Isuzu 6.0L Installation Manual - Bi
Contents
1. 274571 REV A Page 24 Isuzu Medium Duty Installation Instructions LPEFI Electrical Wiring Diagram Main Wiring Harness Isuzu W series Medium Duty HUN SISSEU Jay NO pd YJE Uaa a437 fang Od AB ayy dung jan Waa UO 14 OEM harness LPEFI harness Yu MIEUNA Japuas 3437 jan D D T amp it 3 SS3UJeH Wadd ral 2 SSALICH 44d ed 5 Fl Fell Pay iz fey qld I i memo a i 1 PoE iI 3 5 3 a am T B om 2 EL u 7 274571 REV A Page 25 Isuzu Medium Duty Installation Instructions Installation amp test date VIN Make Model Installer company name Tank Mfg Primary tank serial number Fuel Rail Serial Numbers amp Quantity of propane gallons Loop hose engaged with audible click Yes U No L Primary hose installed correctly into LPDM Hose collar should not be visible refer to installation manual Yes No Open driver door Does purge cvele initiate Yes No LJ Start Vehicle Leak test tank amp LPEFI system complete refer to installation manual for test procedure Yes L No O Leaks found amp repaired Yes O No O Where Any stored DTCs in computer memory Yes I m O List all codes If any DTCs found other than the codes listed in the EPT Installation manual for the specific vehicle repair all codes and retest Does vehicle restart easily after purge cycle is complete Ye2. good idea to inject some methanol into the tank before filling the tank with fuel On average one pint of methanol per 100 gallons of propane or I gallon of methanol per 1 000 gallons or propane will resolve any moisture or water residue 9 On the last purge with vapor leave the tank being purged pressurized and this is a good time to check the tank and valves for leaks check for leaks with an approved leak detection fluid or electronic combustible gas detector 10 If no leaks are found and the purge process is complete the tank is ready to be filled with propane liquid 11 Fill the tank with 5 gallons of fuel before any electrical components are reconnected This will insure there is no or very little air in the tank 274571 REV A Page 30 Isuzu Medium Duty Installation Instructions Connect Hose to Fill Port pen Valve Slowly Open Valve Slowly 274571 REV A Page 31 Isuzu Medium Duty Installation Instructions Place the Purge Box in alignment over the four holes on the top right corner of the plate Place the Relay in alignment over the 2 holes in the top left area of the plate Put washers on all of the screws then place the screws with washers in all four holes in the purge box and two screws in the relay on the front side of the Purge Box and Relay On the backside of the Plate place a nut on each screw and tighten the nuts with your fingers 2 Place the 5 32 Allen head wrench in the hole on the s
3. REV A Page 7 Isuzu Medium Duty Installation Instructions Bi Phase Technologies LLC Facts about Propane amp Propane Powered Vehicles Propane gas is the most widely used alternative fuel with nearly 4 million vehicles worldwide running on propane More than 350 000 vehicles run on propane in the U S according to the U S Department of Energy s Alternative Fuels Data Center Propane powered vehicles offer the best combination of durability performance and driving range The first propane powered vehicle ran in 1913 Bi Phase Technologies LPEFI Liquid Propane Electronic Fuel Injection system has surpassed other technologies today by introducing liquid fuel injection This technology improves power efficiency and operating characteristics For more information call for our General Information and Training Manual Safety comes first is a motto you should always live by Without knowledge of a product it is hard to follow this motto In our manuals we try to stress the need for knowledge and provide warning signs to alert you It is your responsibility to know the law NFPA National Fire Protection Association has manuals to help you understand safe handling of many products We recommend that you obtain and read their NFPA 58 Standard for the Storage and Handling of Liquefied Petroleum Gases To further enhance the industry s safety and service a number of training programs and efforts have been implemented throughout t
4. Remove the new fuel rails from the package retain the envelope with the rails ra 15 16 socket amp Note The envelope contains decals owner information card ratchet with same and a warranty registration card The warranty registration Sze wrench card along with the Post Installation Inspection form must be filled in and returned to Bi Phase Technologies for warranty to be valid Label placement is described later in this installation manual Place both rails on the bench as shown in the photo at left Pa 3 8 QD tool The bottom rail in the photo is the passenger side rail The bushings and hold down clamps are not ZA mounted on the rails and will need to be Clean motor oil installed prior to installation on the engine A Caution Gasoline under pressure Gasoline is flammable amp toxic Use extreme caution and eliminate all sources of ignition while handling Wear gloves amp goggles Lubricate the lower o rings green on each injector and place each rail on the engine with the QD hose inlet connector facing toward the rear of the engine Note The injector electrical connectors should be facing outward to allow clearance between injector amp intake plenum The electrical connector could interfere with the installation of the rail or the installation of the rail could damage the injector if not pre positioned outward Before installing fuel rail install spacer between the ma
