Cruise Pulse Width Modulation ON time for the Pressure Control Solenoid on the regulator This varies from O to 255 Engine speed Verify RPM displayed is approximately equal to vehicle RPM on Tach or scanner The measured pressure of the propane in the regulator measured in absolute pressure Throttle Position Sensor signal Range 0 1023 Converted TPS In signal increasing value from approximately 0 at idle to near 100 at full thrott2. BoostEnable 5 Time 80Sec 0 30 20 80sec 6 33min Pedal Extend 3600 4600s100 4RpmLimit 3600 BoostLimit 45 15 45 APedal Lo 128 Hi 840 0 1020 s4 0 1020 s4 Alerts AlertsPer Figure 11 Optional Hand Held Monitor Flow Chart Note At time of printing the software version displayed was V05 MO5 Newer version numbers will display as upgrades apply SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 POWER HAS NEVER BEEN EASIER d E j JSF 4 LLS oy x ISG Ss oo LS oatken SIL S22 S Cc s S S 5 a EEP B gt E Figure 12 Outlet Orifice Assembly Figure 13 Vacuum Line Routing Refer to Figure 13 to verify vacuum hose routing Note Figure shows straight fittings Kit includes 90 fittings Service In case of malfunction this component will be repaired free of charge according to the terms of the warranty When returning components for service Proof of Purchase must be supplied for warranty verification After the warranty period has expired repair service is charged based on a minimum and maximum charge All returns must have a Return Material Authorization RMA number issued to them before being returned To obtain an RMA number please contact MSD Customer Service at 915 855 7123 or fax a request to 915 857 3344 Send the unit prepaid with proof of purchase to the attention of MSD Igniti
3. 2 pg 12 s atung 2 Install Propane Pressure Sensor Boost 3 Install Fuel Pressure Switch and propane iaeaha lock off solenoid 4 Install the 90 coolant hose elbow fittings Wy J i Ny Mig to the regulator s coolant inlet outlet vy ports Mentha Mounting propane j Note Figure 1 shows straight fittings but Soraa aoe senate the kit includes 90 fittings 5 Install Fuel Line Fitting MOUNTING THE VAPORIZER REGULATOR 1 Locate the relay support bracket on the driver side fender between the windshield washer bottle and the firewall Figure 2 2 Remove the 6mm thread bolt holding the relay support bracket and remove the bracket 3 Remove the relays from the bracket and tie them out of the way 4 Using the supplied self tapping screw tap the boss in the lower part of the fender 5 Mount the regulator assembly to the bracket so the inlet is on top 6 Mount the regulator and bracket assembly H g aa to the driver side fender using the two Rm lt P eee mounting screws Figure 3 f 4 Note Some applications such as early 98 models may require alternative mounting For these applications verify the regulator is mounted with the regulator inlet at the top 7 Connect the liquid supply line to the lock off solenoid inlet Figure 3 Mounting the Regulator Assembly SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 INSTALLATION
4. 585 7000 FAX 407 585 1900 2005 Superchips Inc FRM27143 Created 11 05 Printed In U S A
5. INSTRUCTIONS 3 INSTALL THE PROPANE DISCHARGE FITTING 1 Remove the flex section of the air intake tube between the air cleaner outlet and the turbo inlet Use care not to allow any foreign material to fall into the turbine inlet or air cleaner outlet 2 Drill a 3 4 hole in the tube in the area shown in between the Air Cleaner and the Turbo Figure 4 3 Insert the discharge fitting in the 3 4 hole 4 From the inside install the concave washer to the threads of the fuel discharge fitting so the domed side faces the discharge fitting and it aligns with the curve of the intake tube 5 Install flat washer and nut Figure 4 Installing the Propane Discharge Fitting Note Tighten so that washer is seated to tube and fitting is aligned with vapor hose from regulator Do not over torque Coating with Red Loctite 272 or Blue Loctite 242 is highly recommended 6 Insert the supplied cotter pin through the Discharge Fitting and bend the ends outward to prevent the nut from coming loose 7 Reinstall the air intake tube to the engine 8 Route the Propane Vapor Hose from the Regulator Outlet to the Discharge Fitting It needs to be cut to fit This hose is wire re inforced and should be cut with cut off saw or band saw Note Verify there are no kinks in the hose and it is routed a safe distance away from sharp edges and hot engine components INSTALL MAP SENSOR VACUUM TEE You must tee in a map sensor line that runs the
