INSTALLATION INSTRUCTIONS FOR PART #50103 Diesel TOW MAX WATER / METHANOL INJECTION SYSTEM FORD POWERSTROKE 7.3L DIESEL

Transcription

1 Cntact Us: Phne Office (719) Fax (719) Tech Supprt Line (Tll Free) (866) Web Mail Snw Perfrmance, Inc 1017-A East Highway 24 Wdland Park, CO INSTALLATION INSTRUCTIONS FOR PART #50103 Diesel TOW MAX WATER / METHANOL INJECTION SYSTEM FORD POWERSTROKE 7.3L DIESEL Ntes The cntents f this dcument are subject t change withut prir ntice. N part f r this entire dcument may be reprduced in any frm withut prir written permissin f Snw Perfrmance, Inc under the cpyright except fr private use. The names, addresses and telephne numbers mentined are current as f September 9, Nte that this infrmatin is subject t change. Please refer t fr current infrmatin. rprated

2 CONTENTS Kit Cntents...3 Intrductin...4 Nzzle Identificatin Chart:...4 Installatin - Mechanical...6 Installatin - Electrical...11 Variable Cntrller Installatin...11 Cntrller Operatin...13 Variable Cntrller Tuning...15 Bst Only Mde...15 Testing the System...16 Tuning Quick Reference...18 Fluid Level Switch...20 Install Ntes...21 Warranty/Disclaimer Infrmatin...21 LIMITATION OF LIABILITY REPAIR OR REPLACEMENT OF A DEFECTIVE PRODUCT IS THE ORIGINAL RETAIL PURCHASER S EXCLUSIVE REMEDY UNDER THIS WARRANTY. DAMAGE OR INJURY TO THE ORIGINAL RETAIL PURCHASER, TO HIS OR HER VEHICLE, CARGO, OR PROPERTY, AND/OR TO ANY OTHER PERSON OR PROPERTY IS NOT COVERED BY THIS WARRANTY. THIS WARRANTY IS EXPRESSLY MADE IN LIEU OF ANY AND ALL OTHER EXPRESS WARRANTIES, WHETHER ORAL OR WRITTEN. SNOW S SOLE LIABILITY IS LIMITED TO THE REMEDY SET FORTH ABOVE. IN NO EVENT WILL SNOW BE LIABLE FOR ANY DIRECT, INDIRECT, CONSEQUENTIAL, INCIDENTAL, SPECIAL, EXEMPLARY, OR PUNITIVE DAMAGES OR FOR ANY OTHER DAMAGES OF ANY KIND OR NATURE (INCLUDING, BUT NOT LIMITED TO, LOST PROFITS OR LOST SALES). SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. Nn-Warranty Repair/Retest Prducts returned due t damage r misuse and Prducts retested with n prblem fund are subject t repair/retest charges. Prduct will be returned t custmer at custmer s expense. A credit card number must be prvided in rder t btain an RMA (Return Merchandise Authrizatin) number prir t returning Prduct. Technical FAQ: CAUTION Yu must cmpletely read thugh these instructins befre installing and perating this prduct. Failure t d s can result in damage t this prduct and the vehicle.