5. a period of time due to the porosity of the steel release this pressure build up before starting the purging process 2 Open the valve to release such pressure build up and allow it to equalize to atmospheric pressure 3 Connect the propane vapor source to the fill connection on the tank or 1f the tank is equipped with a vapor service valve hook up to the vapor service valve 4 The propane vapor used can be a small cylinder such as a barbeque grill cylinder these cylinders are vapor service only attach an adjustable high pressure regulator to the cylinder and adjust the outlet pressure of the regulator to 15 p s 1 this is to be connected to vapor service only 5 Slowly open the vapor service valve on the cylinder and allow vapor pressure to equalize into the tank being purged to15 p s 1 and turn off the valves 6 Release all the pressure in the tank being purged to atmosphere or to a flare stack and close the valve when all the vapor pressure is released 7 In order to ensure that at least 95 of the air 1s removed the container must be pressurized and bled down or depressurized several times usually 3 to 5 times is sufficient 8 The closer to the top of the tank the valve you are using to release the pressure or depressurize the tank the better Note If there is any indication of moisture or water in the tank and most of the liquid water was removed during service of the tank there remains some moisture In this case it is a
6. as shown in the photo Attach the fill fitting to the bracket on the tank Install the 90 degree from the longest hose to the fill fitting Torque to 44 48 ft lb Install the other end of the hose to the 80 valve Torque to 44 48 ft lb To Primary Tank Stop Fill Yah Torque 44 48 ft ib Ay l l l Pee Warning Stop fill valve elbows are never tightened at the tank manufacturer The valve is tight but the elbow must be tightened and clocked to the proper position Do not allow the valve itself to move while tightening the elbow uns e Attach fill filter to frame rail will clamp as shown Isuzu Medium Duty Installation Instructions Primary hose e Route the primary fuel line with flare end fitting toward the front of the engine e The hose will route from the LPDM over the top of the tank e Turn the hose toward the transmission bell housing it will run over the rear of the engine e Continue to route the hose around the passenger side of the engine and loop back towards the right injector rail e Before lowering cab modify the engine cover by removing 8 out of the lower right corner of the cover e Cut at the bottom of lower rib e After lowering cab verify engine cover does not touch the loop or primary hose Attach primary fuel hose to injector rail e Pull out about 2 1 2 inches of the white inner hose out of the primary fuel line e Lubricate inner line with clea
7. avoid ignition inside the tank Any spark or flame can ignite a cloud of propane vapor in or near the tank which could cause severe burns personal injury and or property damage Always disconnect the negative battery terminal first Purging the tank is different from the purge cycle in the LPEFI system Purging the tank means removing the air oxygen and moisture from inside the tank before putting the tank into service This is a required procedure on all new tanks tanks that have never been filled with propane or tanks that have been evacuated and opened to the atmosphere for service or for any reason Note Purging the tank is always required if the tank is evacuated and any valve or component is removed that causes the tank to be exposed to the atmosphere Why Purge a Tank Most tanks are steel and are prone to rust To prevent rust purging will remove air oxygen and moisture which causes rust Also by purging and removing the air oxygen from the tank there is no chance of air in the tank causing pressure fluctuations This trapped air could also cause excess pressure in the tank and could cause a slow fill situation New tanks come purged with an inert gas and this same situation could also occur if the inert gas is not purged from the tank Always follow proper purge procedures The LPEFI system uses an electric fuel pump mounted inside the tank Propane must be mixed with air between 2 15 and 9 6 fuel to air mixture to be comb