6. ation with a red line Move the black line away from that point and the time between the red and black lines will be displayed at the top of the history1 window Press the space bar again to remove the red marker e Multiple files may be opened in the same window and all the lines of data will be displayed in the trace box e The same data line in different files will have the same color in all files SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 INSTALLATION INSTRUCTIONS 11 MENU TREE The following menu tree shows the different screens and programs of the PN 4810 and Monitor PN 4810 Flow Chat with Hand Held Monitor Monitor List Acq List Alert List 1 ScanTime 1Sec 1 Rpm 14 2 Track Error 2 Pwm 127 2 LpPsia 10 3 Dual Pedal 3 Rpm 12500 3 TpsPct 8 4 Pedal Open 4 Lp Psia 30 0 4 Target 8 5 Pedal Short 5 Target 30 0 5 Pwm 8 6 Lp Temp Open 6 TPS In 1023 6 Boost 10 7 Lp Temp Short 7 TPS 100 7 FuelRelay 1 8 Lp Psia Low 8 Fuel Temp 255 8 AnyAlert 1 9 Map Psi Low 9 Map In 99 9 9 Track Error 1 10 Fuel Deg Low 10 Acq Run ARM 11 Lp Sys ACTIVE 12 LiquidSol OFF 13 Baro 12 5 14 Cruise OFF 15 PwrLevel 100 10 FuelDegLow 1 total 62 MSD PROGRAMME fe MONITOR Monitor Stats Fuel Acq As ScanTime 1Sec Stat 1 SCAN H Rpm 1800 ENTER NEXT ScanTime 1Sec LAUNCH REVILIMITER 0 100 OFF Once Loop Alert A4PwrLevel100 Acq RunLoop
7. dash is recommended Figure 7 1 Mount the controller under the driver side of the dash behind the removable panel to access the fuse group 2 Route the wiring harness through the firewall Find a suitable location or drill a hole to route the wires through Use care not to cut or damage the wires Also use WIRE TO BE S SPLICED a grommet to insulate the wiring BARREL WIRE TAP a 1 Insert Male End Cup into wire to be spliced Figure 8 eee Apply Silicone Sealant in Barrel end 3 8 lt Hand tighten Barrel into Male End Cup 10 mm Strip wire approximately 3 8 10mm MALE Insert wire into Male End exposing only bare wire END Hand tighten male end to Barrel Connection complete Oo o1 B amp B W PP Figure 8 Using a Wire Tap SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 INSTALLATION INSTRUCTIONS 5 WIRING CAUTION Do not cut or splice into any critical safety circuits such as ABS SRS control air bag or dash displays Red Connect to the Fused Key On power source 10 Amp minimum Connect to the negative post of the battery Throttle Position Sensor TPS Signal Connect to Gray White wire of the TPS connector Figure 9 page 6 Note The Throttle Position Sensor is located above the Accelerator Pedal Trigger Wire RPM Signal Connect to the Light Green White wire that is grouped with a Red W
8. e that some tanks only offer a vapor fitting CAUTION Propane is heavier than air and will settle in low laying areas Propane vaporizes at 40 Fahrenheit and will freeze items if contacted Note The addition of propane will increase the exhaust gas temperatures It is recommended to install an exhaust pyrometer to monitor these temperatures and ensure they stay within a safe level Note Consult your vehicle s owner s manual in regards to vehicle powertrain warranty programs whenever adding aftermarket performance products Note Apply proper amount of pipe thread sealant on all fittings Note If your 1999 model truck has a build date prior to December 1998 there will be some installation differences Please contact MSD for information on where to mount the DPI Regulator assembly and how to obtain an rpm signal SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 INSTALLATION INSTRUCTIONS Propane Fuel Line HARDWARE INSTALLATION wom lt 2 lo Fitting E JETEN 4 aap VAPORIZER REGULATOR COM Coolant O ewe PONENT ASSEMBLY Hose ii N Bien The Vaporizer Regulator assembly must have seis eee 4 i or some components installed prior to mounting 7 RQ mae Control the unit Figure 1 shows the location of the y i 57 7 Solenoid supplied components ACO ER 1 Install the Outlet Orifice Verify assembly s Cin Hose is inserted as shown in Figure 1