3 Warranty Warranty Plicy Snw Perfrmance, Inc. warrants that the Prduct shall cnfrm t and perfrm in accrdance with published technical specificatins and shall be free f defects in materials and wrkmanship fr 90-days prviding: 1. Yu are the riginal purchaser and prvide prf f purchase. 2. Fr 1-year warranty, the Warranty Card that came with system (nt applicable t separate parts purchases) is returned t Snw within 45-days f purchase. If valid warranty card nt n file with Snw, the standard 90 day warranty applies frm date f purchase. 3. Fr Lifetime warranty,, the Warranty Card that came with system (nt applicable t separate parts purchases) is returned t Snw within 45-days f purchase and Bst Juice injectin fluid is used exclusively.* 3. An RMA # has been attained and is displayed n package cntaining returned part. 4. Parts Warranty ~ 90 day warranty n parts purchased separately if used in cnjunctin with a Snw System. N warranty implied if used with a nn-snw part/system. Subject t Snw s inspectin f the prduct, Snw will remedy defects in materials and/r wrkmanship by repairing r replacing, at Snw s ptin, the defective prduct withut charge fr parts r labr, subject t the limitatins and exclusins described in this warranty. This warranty des nt cver prblems caused by nrmal wear and tear including aesthetic xidatin f surfaces, accidents, unlawful vehicle peratin, r mdificatins r repairs t prduct nt perfrmed r authrized by Snw. This includes any prduct that is disassembled r taken apart fr any reasn. * Bst Juice usage evidenced by invices/ receipts. In additin, this warranty des nt cver prblems resulting frm cnditins beynd Snw s cntrl including, but nt limited t, theft, misuse, verlading, r failure t assemble, munt r use the prduct in accrdance with Snw s written instructins r guidelines included with the prduct r made available t the riginal retail purchaser. In the event f failure, Snw will repair r replace the part at Snw's sle discretin. Failures resulting frm misapplicatin r misuse f the Prduct, failure t adhere t any specificatins r instructins, r failure resulting frm neglect, abuse, accidents, r act f nature are nt cvered under this warranty. Warranty service may be btained by calling , getting an RMA (Return Merchandise Authrizatin), delivering the part t Snw alng with prf f purchase. Custmer agrees t insure the Prduct r assume the risk f lss r damage in transit, t prepay shipping charges t Snw, and t use the riginal shipping cntainer r equivalent. Shipping fr Warranty replacement parts shipped utside the cntinental US will be charged t custmer. Parts UHO Pump (Ultra High Output) 7 Galln Reservir 25 ft High Pressure Tubing 3 ft Black Wire Lm 18 1/8 Silicne Tubing Electrical Packet 2 Blue Butt Cnnectrs 3 Small Eyehks 1 Male Cnnectr 3 Female Cnnectrs 10 Tie Wraps 1 Arm Switch 5 Duble Sided Tape 1 Brass Hse Barb Diesel TOW MAX Cntrller Temperature Prbe Yellw Temp Prbe Cnnectr Required Tls Electric Drill w/ Drill Bits Utility Knife Screwdriver Phillips Assrted Wrenches 1/8-27 NPT Tap Kit Cntents Mechanical Packet 1 Nzzle Hlder 7 Galln Fitting Set: 90 Elbw 3/8 Reducer Bushing w/ filter screen 4 #8x1&1/2 Screws 4 #8 Washers 1 Dual Nzzle Upgrade 1 Slenid Upgrade 1 Temp Prbe Cmpressin Fitting 3/16 1 E-6000 (GOOP) 1 375ml/min Nzzle 2 625ml/min Nzzles Upgrades 2.5 Galln Reservir Hse Adaptr r Bung Level Switch Nn-Warranty Repair/Retest Prducts returned due t damage r misuse and Prducts retested with n prblem fund will be returned t custmer at custmer s expense.