8. completely in push the entire fitting into the rail until it clicks and locks Secure the loop hose Connect the loop hose to the fuel line bracket Verify the hose is routed in a way that there is no interference with chassis components that could cause chaffing Look at the QD fitting and verify the four locking tabs are secured on the hose fitting Install the P clamp on bracket as shown Completing Wire Harness Installation Primary tank Main LPEFI harness to purge box relay and LPDM branch is 4 connectors on 4 branches tied together Refer to page 31 e Using the cover plate previously remove attach control and relay to plate with hardware provided Secure to plate with 5 32 hex and 3 8 socket Connect main LPEFI harness connection to electronic purge box and relay and LPDM Assemble cover plate to rear of the primary tank Secure hardware to cover plate and tank WARNING Do not make the final electrical connections until the LPEFI system is cal asa sealed ae power could cause the valves in the tank to open releasing fuel into the hoses Pa 13 mm wrench or Ratchet amp socket Fa 1 wrench Ratchet amp socket Fa 1 wrench Ratchet amp socket Fa 7 16 wrench Ratchet amp socket Page 20 Isuzu Medium Duty Installation Instructions Install labels on the truck registration Note For best results when applying labels dip the label s in soapy water before you apply it to th
9. detection fluid or an electronic leak detector to verify there are no leaks If any leaks are found stop and repair the leaks The battery should not be connected at this time If the tank was filled before installation it should have been checked for leaks at that time Connect a fuel pressure test gauge to the Shrader valve on the LPDM Fuel pressure should be 0 psi at first If the connections on the electronic purge control assembly have not been made connect at this time Connect the battery You may hear a click at the tank Open the driver door to start a purge cycle You should hear the solenoid valves click and the pump running inside the tank If not check the electrical connections and refer to the troubleshooting section in the service manual 8 Simultaneously with the preceding step you should inspect all hose connections the LPDM the fuel rail connections and the injectors for leaks If any leaks are found you should disconnect the electronic purge control assembly evacuate the lines and repair See the service manual for procedures 9 When the purge cycle ends listen for leaking fuel near the hoses and around the entire system If you do not hear any obvious hissing or smell propane turn on the ignition key but do not start This will start the fuel pump followed by a purge cycle 10 When you hear the fuel pump stop running notice the fuel pressure on the test gauge This pressure should be anywhere from 30 psi in cold wea
10. Duty Installation Instructions LPEFI PURGE LOGIC Opting a olay of condition LPEFI function Results l Engine Off 2 Door closed longer than 10 Liquid propane 15 delivered to the mumites injectors and propane vapor 15 Door purget 3 open the door Purge for 15 seconds retirn to the tank Liquid propane us delivered to the l injectors and propane vapor 5 Key Purge 2 key to on position Purge for 15 seconds retum to the tank FP injechons open to deliver fuel to sug mut fotitan ein pag injectors open to deliver fuel to Ming rmming T jmd fm fig ki No fuel is delivered to the Valves closed pump stops myectors closed att closed The door opening feature will only mutate a purge after the door has heen closed for more than 10 minutes FA purge can always be mutated by tuming the wtution key to the on position A purge will be begin and complete within 12 to 15 seconds If another purge 15 desired tum the irution key off and on again Tank control box wiring Outputs Inputs Vehicle Inputs to tank from vehicle 1 must be grounded do not rely on box mounting screws 2 12V batt always on through a 15 A fuse 3 looks for 12V when engine is running 4 ground to activate manual purging 5 12 V output to indicator lamp 6 GM boxes ground to start purge cycle Tank Outputs Ford boxes 12 V to 1 2 83 will start purge cycle provide 12 V when active al GND Button Key u amp e z Pump
11. Isuzu Medium Duty Installation Instructions Bi PHASE TECHNOLOG IL E S Making Alternative Fuel Standazd LPEFT Installation Manual For 2012 Isuzu Medium Duty Trucks with 6 0 Liter Engine Models W5500 Mono Rail System 274571 REV A Revised Feb 22 2012 pitts th nerapna nn Isuzu Medium Duty Installation Instructions REVISION HISTORY REV DESCRIPTION DATE D F T G 274571 REV A Page 2 Isuzu Medium Duty Installation Instructions Bi Phase Technologies LLC Introduction This instruction booklet shows how to convert a gasoline vehicle to run on clean burning propane utilizing our LPEFI Liquid Propane Electronic Fuel Injection system The system is vehicle specific and installing a system on any vehicle that the kit was not designed for will void the warranty and may also violate emission laws Anyone who installs or repairs the LPEFI system must be trained and certified This must also include training in the safe handling and characteristics of propane Bi Phase Technologies provides such training upon request Some states may require a license to work on propane vehicles Consult your state or local authorities or your state propane gas association Bi Phase Technologies LLC is not responsible for your oversight to comply with federal state or local laws regulating the installation or repair of propane gas systems The LPEFI system is a Sequential multi port fuel injection system
