Digital Propane Injection® for GM Duramax 6.6L Turbo Diesel
Contents
1. 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 AS 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 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 Ignition 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 sh2. 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 To Propane Pressure Sensor INSTALLATION INSTRUCTIONS To Fuel Lock off Solenoid To Boost Superchips neo P r es S u re DIGITAL PROPANE INJECTION Sensor To Pressure Control RED Solenoid GRAY BLACK Cun To Fuel pressure RED GREEN Either side BROWN L BLACK GREEN WHITE Battery BLACK Ground Orange DPI Wire Throttle Position Sensor PS COM E To LED IHH GRAY_ To Tach To Enable Switch BROWN WHITE RED To Switched 12 Volts ORANGE TPS To Blue Wire Pin F of TPS Harness Above the throttle pedal WHITE RPM Signal To White Wire Pin K 16 Pin connector underneath fuse box on the driver side fender well V Bottom of Y Fuse Panel 16 pin Black Connector Pin K White Wire to DPI Driver Side White Wire Fender 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 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 al
3. from any sharp objects or engine Figure 5 Connecting the MAP Sensor heat sources Note 05 models must add a manifold pressure port to supply the DPI sensor Mark the turbo outlet pipe the tube going from the turbo to the intercooler for the installation of the new port in a location to clear surrounding hardware and tubes Remove the tube from vehicle Take care to cover open ends in vehicle to protect from debris and parts Drill tube and tap to 3 8 npt Clean any debris from tube Install 1 8 npt x 1 4 hose 90 degree fitting supplied Reinstall tube and tighten clamps SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 e 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 one of the heater hoses from the top of the engine to the firewall 2 Route and clamp a new hose from the top of the engine to either of the water connections on the Vaporizer Figure 6 3 Route and clamp a new hose from the remaining water port of the vaporizer to the port on the firewall 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 di
4. only when an alert flag is set Run loop 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 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 rpm value is rais
5. 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 SUPERCHIPS www superchips com 1790 Airport Blvd Sanford FL32773 407 585 7000 FAX 407 585 1900 HARDWARE INSTALLATION VAPORIZER REGULATOR COM PONENT 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 and straight coolant hose elbow fittings to the regulator s coolant inlet outlet ports as shown 5 Install Fuel Line Fitting MOUNTING THE VAPORIZER REGULATOR 1 Locate the fender to firewall support brace on the rear of the driver side fender and remove the bolts and bracket 2 Mount the regulat
6. A i a A a a v v POWER HAS NEVER BEEN EASIER Digital Propane Injection for GM Duramax 6 6L Turbo Diesel Vehicles PN 4850 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
7. ILE W Notes FILE led GM Duramax Default data and menu for Diesel Engine Propane Fumigator 4850V05 Uses menu 4850405 WY start Inbox Microsoft Out TRE GraphView FILE 8 untitled Paint EJ 5 ovo 8 56am Figure 10 Pro Data Screen and Program Windows SUPERCHIPS www superchips com 1790 Airport Blud 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 recorded 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 0 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
8. ed propane will continue to be injected up to the new value SAVE DATA In the GraphView MSD file window go to view click on Run History 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 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 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 To display the values in the graph go to View Pull down menu in the history1 window and click on Tracebox Analysis Box 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 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 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 This will mark that location with a red line Move the black line awa
9. 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 Note Tighten so that washer is seated to tube and fitting is aligned with vapor hose Figure 4 Installing the Propane Discharge Fitting 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 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 Boost pressure line that runs from the boost line to the 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 Cut the factory Boost Pressure hose 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
