Digital Propane Injection® for Dodge Cummins 12 valve `94
Contents
1. 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 location 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 4871 and Monitor PN 4871 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 Psi2. 5 Install flat washer and nut 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 to 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 PORT You must install a map sensor line that runs to the Boost Pressure sensor on the Vaporizer 1 Route the new Pressure Hose along the top of the firewall 2 Insert the Pressure Hose in the Regulator Assembly Boost Pressure Port 3 Install supplied fitting to a portion of the intake manifold Figure 5 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 FL 32773 407 585 7000 FAX 407 585 1900 q INSTALLATION INSTRUCTIONS INSTALL VAPORIZER COOLANT HOSE Note The Vaporizer assembly requires a
3. 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 Orange 94 95 Connect to Orange Dk Blue wire on Pin 22 of Powertrain Controller 96 97 Connect to Orange Dk Blue wire on Pin 23 of Powertrain Controller Trigger Wire RPM Signal 94 95 Connect to the Gray Lt Blue wire on Pin 43 of Powertrain Controller 96 97 Connect to the Gray Black wire on Pin 8 of C1 of Powertrain Controller Boost Pressure Sensor 4 Pin Connect to the 4 pin connector on the Boost Pressure Sensor Port on the Red MSD Connector Block This Boost Pressure Sensor does not use the temperature sensor function w 3 Wires 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 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 Con
4. a guide drill three 5 16 holes through the front section of the passenger side fender well and fender lining Mount the bracket to the regulator Install the regulator assembly on the fender well using the supplied fender washers on the tire side of the fender well Figure 3 Note Some applications may require alternative A mounting For these applications verify the regulator is mounted with the regulator inlet at the top Connect the liquid supply line to the lock off solenoid inlet 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 Drill a 3 4 hole in air box assembly No MAI Sensor on these applications Figure 4 Insert the Discharge Fitting in the 3 4 hole Fuel Pressure Fuel Line Fitting Propane Lock off Solenoid Coolant Hose Fitting Propane Pressure Sensor Figure 3 Mounting the Regulator Assembly SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 INSTALLATION INSTRUCTIONS 3 INSTALLED DISCHARGE Cotter INSTALL att M DISCHARGE FITTING HERE 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. 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 rom 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
6. POWER HAS NEVER BEEN EASIER Digital Propane Injection for Dodge Cummins 12 valve 94 9S8S Turbo Diesel Vehicles PN 4871 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 aware that some t
7. a 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 BoostEnable 5 Time 80Sec 0 30 20 80sec 6 33min Pedal Extend 2700 3700s100 4RpmLimit 3800 BoostLimit 45 15 45 APedal Lo 852 Hi 500 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 FL 32773 407 585 7000 FAX 407 585 1900 POWER HAS NEVER BEEN EASIER Figure 12 Outlet Orifice Assembly Figure 13 Vacuum Line Routing 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 expi
8. anks 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 SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 INSTALLATION INSTRUCTIONS oolan Pressure HARDWARE oe Bo INSTALLATION Sen VAPORIZER REGU LATOR COMPONENT ASSEMBLY The Vaporizer Regulator assembly must have some components installed prior to mounting the unit Figure 1 shows the location of the supplied components 1 Install the Outlet Orifice Verify assembly is inserted as shown in Figure 12 pg 12 2 Install Propane Pressure Sensor 3 Install Fuel Pressure Switch and fuel lock off solenoid 4 Install the 90 coolant hose elbow fittings to the regulator s coolant inlet outlet ports 5 Install Fuel Line Fitting MOUNTING THE VAPORIZER REGULATOR Outlet Orifice Boost Pressure Port Boost Pressure Sensor 1 Using the mounting bracket as