9. hite and Blue wire The wires are located above the parking brake pedal Figure 9 page 6 Alternate Connection To White Pink on Pin 19 of ECU On Driver s side of firewall in the engine compartment Boost Pressure Sensor 4 Pin Connect to the 4 pin connector of the Boost Pressure Sensor on the Red block of Connector the Regulator Assembly This Boost Pressure Sensor does not use the temperature w 3 Wires sensor function See Figure 1 page 2 Propane Pressure Sensor Regulator 4 Pin Connect to the 4 pin connector on the Propane Pressure Sensor on the Regulator Connector Assembly See Figure 1 page 2 w 4 Wires Pressure Control Solenoid and Pressure Protection Switch Green Connect to the Pressure Control Solenoid Connect to either side of the Fuel Pressure Switch Note Connect the White jumper wire provided in the kit between the remaining contacts on the Pressure Control Solenoid and the Fuel Pressure Switch See Figure 13 pg 12 Lock Off Solenoid Yellow Connect these sleeved wires to the 2 pin Weather Pack connector on the Propane Red Lock Off Solenoid Enable Switch Note Mount the switch in an accessible location for the driver Pink Red Connect sleeved wires to the Enable switch Malfunction Indicator Light MIL Connect to the wires sleeved together to the LED Note Mount the MIL or Light Emitting Diode LED in a location visible by the driver Tach Outp
10. le Displays the temperature of the propane at outlet of regulator Manifold Absolute Pressure in the engine intake manifold Status of the DPI data recording system System ON OFF switch Verify display alternates between OFF amp ACTIVE when switched is toggled Displays whether Lock OFF solenoid is ON or OFF Displays setting of power level selected Displays the recorded ambient atmospheric pressure Displays whether the system is in cruise control mode This mode simulates Throttle Position based on engine manifold pressure PROGRAMMABLE ITEMS DATA EDITOR Pedal Note Fuel Note Acq Run alert The two values set the range for reading the factory Throttle Position Sensor TPS Lo Displays TPS In at idle minimum Hi Displays TPS In fully depressed It is recommended to use pre programmed values This value is factory set at 100 for 100 so that the system runs the fuel map as programmed Changing this value will reduce the amount of propane sent to the engine over the entire operating range Setting the start and length of time for the data acquisition file The data file has 2000 points that may be spread out over time Off No data acquired Run once One time window of data begins when the toggle Lp Sys switch is turned on Run loop Data is taken continuously and when saved the last record window is saved This is a traveling window with new data continuously replacing the olde
11. m value is raised propane will continue to be injected up to the new value SAVE DATA e In the GraphView MSD file window go to view click on Run History e In the Run History window go to the Transfer Click on Acq to plot This will store the last window as set in the data editor menu of data from the DPI to the PC e To save the data file go into the Run History window go to the File pull down menu click on Save Acq as and either use the name supplied or enter in a new name and click on Save VIEW PREVIOUSLY RECORDED DATA FILE e Open the Graphview File MSD window go to View pull down menu and click on history1 In the file pull down menu click on Open Acq and select a file e To display the values in the graph go to View Pull down menu in the history1 window and click on Tracebox Analysis Box e As the cursor is moved across the window a vertical black line moves along with it and the values of lines where they cross the vertical black line are displayed in the trace box e The lines of data in the history1 window may be turned on and off by clicking the x next to the data name in the trace box e Time between events may be displayed by moving the vertical black line either with the cursor or the left right arrow keys to the first event and hitting the spacebar on the keyboard e This will mark that loc
12. n such as 05 Turn Ignition power On N O Oi D a SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 8 INSTALLATION INSTRUCTIONS Note Do not cycle the ignition switch repeatedly or leave on for an extended period of time This can cause the Engine Heaters Glow Plugs to turn on and drain the battery Observe the following windows GraphView Product Connected Data Source Note File name will be displayed when file is opened as in Step 6 on page 7 None on either or both indicates communication failure I GraphView FILE fa O Data Editor EE File Transfer View Port Help Print File View Show Active ee Sop 0 00 10 00 20 00 30 00 40 00 50 00 60 00 70 00 80 00 4810 V05 M05 100 00 Data Source 80 00 MSD User 05 MOS H 60 00 jli MONITORS PwrLevel 00 40 00 a D EET r BoostEnable 1 u Pwm 255 L o ha 20 00 Ee Rpm 2574 Lp Psia 21 1 RunLoop l Target 21 5 Time 80sec Maintence Log TPS In 478 Jorn Pedal TPS 49 Fuel Temp 79 ir FaultA 2 Track Error Map In 32 1 FaultB 2 Track Error Acq Run RUN RpmLimit 3600 FaultC 0 Lp Sys ACTIVE BoostLimit 45 FaultD 0 LiquidSol ON 7 FaultE 0 Baro 12 5 FaultF 0 Cruise OFF FaultG 0 PwrLevel 100 FaultH 0 Faultl 0 FaultJ 0 l 1 rj w 0 00 m Clea Rpm FILE Jeee AlertsPer Alerts Scan 1 e oJ a etl on pe N