12. and through the box and down the inside driver side of the frame to the rear of the truck Leave the white wire trunk of the LPEFI harness loose along the outside driver side chassis frame rail to permit routing to the front of the truck to the inside of the cab Remove the cover from the top of the gasoline fuel tank Unplug the gasoline fuel pump harness and reroute it down the driver side frame rail Plug the LPEFI 4 pin connector to the fuel pump harness Secure harness with tie wraps every 8 inches Main LPEFI harness to battery box branch is an orange wire with an in line fuse and eyelet connector on the end e Route the main LPEFI harness to battery box branch across the cross member then along the inside passenger side frame rail towards the battery box e Remove the battery box cover and install the eyelet on the orange wire with fuse to the positive side of the battery 274571 REV A Page 14 Isuzu Medium Duty Installation Instructions Note Before securing any of the harness makes sure it is routed to meet the length requirement to make each connection Fa Main LPEFI harness to door switch branch it is a Umane mn white 16 gauge wire BERUHT ER ratchet Guide the main LPEFI wiring harness phillips screw white wire to door switch along the driver side frame to the front of the truck A driver Secure harness with tie wraps every 8 Nylon tie straps inches y P Pliers 1 wrenc
13. crew and the 3 8 socket attached to on the nut and tighten the nut and screw 1 3 Once all four bolts are secured put the warning label sticker on the back of the plate n the middle as shown 274571 REV A Page 32
14. e truck Slide the Rubber squeegee label into position and then use a rubber squeegee to force out the air and water e Install PCM Label above OBD connector on dash panel see photo 1 Install the EPA emissions label on rear of cab in engine compartment see photo 2 Install the warning label on the driver s side rear corner of the cab see photo 3 If the truck does not have a box or body installed yet put the propane diamond in the glove box for later placement see photo 4 After the body is installed on the truck install the PROPANE diamond on the back panel of the truck toward the bottom right corner do not install on the bumper Place laminated owners information cab card in the glove box with the OEM s owners manual amp other GM information see photo 5 Place 4 tie wire labels at both ends of the loop hose and primary hose see photo 6 Place LPEFI label on each side of the cab corner panel see photo 7 Fill out vehicle Post Installation Inspection Form and return to Bi Phase Technologies Isuzu Medium Duty Installation Instructions Testing the Installation 1 Visually inspect the tank s the hoses the wiring and the engine compartment Is everything assembled properly 2 Fill the tank with 20 to 30 gallons of propane It is recommended that you purge the tank with propane vapor and check all the fittings on the tank for leaks before filling the tank completely Use an approved leak
15. erating temperature 190 F on your Scan tool Turn the key off and follow the testing procedures described in the Post Installation Inspection Fill out the Post Installation Inspection completely Turn off the engine and disconnect the fuel pressure gauge set Be sure to reinstall the dust cap on the WARNING The pressure test hose may contain cold liquid propane Wear insulated rubber gloves and goggles Shrader valve Drive the vehicle for at least 15 minutes if possible Drive under various conditions and a variety of speeds After the drive notice the long term fuel trims as noted in the post inspection The long term fuel trims should not be the same as they were before the drive The long term fuel trims should not be more than or 20 After driving and inspecting the vehicle turn it off and let it sit with the hood and doors closed for 15 minutes After 15 minutes return to the vehicle open the door to initiate a purge and start the engine If the engine starts easily 3 seconds or so the vehicle is ready to use If there are no leaks no DTCs and the engine runs well smooth idle smooth acceleration good power the vehicle is ready to use If you did not fill out the warranty registration card in the Installing Labels Procedure do so now Also complete the Post Installation Inspection and return both to Bi Phase Technologies to establish the warranty start date for your vehicle 274571 REV A Page 23 Isuzu Medium
16. h or Remove the grill and driver side headlamp socket amp ratchet assembly Route the white wire through the grommet to the inside of the cab Remove carpet trim Connect white wire to the yellow wire with the red tracer 274571 REV A Page 15 Isuzu Medium Duty Installation Instructions Install LPEFI system Gauge a Phillips screwdriver Wire connector tool or equivalent Warning Disconnect the battery before you Magnet work on any part of the LPEFI system Wipe magnet Install fuel level sending unit on the primary around gauge tank Note Use the 40 250 ohm resistance fuel level gauge sending unit supplied in the kit When installing a fuel level gauge sending unit always reset the sender to zero using a small magnet after installed on the tank the sending unit s needle should register zero or empty unless there is fuel in the tank Main LPEFI harness to sending unit branch it is a black two pin connector e Connect the main LPEFI harness to sending unit branch to the fuel level gauge use A nylon wire ties to secure the primary hose Me wrench Ge socket amp ratchet Note Always be aware of routing Do not route near the exhaust and always use split loom to prevent chaffing Prepare to install the LPEFI protecting cover with the 3 8 bolts provided at this time leave the bolts loose and do not connect the main LPEFI harness to purge box relay and LPDM to the electronic con