4 Intrductin The TOW MAX Diesel Bst Clers are designed t maximize fuel ecnmy and safe pwer while twing. This cntrller senses nt nly manifld bst pressure but als exhaust gas temperatures. Using tw inputs allws fr the smthest injectin cntrl. Mre imprtantly, it als keeps the EGTs as lw as pssible if they begin t climb, even if the bst stays cnstant, the TOW MAX cntrller will read this and inject mre water-methanl t cmpensate. The adjustments t the delivery n the fly are accmplished with tw easy-t-use push buttns, allwing fr mre r less injectin, r switching frm bth bst & EGT referenced injectin (smthest, best fr twing and EGT cntrl) t just bst referenced injectin (mst respnsive, best fr perfrmance and racing). Please refer t the fllwing system diagram during install. Cmpletely read thrugh this instructin manual befre attempting installatin. Cntact Snw Perfrmance fr any questins r cncerns. Nzzle Identificatin Chart: Nzzle Number Nzzle Size Nzzle Number Nzzle Size 1 60 ml/min ml/min ml/min ml/min ml/min ml/min Install Ntes Pump Setting (psig) Nzzle Size (ml/min) Cntrller Setting Misc: Disclaimer D nt use this prduct until yu have carefully read the fllwing agreement. This sets frth the terms and cnditins fr the use f this prduct. The installatin f this prduct indicates that the BUYER has read and understands this agreement and accepts its terms and cnditins. Perfrmance prducts by their nature are designed t increase hrsepwer and perfrmance nt engineered in the riginal vehicle and the increased stress culd result in damage t related systems. This is a high perfrmance prduct use at yur wn risk. Snw Perfrmance Inc., Its agents, emplyees r wners shall nt be under any liability whether in cntract r therwise whether r nt resulting frm ur negligence r cntents f infrmatin supplied fr any damage r lss resulting frm such infrmatin. The BUYER is respnsible t fully understand the capability and limitatins f his/her vehicle accrding t manufacturer specificatins and agrees t hld the SELLER harmless frm any damage resulting frm failure t adhere t such specificatins. The SELLER disclaims any warranty and expressly disclaims any liability fr persnal injury r damages. The BUYER acknwledges and agrees that the disclaimer f any liability fr persnal injury is a material term fr this agreement and the BUYER agrees t indemnify the SELLER and t hld the SELLER harmless frm any claim related t the item f the equipment purchased. Under n circumstances will the SELLER be liable fr any damages r expenses by reasn f use r sale f any such equipment. The BUYER is respnsible t bey all applicable federal, state, and lcal laws, statutes, and rdinances when perating his/her vehicle, and the BUYER agrees t hld SELLER harmless frm any vilatin theref. The SELLER assumes n liability regarding the imprper installatin r misapplicatin f its prducts. It is the installer's respnsibility t check fr prper installatin and if in dubt, cntact the manufacturer.

5 Fluid Level Switch (ptinal) Red Lw Fluid LED Black Black Instructins Lcate desired level switch munting psitin. Suggested placement is 1/5 f max reservir height. Carefully drill side f reservir using 13/16 bit. A step bit is recmmended fr best drilling results. Hle must be free f nicks r shavings fr prper sealing. Remve rubber seal frm level switch. Insert seal int reservir until fully seated. Gp can be used arund the edges f the hle. Lubricate exterir f level switch with water and insert int seal until fully seated. Psitin level switch s GT symbl is at six clck psitin. Wait 30 minutes fr Gp t cure, then test fr leaks. With fluid level abve level switch, flat shuld be angled up. With fluid level belw level switch, flat shuld be in hrizntal psitin. Cnnect ne black wire frm level switch t grund. Cnnect ther black wire frm level switch t white wire frm LED. Cnnect red wire frm LED t +12 vlt key n pwer surce.

6 Installatin - Mechanical Step 1 Reservir Install Install 90 degree elbw int reducer bushing using E6000 sealant. Turn ½ turn past finger tight. D nt use Tefln sealants n Snw Perfrmance fittings. Install reducer bushing int reservir utlet using E6000 sealant. Turn ½ turn past finger tight. Maintenance Remve nzzle(s) and clean screen filters at least nce per year using carb cleaner. The Bst Cler has been designed t perate with high cncentratins f methanl. Oil r ther additives are nt required fr system lubricatin. Fr best perfrmance, cling and system life it is recmmend that Snw Perfrmance Bst Juice (#40008) be the exclusive fluid used in the system. Test fit reservir in desired munting lcatin. Typical placement is tucked up alng the side f a pickup bed r in a bed munted tl bx. Check the area under the bed near the desired munting lcatin. Nte the lcatin f fuel tanks, fuel lines, and wiring. Mark the lcatin f the fur aluminum munting strap tab blt hles. Drill thrugh bed with apprpriately sized drill bit. USE CAUTION WHILE DRILLING. Munt reservir with aluminum munting straps using apprpriate hardware.