13. nditions are detected and meet program requirements Engine RPM Throttle Position Intake Manifold Pressure Boost and System Request On Off e Temporarily connect the LP Lock Off Solenoid to 12v and Ground e Verify no leaks are present outside of regulator assembly CAUTION If a leak is detected shut the fuel tank off immediately Repair leaks if necessary and repeat test repair until no leaks are detected Connect LP Lock Off Solenoid to ECU harness SYSTEM OPERATION TEST e The DPI system comes fully programmed and ready to run without using a computer You only need to connect a computer if you wish to monitor the DPI system operation or to change programmable features It is recommended to start and test drive the vehicle before making any changes to the software Programming and Acquisition Information for the Superchips DPI Pro Data Graphview Software System Requirements Windows 95 or later Software MSD Graphview Pro Data software Connect the monitor cable included in the kit This is a standard 9 Pin Serial cable DB9 from the RS 232 connector on the DPI ECU to a serial port on the PC INSTALLATION OF THE PRO DATA SOFTWARE 1 Insert CD Rom Click on version of Software you want to install from the MSD Ignition Pro Data menu screen Follow steps to load software Click on MSD Graph View Icon Click on File then Open Click on the 4810 folder then click on 4810v ign determines the versio
14. on Customer Service RMA 12120 Esther Lama Suite 114 El Paso Texas 79936 When returning the unit for repair leave all wires at the length in which you have them installed Be sure to include a detailed account of any problems experienced and what components and accessories are installed on the vehicle The repaired unit will be returned as soon as possible after receipt COD for any charges Ground shipping is covered by warranty All units are returned regular UPS unless otherwise noted For more information call the MSD Customer Service Line 915 855 7123 MSD technicians are available from 7 00 a m to 6 00 p m Monday Friday mountain time Limited Warranty Msp IGNITION warrants MSD Ignition products to be free from defects in material and workmanship under normal use and if properly installed for a period of one year from date of purchase If found to be defective as mentioned above it will be replaced or repaired if returned prepaid along with proof of date of purchase This shall constitute the sole remedy of the purchaser and the sole liability of MSD Ignition To the extent permitted by law the foregoing is exclusive and in lieu of all other warranties or representations whether expressed or implied including any implied warranty of merchantability or fitness In no event shall MSD Ignition be liable for special or consequential damages SUPERCHIPS wwwsuperchips com 1790 Airport Blvd Sanford FL 32773 407
15. s A i i A A A J POWER HAS NEVER BEEN EASIER Digital Propane Injection for Ford 7 3L 99 03 Powerstroke Turbo Diesel Vehicles PN 4810 U S Patent Pending IMPORTANT Be sure to read and understand all instructions before installation Failure to do so may lead to damage of property injury and voiding of warranty Parts Included 1 Regulator Assembly 1 Monitor Cable 1 Regulator Mounting Bracket 1 Heater Hose 1 Propane Lock off Solenoid 1 Enable Switch 1 Fuel Pressure Switch 1 Fault Light 1 3 way Pressure Control Solenoid 1 Vapor Hose 1 Propane Pressure Sensor with Fitting 1 Discharge Fitting Elbow Vapor to Intake 1 Boost Signal Hose 2 Fitting Heater Hose to Vaporizer 1 Electronic Control Unit ECU 2 Parts Bag 1 Harness Assembly 1 MSD Pro Data CD PN 9608 WARNING Disconnect the batteries during installation of the DPI system When disconnecting the batteries remove both negative battery cables first and install them last Note The propane tank must be purchased separately and must meet Federal DOT and NFPA 58 requirements as well as state and local requirements that may apply Information is available from your local propane professional which can be located at www usepropane com LIQUID PROPANE REQUIRED The DPI system requires liquid propane at the regulator to function correctly IT WILL NOT work on propane vapor The tanks must be equipped with a liquid pickup Be awar