17. he country The National Propane Gas Association has developed a Certified Employee Training Program CETP which provides service personnel with a complete technical training curriculum We encourage you to contact your state propane gas association or the National Propane Gas Association for more information on how you can benefit from such programs Visit www propanesafety com for more information 274571 REV A Page 8 Isuzu Medium Duty Installation Instructions Bi Phase Technologies LLC Approximate Properties of LP Gases Commercial Propane Specific gravity of liquid water 1 at 60 degrees F Initial boiling point at 14 7 psia degrees F Weight in lbs per gallon of liquid at 60 degrees F Specific heat of liquid BTU Ib at 60 degrees F Cubic ft of vapor per gallon at 60 degrees F Cubic ft of vapor per pound at 60 degrees F Specific gravity of vapor air 1 at 60 degrees F Ignition temperature in air degrees F Maximum flame temperature in air degrees F Limits of flammability in air Percent of vapor in air gas mixture a Lower b Upper Heating values a BTU per cubic foot b BTU per pound c BTU per gallon Chemical formula Vapor pressure in psig a 70 degrees F b 100 degrees F c 105 degrees F 0 504 44 0 4 24 0 630 36 38 8 66 1 50 920 to 1120 3 595 2 15 9 60 2 488 21 548 91 500 C Hs 127 196 210 274571 REV A Page 9 Isuzu Medium Duty Installat
18. ion Instructions Bi Phase Technologies LLC Pre Installation Inspection Recommended If your vehicle is equipped with a single gasoline fuel tank and you will be installing a single propane fuel tank follow the procedure in this manual If the vehicle s new and has less than 1 500 miles we recommend the following e Visually inspect the vehicle Is the malfunction indicator lamp illuminated Does the engine start and run smooth Are there any fluid leaks e Install a diagnostic scan tool and verify there are no DTCs Diagnostic Trouble Codes stored in the computer memory If the vehicle is used and has more than 10 000 miles we recommend in addition to the above e Remove and examine the spark plugs and conduct a compression test e During diagnostic scan mode document the following from the scan tool data stream Short term fuel trim bank 1 amp 2 Long term fuel trim bank 1 amp 2 IAC idle air control Oxygen sensor activity Note Proceed with the LPEFI system installation if all conditions are acceptable If any problems are discovered it is not recommended to install the LPEFI system until the problems are repaired After the installation is complete refer to the Post Installation Inspection found in this manual 274571 REV A Page 10 Isuzu Medium Duty Installation Instructions A Remove gasoline fuel rails fuel line tank amp evaporative emission system if the vehicle is Pi equipped with the EVAP comp
19. lling Lab I een Testing the Installat ion ceccccc Pur LO EEO E EE EE AT Tank Control Box Wiring 2222ceeeeeeseeenc nn Electrical wiring diagram ccc cece eee eee e eee Post Installation Inspection re OWN MN WN 11 12 12 13 14 16 17 18 20 20 22 24 24 25 26 274571 REV A Page 4 Isuzu Medium Duty Installation Instructions Bi Phase Technologies LLC Notes 274571 REV A Page 5 Isuzu Medium Duty Installation Instructions Bi Phase Technologies LLC Propane Safety IN This is a safety alert symbol It is used through out this manual to alert you to potential hazards Whenever you see this symbol you should read and obey the safety warnings that follow Failure to obey these warnings could result in serious personal injury or property damage Please read some of the Specific Warnings below before proceeding with the installation or repair of any propane system A Warning Always unplug the LPEFI control box or disconnect the battery before you work on any part of the LPEFI system The LPEFI tank contains an electronic control box Any time the driver door is opened the LPEFI system could go into a purge mode pumping liquid propane through the hoses and injectors To prevent a sudden release of cold liquid propane disconnect the power from the control box before you loosen any hose fittings Failure to do this could ca
20. n motor oil e Carefully guide the inner line into the center of the rail and feel for the line to engage the internal o ring see picture on left 2 of inner line must be inserted into the rail to make a proper connection e Pull the outer hose onto the fitting on the end of the rail tighten the flare nut torque to 33 38 ft lb use a backup wrench on the rail to keep the brass fitting from turning as you tighten the flare nut do not over tighten the flare nut brass fitting on the rail is tightened to 5 6 ft lb e After tightening the flare nut verify the hose does not come in contact with any components ra 1 4 wrench Pa 7 8 wrench 3 4 wrench 7 16 wrench socket amp ratchet 10 or 12 crescent wrench 7 8 open end wrench 1 open end wrench Isuzu Medium Duty Installation Instructions sert inner hose Install gaske Al amp plate Install LPEFI System Install split bushing locking wedges 3 ra Attach the primary line to the LPDM T 20 Torx driver a Clean motor oil Position the primary hose to be connected to the LPDM by routing the hose over the tank i e Remove retaining screws plate gasket and split collar retainers from LPDM Clean motor oil e Install plate and gasket onto hose end fitting of primary hose e Lubricate hose end fitting metal surface and white nylon inner line e Insert into center of LPDM port and push in slowly un