9. constant flow of engine coolant to maintain proper propane flow Use the manufacturer recommended coolant See your Owner s Manual for information 1 Separate the upper heater hose from the outlet at the top front of the engine block and remove the tube 2 Install a new hose and route from the engine to the vaporizer assembly 3 Install a second hose from the vaporizer assembly to the heater hose port on the firewall taking care to maintain a safe distance from the exhaust and turbo charger 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 A recommended mounting location is on the front section of the passenger side battery tray Figure 7 1 Using the controller as a guide with the large connector towards the outside of the vehicle mark and drill two holes on the forward side of the passenger side battery tray 2 Mount the controller as shown Figure 7 Mounting the ECU WIRE TO BE SPLICED WIRE TAP Insert Male End Cup into wire to be spliced Figure 8 Apply Silicone Sealant in Barrel end Hand tighten Barrel into Male End Cup Strip wire approximately 3 8 10mm Insert wire into Male End exposing only bare wire Hand tighten male end to Barrel Connection complete BARREL O pie oA Figure 8 Using a Wire Tap SUPERCHIPS
10. ed MONITORED ITEMS Pwm RPM LpPsia TPS In TPS Fuel Temp Maplin 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 throttle 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 i
11. ehicle 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 4871 folder then click on 4871v ign determines the version such as 05 Turn Ignition power On N oo D ie SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 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 fX Data Editor O X History File 1 022205test2 File Transfer Yiew Port Help Print Fie Transfer Edit view Sho
12. ire on Pin 43 of Powertrain Controller On passenger side of cowl 96 amp 97 Models To Gray Black Wire on Pin 8 of C1 of Powertrain controller On passenger side of cowl ME DA pa Ge Va f g 4 1 POWERTRAIN CONTROLLER C1 Throttle Position Sensor 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 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 The DPI Controller will not activate the LP Lock Off Solenoid until all conditions 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 Ifa 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 v
13. red 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 Ignition Customer Service RMA 12120 Esther Lama Dock 5 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 e
14. s 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 oldest One window of data is taken only when an alert flag is set SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 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
15. trol 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 Connect sleeved wires to the Enable switch Red 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 Output Optional Connects to tach for 4 cylinder two pulses per revolution SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 6 INSTALLATION INSTRUCTIONS To Fuel Lock off To Propane Solenoid Pressure Sensor UL Man leal To Boost Y CT ai E y Pressure DIGITAL PROPANE INJECTION Sensor A To LED naf GRAY_ To Tach To Enable p lla BED Switch o Pressure TT lj k rel rep i lt GRAY M BLACK _ _ Ca BLACK RED To Fuel e RED GREEN Either side BROWN li RED ane 4 GREEN RED WHITE To Switched 12 Volts TPS SIGNAL ee 94 amp 95 Models To Orange Dk Blue Wire on Pin 22 of ECU On left side of cowl Battery l BLACK Ground 96 amp 97 Models To Orange Dk Blue Wire on Pin 23 of C1 Powertrain Controller On passenger side of cowl WHITE RPM SIGNAL 94 amp 95 Models To Gray Lt Blue W
16. w Active 2071 MO5 k 10 00 20 00 30 00 40 00 50 00 60 00 70 00 Monitor aidsa S t ats Product Connected 2871 V05 MOS Data Source MSD User V05 MOS Pwrlevell 00 BoostEnable 1 MONITORS Pwm 129 4 RunLoop Rpm 1857 Time 80sec Lp Psia 18 6 Target 13 1 4 Maintence Log TPS In 607 aa TPS 69 Fuel Temp 79 le Map In 34 4 be ey FaultB 0 Acq Run RUN Alerts FaultC 0 Lp Sys ACTIVE FE nnn AlertsPer FaultD 0 LiquidSol ON Alerts Scan 1 FaultE 0 Baro 13 0 FaultF 0 Cruise OFF FaultG 0 PwrLevel 100 FaultH 0 Faultl 0 FaultJ 0 Rpm FILE 3 20 gly q Ps e Dodge Cummins 94 97 12v Default data and menu for Diesel Engine Propane Fumigator 2871V05 Uses menu 2871405 2 start Inbox Microsoft Out RB Graphview FILE 2871 Paint kj DMs 9 07 am F 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 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 record
17. xtent 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 www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 2005 Superchips Inc FRM27150 Created 11 05 Printed In U S A
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