7 Tuning Quick Reference If cmbustin quench ccurs as evidenced by engine bucking, reduce the injectin quantity. This can be dne by: 1. Using a smaller nzzle(s). 2. Using Screen 10 and Screen 11 t adjust the gain. Cautin****** Prlnged quench may cause lwer engine damage ver a perid f time. Als, fresh methanl less than 1 mnth ld when expsed t atmsphere and using a greater methanl cncentratin up t 50% - will reduce cmbustin quench. 100% water will cl cmbustin and EGTs and will increase pwer apprx HP. 75/25 water/methanl will reduce EGTs and pwer will increase apprximately 40 HP. 50/50 water/methanl will reduce EGTs and increase pwer apprximately 70+ HP. Cautin****** T avid gravity feeding f fluid with rear munt reservirs, it is essential t use a slenid in-line between the reservir and pump. D nt perate yur rear munt equipped vehicle withut a slenid installed. Step 2 Pump Install Munt the pump s the inlet is psitined at the lwest pint f the reservir r lwer. Pump can be munted hrizntally r vertically using the supplied screws and washers. Ensure that n sharp bends in the high pressure tube ccur near the pump. Sharp bends can cause stress n the inlet and utlet prts f the pump, causing leaks. Trim tube with a utility knife r razr blade, making sure t eliminate any burrs r kinks n the end. Insert firmly int the pump abut ½ inch thrugh the light grey lcking cllar. Nte the arrws indicating flw directin n the tp f the pump. T remve the hse, gently and evenly push the light grey lcking cllar int the head unit f the pump, then pull n the hse gently. Cautin: T avid pling in the intake it is recmmended that: 1. The engine be run withut water/methanl fr at least 5 minutes after injectin befre turning the engine ff. 2. The armed switch is turned t the ff psitin when the engine is ff. Cautin: D nt attempt t inject water/methanl until the engine has reach perating temperature. A cld engine is mre susceptible t quench and pr perfrmance. Measure the distance frm the reservir utlet t the pump inlet. Cut the ¼ red tubing using utility knife. Make cuts are as square as pssible.

8 Ensure there are n kinks in the tubing and insert tubing int quick discnnects at pump and reservir until fully seated. Keep the pump within 2 feet f the reservir. The pump can be munted under the truck bed in a place prtected frm rad spray. Cautin****** Pump must be shielded frm rad debris and tire wash. Failure t d s will result in pump failure Step 3 Nzzle Selectin Activatin f pump fr shrt perids (1-5 sec.) will purge air bubbles frm the system. This can be accmplished during initial use. Step 2 Test Cntrller With the nzzles remved frm the intake, place the cntrller in bst nly mde by disabling the EGT Cntrl mde. Set gain t 100. Using a hand pump, apply psig f pressure t the bst line leading t the cntrller. Pump shuld activate, fluid shuld flw, and tank level shuld g dwn. Nzzle sizing is a functin f hrsepwer, which apprximates the engine airflw, and bst, which apprximates intake charge heat. Often nly ne nzzle is needed. Recmmended starting pints: WHP 625 ml/min nzzle WHP 375 & 625 ml/min nzzle WHP 2 X 625 ml/min nzzle Seal the nzzle int the nzzle hlder using included GOOP sealant. Using a sealant that is nt permanent will allw fr nzzle changes during tuning. Simply remve the nzzle, clean the threads, and reinstall using sealant. Assemble desired nzzle int nzzle hlder using E6000 sealant. The end f the nzzle with the fine mesh screen is t be inserted int the nzzle hlder. Trque 1/2 turn past hand tight. D nt use Tefln sealants n Snw Perfrmance fittings.