21. nifold and the rail bracket Using the original 6 mm bolts taken from the gasoline rail mounting bracket secure the LPEFI injector rails to the intake manifold tighten to a torque of 12 NM 106 in Ib Isuzu Medium Duty Installation Instructions y 4 RARVRAV Install original gasoline injector wiring harness and connect each injector connector to the proper cylinder Remove and discard the bracket on the rear of the driver side head Note When disconnecting or connecting injector connectors be careful and pull locking tab up to disconnect and push in on connector squeeze to disconnect After reconnecting push locking tab down to lock connector Be careful not to break this plastic tab and locking piece New Spark Plugs e Replace the spark plugs with NGK IFR7F 8DS a stock 5794 14mm x 5 8 Hex Iridium ea Platinum resister plugs Plug gap 8mm or 0 31 274571 REV A Page 13 Isuzu Medium Duty Installation Instructions Main wire harness A Warning Disconnect the battery before you M 7 8 wrench work on any part of the LPEFI system Note Route the main LPEFI harness before completing any connections Fa Nylon ti Main LPEFI harness to existing Isuzu fuel pump en wire harness e Lay out the main harness with the four pin A connector pointed toward the rear of the N ylon tie straps truck Remove the cover from the wire harness junction box Route the harness under the frame
22. onents 10 mm socket amp VY drive ratchet Warning Disconnect the battery before you work on any part of the LPEFI system a 8 mm socket amp 4 drive ratchet Unplug injector wiring harness from each A injector for use on the LPEFI injectors Drain pan Remove four 6 mm mounting studs and nuts holding the gasoline fuel rails to the intake manifold A 3 8 QD tool I Pa Using a 3 8 QD tool disconnect the supply Pliers fuel lines from the steel line attached to the passenger side frame rail Remove the plate from the top of the intake and pull the two wire harness s up so the rails can be removed Place drain pan under passenger side of bell housing to catch any gasoline spilled while disconnecting the fuel lines Note Gasoline residue could drain out of the lines and rails when you disconnect A Caution Gasoline under pressure Gasoline is flammable amp toxic Use extreme caution and eliminate all sources of ignition while handling Wear gloves amp goggles Remove the EV AP purge valve from the fuel rail Install a vacuum cap to the canister purge solenoid Remove the gasoline fuel rails from the engine Drain all gasoline from the fuel tank lines and discard in the proper environmental manner Isuzu Medium Duty Installation Instructions Prepare the LPEFI fuel rails for installation e
23. s No Does vehicle engine idle smoothly Yes No O Vehicle Comments Tank Temps amp Operating Pressures LPDM Scan Tool DataStream Tank temperature bottom of tank F PCM Flash performed Room temperature F Pump Pressures with 3 Switch Box Tank pressure Supply amp Return Valves on Example 100 psi Pump boost pressure Supply amp Pump on psi Note Pump boost is calculated by how much the pressure increases from tank pressure Pump acceptable boost is min 35 psi Example 135 ps Purge reduction pressure Supply Pump on amp Return psi Note Purge reduction is calculated by how much the pressure decreases from pump boost pressure Purge reduction range is 1 to 15 psi or tank pressure Example 125 psi Note If specifications are out of range reference page J1 and 29 af the Bi Phase EPEFT Diagnostic Manual ECT Temperature Fuel Trims at Idle Bank 1 Bank 2 LIFT Note Fuel trims range from 0 to 17 and shouldn t differ between bank by more the 10 Nate If specifications are out of range reference page 31 and 29 of the Bi Phase LPEFI Diagnostic Manual Technician Name This inspection form must be returned to Bi Phase Technologies Fax 651 681 444 Any problems found must be noted in the comment section and if a problem cannot be resolved Bi Phase Technologies must be contacted at 1 888 465 0571 274571 REV A Page 26 Isuzu Medium Duty Installation Instructions Supplemen