16. sensor on the Vaporizer x Sensor 1 Route the new Pressure Hose along the Location top of the firewall 2 Insert the Pressure Hose in the Regulator Assembly Boost Pressure Port 3 Cut the factory MAP sensor hose and install the supplied Tee in line Figure 5 4 Connect a new pressure hose to the tee Note Verify the Manifold Pressure Hose is not kinked and is routed in a safe secure manner that is away from any sharp objects or engine heat sources Figure 5 Connecting the MAP Sensor SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 q INSTALLATION INSTRUCTIONS INSTALL VAPORIZER COOLANT HOSE Note The Vaporizer assembly requires a constant flow of engine coolant to maintain proper propane flow Use the manufacturer recommended coolant See your Owner s Manual for information 1 Remove the 3 8 hose from the driver side of the surge tank 2 Cut hose in kit to install T fitting as shown in Figure 6 3 Route a new hose from the T fitting to the vaporizer 4 Route and clamp a new hose from the vaporizer to the driver side engine block using the supplied 3 8 NPT fitting as shown in Figure 6 MOUNTING THE CONTROLLER The DPI s ECU can be mounted in almost any location and any position under the hood Mount away from high temperature sources such as exhaust manifold as well as direct pressure wash spray Mounting it under the
17. st One window of data is taken only when an alert flag is set SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 10 INSTALLATION INSTRUCTIONS Note THESE DATA FILES ARE NOT AUTOMATICALLY SAVED Select a length of time 20 sec 80 sec 6 min 33 min Note Shorter file lengths have faster sample rates which give better definition to the data lines and will better show what happens before during and after a particular event such as a transmission shift Boost enable This is the manifold pressure at which the Ip system will activate The default setting is zero so that the propane system will begin to inject propane during normal driving conditions If so desired the boost enable value may be raised so that propane is only injected during acceleration and hill climbing Extend Boost limit This value is the manifold pressure above which propane injection will be disabled The default setting is 45 psi which is the maximum of the factory supplied sensor This value may be lowered to correspond to the vehicle maximum boost level If the value is raised above 42 psi the pressure sensor will not be able to send a value this high to the computer therefore propane will not be disabled due to overly high manifold pressure RPM limit The maximum engine rpm up to which propane will be injected The default value is set for each motor type based on the factory limits If the ro
18. ut Optional Connects to tach for 4 cylinder two pulses per revolution SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 S INSTALLATION INSTRUCTIONS To Fuel Lock off To Propane Solenoid Pressure Sensor MC pg F To Boost Y Pressure Sensor SINE To LED Wh i GRAY To Tach Th Fhanle witc To Pressure BLUE T T CRo i solenoid GRAY T a BLACK _ i Ox BLACK PED To Fuel ee RED GREEN Either side BROWN IE RED Black GREEN RED WHITE To Switched 12 Volts ORANGE To Gray White Wire of TPS Harness Above the throttle pedal To RPM Signal Lt Green White Wire Ground Grouped with Red White and Blue wires above brake pedal Alternate Connection To White Pink on Pin 19 of ECU On driver s side of firewall in the engine compartment eae LT GREEN ee A pe i WHITE WIRE TO Gray White ea IPE NR 4 DPI WHITE Wire i AA 0 a lt 7 Throttle Position Sensor Trigger Wire Location Figure 9 Wiring the Digital Propane System SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 INSTALLATION INSTRUCTIONS 7 PROPANE DELIVERY AND LEAK TEST e It is recommended to have the propane tank filled by a qualified supply service and have them verify that there are no leaks in the system e The DPI Controller will not activate the LP Lock Off Solenoid until all co
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