10. ion such as 05 Turn Ignition power On m og AO N 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 None on either or both indicates communication failure File name will be displayed when file is opened as in Step 6 on page 7 D X history File 1 022205test2 36 20 Sec 44 00 Percent ZoomX 1 0 ZoomY 1 0 jx File Transfer Edit View Show Active 0 00 10 00 20 00 30 00 40 00 50 00 60 00 70 00 Product Connected 4850 VO5 M05 100 00 Data Source H 80 00 MSD User V05 M05 MS Graph View FILE t3 S Data Editor ansfer Yiew Port Help Print 60 00 BoostEnable 1 MONITORS Acq 40 00 Pwm 216 20 00 RunLoop Rpm 2283 Time 80sec 0 00 Lp Psia 21 1 Pedal Target 22 0 TPS In 396 TPS 6 65 Fuel Temp 80 HSD Maintence Log Print Clear FaultA 2 Track Error Map In 31 7 Acq Run RUN Lp Sys ACTIVE LiquidSol ON A RpmLimit 3600 BoostLimit 45 ERe Alerts E Alert 1 I AlertsPer Alerts Scan 1 FaultB 0 FaultC 0 FaultD 0 FaultE 0 FaultF 0 FaultG 0 FaultH 0 Faultl 0 FaultJ 0 Baro 13 5 Cruise OFF PwrLevel 100 eRpm F
11. ipping 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 www superchips com 1790 Airport Blvd Sanford FL 32773 407 585 7000 FAX 407 585 1900 2005 Superchips Inc FRM27146 Created 11 05 Printed In U S A
12. l conditions are detected and meet program requirements Engine RPM Throttle Position Intake Manifold Pressure Boost and System Request On Off Temporarily connect the LP Lock Off Solenoid to 12v and Ground 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 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 4850 folder then click on 4850v ign determines the vers
13. or assembly to the bracket so the inlet is on top Figure 2 3 Mount the regulator between the fender to firewall brace bracket assembly and the driver side fender using the two mounting screws Figure 3 Note Complete the Trigger RPM wiring before installing the fender to firewall bracket 4 Install remaining brace bolts Note Some applications may require alternative mounting For these applications verify the regulator is mounted with the regulator inlet at the top 5 Connect the liquid supply line to the lock off solenoid inlet Figure 2 INSTALLATION INSTRUCTIONS Fuel Pressure Switch Fuel Line Propane Fitting Lock off Solenoid Pressure Control Solenoid Coolant Hose Fitting Hose Fitting Outlet Orifice Mounting Bracket Regulator Mounting Bracket Regulator Bracket Support Bracket 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 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 Drilla 3 4 hole in the tube in the area shown in between the MAF Sensor and the Turbo Figure 4 3 Insert the Discharge Fitting in the 3 4 hole 4 From the
14. panel on the driver side fender Figure 9 pg 6 Note Complete trigger wiring prior to installing fender to firewall bracket Remove fuse box cover Release fuse box latch towards outside of fuse box and rotate up and inward to access connector 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 Figure 1 pg 2 Propane Pressure Sensor Regulator 4 Pin Connect to the 4 pin connector of the Propane Pressure Sensor on the propane inlet Connector of the Regulator Assembly Figure 1 pg 2 w 4 Wires Pressure Control Solenoid and Pressure Protection Switch 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
15. rect pressure wash spray Mounting it under the dash is recommended Figure 7 1 Mount the Controller above the throttle pedal on the firewall shield 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 a grommet to insulate the wiring WIRE TO BE SPLICED WIRE TAP BARREL 1 Insert Male End Cup into wire to be spliced Figure 8 2 Apply Silicone Sealant in Barrel end 3 Hand tighten Barrel into Male End Cup 4 Strip wire approximately 3 8 10mm 5 Insert wire into Male End exposing only bare wire gt 3 8 6 Hand tighten male end to Barrel Connection 10 mm complete k 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 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 the Blue wire in Pin F of the TPS connector Figure 9 pg 6 Note The Throttle Position Sensor is located above the Accelerator Pedal Trigger Wire RPM Signal Connect to the White wire on Pin K of the 16 pin Black connector The wire is located under the fuse
16. 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 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
17. y 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 Multiple files may be opened in the same window and all the lines of data will be displayed in the trace box 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 MENU TREE The following menu tree shows the different screens and programs of the PN 4850 and Monitor PN 4850 Flow Chat with Hand Held Monitor Monitor List ScanTime 1Sec Pwm 127 Rpm 12500 Lp Psia 30 0 Target 30 0 TPS In 1023 Alert List Track Error Dual Pedal Pedal Open Pedal Short gt o a r eds o e Lp Temp Short Lp Psia Low Map Psi Low O Fuel Deg Low TPS X 100 FuelRelay 1 Fuel Temp 255 AnyAlert 1 Map In 99 9 Track Error 1 Acq Run ARM 10 FuelDegLow 1 Lp Sys ACTIVE total 62 LiquidSol OFF Baro 12 5 Cruise OFF PwrLevel 100 Ms DD PROGRAMMET MONITOR OONDAUFWDN 2 3 4 5 6 Lp Temp Open 7 8 9 1 OONDAUPWN Monitor Fuel Stat 1 SCAN ScanTime 1Sec s ScanTime 1Sec H Rpm 1800 REVILIMITER OFF Once Loop Alert APwrLevel100 Acq RunLoop BoostEnable 5 Time 80Sec 20 80sec 6 33min Pedal Extend 3600 4600s100 Pedal RpmLimit 3600 Lo 152 Hi 524 BoostLimit 45 0 1020 s4
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