24. suzu Medium Duty Installation Instructions Bi Phase Technologies LLC A Danger Do not vent or release propane indoors or near sewers pits or low lying areas Propane can accumulate in low spots creating a fire hazard Propane can also displace oxygen creating a suffocation hazard Propane is heavier than air It can fill low sheltered areas with flammable vapors If these vapors are ignited they can create a fire or explosion causing severe property damage injury or death Never release propane near sewers pits or indoors A Warning Keep all sources of ignition away from propane vehicles while the fuel system is being serviced Even if the tank and fuel lines are empty there may still be flammable vapors near the vehicle Do not allow smoking sparks flames running vehicles or other sources of ignition near the vented propane Failure to do this could result in fire or explosion causing severe property damage injury or death IN Warning Do not disconnect any propane hoses unless they have been properly drained completely Propane in the hoses is kept under pressure even when the engine is off When you disconnect a hose the internal pressure is released all at once Always drain the fuel lines before you disconnect them Failure to do this can result in damage to the hose fitting and possible injury A WARNING NO SMOKING OR OPEN FLAMES IN OR AROUND PROPANE VEHICLES DURING FUELING OR SERVICING 274571
25. t Remove cover plate and set as de save mounting hardware Install LPDM 2 Insert rubber o ring into LPDM flange 274571 REV A Page 27 Isuzu Medium Duty Installation Instructions 3 Insert the pump from the LPDM into filter cup Position the pump in cup so the clip goes between the hose and the wires on the pump Attach the spring to other side of the cup 4 Proceed to mounting and tighten LPDM to tank flange Make sure all hoses and wiring is pushed inside the tank with no kinks or sharp bends LPDM is clock at 11 00 position 4 Tighten to 20 25 ft lb 27 34 N m 5 Install the new aluminized coated bolts that came with the new o ring and hand tighten note anti seize compound is not necessary with these aluminized coated bolts but not prohibited 6 A deep well 3 8 12 point socket is required to tighten the bolts 7 Tighten the bolts evenly a little at a time 8 Finish tightening the bolts in the order shown below or in a crisscross pattern torque the bolts to 20 25 foot pounds 9 Purge the tank purging the tank can be performed after the tank is mounted to the frame 274571 REV A Page 28 Isuzu Medium Duty Installation Instructions Purge the Tank A warning Purge the tank outdoors in the open away from buildings other vehicles electrical devices gas appliances and other sources of ignition Disconnect the electrical connection from the tank control box and disconnect the battery to
26. that injects propane in a liquid state to the engine It works much the same way as a modern sequential multi port gasoline fuel injection system and can be diagnosed with the same diagnostic scanners used for gasoline vehicles The LPEFI system is covered by U S and International patents The LPEFI system is also certified to the United States E P A standards The information in this manual is believed to be accurate as of its date of publication but it is subject to change Up to date information and changes if any can be requested from Bi Phase Technologies In the event of any safety related changes Bi Phase Technologies will notify all customers who returned the warranty registration card for the affected vehicles For more information contact Bi Phase Technologies LLC 2945 Lone Oak Drive Suite 150 Eagan MN 55121 651 681 4450 Tech Support line 888 465 0571 274571 REV A Page 3 Isuzu Medium Duty Installation Instructions Bi Phase Technologies LLC Table of Contents Propane Sa Wiener Facts about Propane amp Propane Powered Vehicles Approximate Properties of LP Gases Pre Installation Inspection cece eee cece ee ees Instructions Remove gasoline system LPEFI System Prepare LPEFI fuel rails Install LPEFI system Fuel rails Spark Plugs Main wire harness Gauge Tank Primary amp loop hose Completing Wire Harness Installation Insta
27. ther to 180 psi in hot weather 11 Turn the key off then on again to start another purge cycle 12 While the pump is running observe the fuel pressure It should be 35 to 55 psi higher than it was in step 11 13 Turn the key off and check for leaks at every hose fitting on the vehicle Apply an approved leak detection fluid similar to soapy water or use an electronic propane leak detector The tank tank valves fuel injectors and fuel rails have been tested at the factory but you must recheck and check the hoses and hose fittings On dual tank trucks check all of the hoses between the tanks too oe WARNING Do not use an open flame to check for leaks AN If you smell propane it is from a leak The LPEFI system uses sealed fittings and lined hoses and there should never be a propane odor from an LPEFI vehicle Typical Leak Checking Method 274571 REV A Page 22 14 15 16 17 18 19 20 21 22 23 24 29 Isuzu Medium Duty Installation Instructions Testing the Installation cont d If there are no leaks start the engine Connect a diagnostic scan tool to the vehicle The connector is usually under the bottom of the dash With the engine running check the diagnostic trouble codes DTCs Correct any problems you find If the engine is not running smoothly refer to the LPEFI service manual If there are no codes and the engine is running smoothly let the vehicle run until it is to full op