9 Testing the System Nte: fr best results, prime pump befre use T clear air frm the pump and insure that the system is primed: Fill reservir with water apprx ¼ full. Remve tubing frm nzzle (r slenid if slenid used in-line between pump and nzzle) and run tube int separate cntainer. Apply 12 VDC t red pump wire fr apprximately 5 secnds r until fluid flw is cnsistent. Pump is nw primed. Recnnect tubing frm pump utlet t nzzle (r slenid). If using a slenid in between the pump and the reservir: Remve the slenid and place a slid piece f tube between the pump and the reservir and prime the system. Then replace the slenid in between the pump and reservir. Step 1 Test Pump and Mechanical System Discnnect pump frm cntrller. Using a 12 vlt surce, apply pwer t red wire f pump. Pump shuld activate and fluid level in tank shuld g dwn. It is recmmended t als check the nzzle spray pattern while fllwing this prcedure. Als check fr leaks. Crrect Incrrect NOTE: If nzzle is munted lwer then the reservir, a slenid (#40060) must be used t prevent draining. Step 4 Nzzle Munting The nzzle assembly shuld be installed 90 t the directin f airflw. On rund intake tubes, this is 360 arund the tube meaning the nzzle can be munted in any directin. This will ensure maximum cling as the nzzle sprays in a cne pattern. Chse and mark munting lcatin fr nzzle placement. Nzzles can be lcated n the charge tube between the intercler utlet and the intake inlet. Place nzzles at a lcatin where they have an unbstructed spray pattern int the airflw. Remve the selected piece and drill and tap (11/32 pre-drill, 1/8-27 NPT tap) fr ne r tw nzzles. Nte that NPT is a tapered thread, and be cautius nt t ver-tap thin walled pipes. Test fit nzzles int the pipe t ensure a tight fitment. If pump ges n and fluid level desn't g dwn, there is an bstructin in the tube r nzzle.

10 Variable Cntrller Tuning EGT Cntrl Mde When EGT Cntrl mde is enabled, the cntrller will measure EGTs and bst pressure t calculate the injectin rate. In this mde, a high gain setting will result in a larger injectin rate. The nzzle is munted using its external 1/8 NPT threads. Tighten the nzzle and nzzle hlder assembly ne half turn past finger tight using E6000 t seal the threads. Step 5 Nzzle Cnnectin and Slenid Cnnectin Slenid is flw directinal. Be sure t nte which prt is the INLET/PRESSURE prt (2 r IN) and which is the OUTLET prt (1 r OUT). The main utlet line cming frm the Reservir cnnects t the slenids inlet. The utlet f the slenid cnnects t the inlet f the pump. Measure the distance frm the pump utlet t the nzzle hlder. Cut the ¼ tubing using utility knife. Make cuts are as square as pssible. Ensure there are n kinks in the tubing and insert tubing int quick discnnects until fully seated. Gently pull n tubing t ensure a gd cnnectin. Use tie wraps t help rute tubing and t ensure it desn't cntact mving r ht parts in the engine cmpartment. Have tubing cnnect t quick cnnect fittings at shallw angles. Having an immediate sharp bend may unseat the tubing frm the internal -ring and create a leak. Tggle t Screen 8. Set EGT Cntrl t ON. Tggle t Screen 10. Adjust the gain up t 100. If cmbustin quench ccurs as evidenced by engine bucking, reduce the injectin quantity r lwer the gain setting n the mdule. This can be dne by: Using a smaller nzzle(s). Adjusting the gain. T adjust gain dwn, tggle t screen 11. Adjust the gain dwn until engine runs smth with n bucking. Bst Only Mde The cntrller has a bst nly mde. When EGT Cntrl mde is disabled, injectin is a functin f bst pressure nly which is desirable in racing applicatins and day t day driving where mre immediate injectin is desired. Tggle t Screen 8. Set EGT Cntrl t OFF. Tggle t Screen 10. Adjust the gain up t 100. If cmbustin quench ccurs as evidenced by engine bucking, reduce the injectin quantity r lwer the gain setting n the mdule. This can be dne by: Using a smaller nzzle(s). Adjusting the gain. T adjust gain dwn, tggle t screen 11. Adjust the gain dwn until engine runs smth with n bucking. Cntinual insertin and remval frm quick cnnect fittings will mar the end f the tubing. Over time the internal gripping teeth may lse their