28. til metal hose end fitting is touching the top of the brass bushing in the port Secure the Primary Hose Primary hose loop will determine how much slack is available to secure the primary hose verify the primary hose is routed in a way that there is no interference with chassis components that could cause chaffing Insure that the hose is aligned so that no tension will be created on the fuel rail or the hold down clamps Install 3 P clamps on top of the tank shown Connect the hose to the fuel line bracket with a large P clamp Refernce photo on page 19 Rear Primary Hose Bracket dB BO e Attach as shown with the supplied hardware e Torque bracket to 24 ft lbs Front Primary Hose Bracket e Attach as shown with the supplied hardware e Torque bracket to 24 ft lbs 274571 REV A Page 19 274571 REV A Isuzu Medium Duty Installation Instructions Attach the loop hose to the injector rails Start with the 80 degree hose end on the crossover hose lubricate the white nylon inner line and insert into injector rail on the driver side Lubricate white nylon inner line on the 45 degree hose end and insert into the injector rail AN very IMPORTANT Take extreme care to center the nylon line into the rail end fitting and slowly push the line all the way in turn the hose from side to side or twist it as you are pushing it in Once the white inner line is
29. trol box and relay WARNING Do not make the final electrical connections until the LPEFI system is com ae sealed Applying power could cause the valv es in the tank to open releasing fuel into the hoses Isuzu Medium Duty Installation Instructions Tank Note Verify tank is holding pressure before installing Tanks are ship under pressure with argon To verify open spitter valve if argon gas escapes close valve and continue if not contact Bi Phase Technologies Before mounting tank to frame see supplement on pages 26 30 Pa SER SE 11 16 drill bit and a Primary tank is installed on the driver side drill e Measure the tank to mark the holes to be drilled in the frame the front tank support mounting holes are located 14 1 8 from the Front of body must not extend beyond this line Warning measure rear mounting hole appropriate with the rear tank mounting bracket Use an 5 8 drill bit to drill mounting holes 7 use the 5 8 bolts washers amp nuts provided 15 16 wrench socket amp ratchet or in the kit to mount tank inpact Raise the tank into place and install the bolts two bolts per support tighten all the mounting bolts until the Belleville washers are flat or torque to about 52 ft lb or 70 Nm Note Due to the OEM placement of the exhaust system a tank heat shield is required Fill hose installation Install the fill hose assembly exactly
30. use personal injury and fire hazard A Warning Never loosen fittings or vent any propane unless you are wearing insulated PVC rubber gloves Escaping liquid propane can cause frostbite and severe freeze burns Propane is stored as a liquid When you release liquid propane it tries to evaporate as quickly as it can by absorbing heat from its surroundings Everything it touches gets chilled to 44 degrees F 42 deg C If liquid propane sprays on your fingers it will freeze them right down to the bone Anyone who works with liquid propane must wear insulated PVC rubber gloves AN Danger Do not remove any valves bulkheads or fittings from a propane tank unless the tank has been properly drained evacuated completely The pressure inside a propane tank can push a loosened bulkhead or valve out with enough force to cause injury Release of propane in an uncontrolled situation will create a flammable explosive mixture of air and propane which could cause serious injury death and property damage Propane is stored under pressure When you remove a valve or bulkhead from the tank all of the pressure is released at once in a violent rush Always drain the tank before you work on it Failure to do this will result in damage to the tank or valves and can result in severe injury or death You should drain the tank using a flare stack in an approved safe manner Your propane supplier can help you with this 274571 REV A Page 6 I
31. ustible or flammable If not purged a spark from the electric fuel pump could ignite such a mixture Fortunately this combustible mixture is seldom found inside a tank and by purging the tank prior to filling or refilling the tank will prevent the air fuel mixture from ever reaching a combustible mixture How to Purge a Tank Warning You purge the tank in the open outside at least 25 feet from any building You can perform the purge with the tank installed on the vehicle You should not connect any electrical connectors to the tank after service or before filling a new tank If the tank is connected electrically DISCONNECT it from the tank control box and disconnect the vehicle battery always disconnect the negative terminal first Itis also recommended that the tank be grounded to earth ground with a cable like a battery jumper cable to prevent sparks due to static electricity 274571 REV A Page 29 Isuzu Medium Duty Installation Instructions At this point all replaced components should be installed and tightened to specification The following procedures or method is approved by the United States National Propane Gas Association NPGA For more information you can go to their website at www npga org 1 Remove the brass cap from the vapor or spitter service valve on the tank you want to purge the tank should not have fuel at this time it should be totally evacuated some pressure may build up if the tank was closed up for
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