11 Screen 5 This mde displays the bst, EGT and injectin in Metric units Screen 6 This display shws bth digital and bar graph readings fr bst and EGT in English units. Screen 7 This display shws bth digital and bar graph readings fr bst and EGT in Metric units. Screen 8 BAR DegC %Injectin EGT Cntrl Change PSI DegF BAR DegC hld f the tubing which may create a leak. If this ccurs simply remve the tubing and make a fresh cut using a razr blade. Step 6 Install EGT Prbe Drill and tap exhaust manifld pre-turb. If this is perfrmed with the exhaust manifld still n the engine, start the engine and let it idle while drilling and tapping. This will prevent shaving frm entering the exhaust and turb. During tapping, cat tap with heavy grease s it will cllect any metal shavings. This is the setup screen fr the Bst Only cntrl mde. Pressing the right Buttn (buttn 2) will tggle the setting between ON and OFF. If the EGT Cntrl is ON, the matrix value fr the injectin is used. If the EGT Cntrl is OFF, the Bst Only injectin setting will be used. The selectin f this functin is als stred in system memry and recalled n pwer n. EGT cntrl is used in twing r heavily laded situatins. Screen 9 Bst Range Change This screen is used t select between LOW, MED, and HI bst mde. Fr vehicles making 8-18 psig f bst, use LOW mde. Fr vehicles making psig f bst, use MED mde. Fr vehicles making 25+ psig f bst, use HI mde.. Injectin Gain Increase Screen 10 This screen is used t increase the injectin gain setting. Pressing and releasing Buttn 2 will increase the gain setting. This setting is als remembered n pwer up. 5%-10% changes in gain will make significant changes in injectin. Screen 11 Injectin Gain Decrease This screen is used t decrease the injectin gain setting. Pressing and releasing Buttn 2 will decrease the gain setting. This setting is als remembered n pwer up. Munt the Temp Prbe using the 3/16 cmpressin fitting (prvided). Installatin - Electrical Variable Cntrller Installatin

12 Cntrller Operatin The cntrller has an LCD display screen. The display sftware allws fr seven different display mdes and three cntrl/setup screens. Attach cntrller t secure lcatin with easy access in driver s cmpartment using supplied tape. Cnnect silicne tubing frm intake plenum bst line (use the included bst T ) t clear tubing cming frm the cntrller and secure with a tie wrap. CAUTION: Discnnect the negative battery terminal while cnnecting wires t prevent electrical fire r damage t cntrller. Cnnect BLACK wire t a gd grund lcatin. Cnnect WHITE wire t Pump RED pwer wire. Cnnect RED wire t inline switch and cnnect t +12 vlt key n surce. Wire the Yellw K type temp prbe cnnectr t temp prbe installed in Step 6 abve. The YELLOW wire cnnects t the POSTITIVE terminal, the RED wire cnnects t the NEGATIVE terminal f the cnnectr. Cnnect t the lead frm cntrl mdule. Always have a gd electrical grund cnnectin. Pr grund will result in erratic peratin f cntrller. T cntrl the screen selectin, the unit has tw peratr buttns; ne t the left f the screen (Buttn 1) and ne t the right f the screen (Buttn 2). Pressing and releasing Buttn 1 will cause the display t sequence t the next mde. Buttn 2 is nly active in the cntrl/setup screens, and is used t change the current cntrl setting f the setup screen displayed. The system memry will remember the current display setting even if the unit is turned ff. The cntrller will turn n at the last used display setting. Additinally, Buttn 2 is used fr the Injectin ON/OFF functin. Pressing and hlding Buttn 2, then pressing Buttn 1, then releasing bth buttns will change the system t read nly withut changing the display screen. All screen display functins will remain active even when the injectin is turned ff. T get the cntrller ut f read nly mde, just repeat the prcedure. Screen 1 This mde displays Bst Pressure (P), Temperature (T) and Injectin percentage (I) as three independent bar graphs. The pressure scale is scaled prprtinal t the L/Hi bst selectin. Bst Screen 2 EGT This mde displays the bst pressure and EGT temperature in PSI and ºF. Screen 3 P I Bst EGT T This mde displays the bst pressure and EGT temperature in BAR and ºC. Screen 4 This mde displays the bst, EGT and injectin in English units. PSI DegF %Injectin