DFS Dynamic Fuel Systems Inc. Dynami c Fuel System s Inc. Diesel Magnum US PAT# 7100582 Installation Manual Diesel Magnum US PAT# 7100582 Installation Manual Ver 52.1 www.dynamicfs.com www.fireemup.com Attention! The Diesel Magnum must be installed by qualified and certified technicians only. These instructions must be followed in their entirety for the unit to function correctly. Any deviation from these instructions or if the installation is performed by anyone other than a certified installer will void the manufactures warranty and release the manufacturer from any and all liability.
Page 2 Diesel Magnum Page 19 Table of Contents Recommended Practices Introduction 3 Parts Included & Specialty Tools Required 4 Installation Instructions 5-18 Recommended Practices 19 1. Always use pipe thread lubricant/sealant on all pipe thread connections. 2. Always solder all wiring connections. Crimp and butt connections are not acceptable. 3. Always use protective poly loom on all wiring. 4. Always adhere to NFPA 58 and DOT requirements when installing Propane tanks, lines and equipment. 5. If you are unsure on any steps in this instruction manual consult your Dealer or Master Distributor. 6. Always use safe work habits when dealing with Propane. It is flammable. Propane can cause severe damage to your body as it boils at 40 degrees Fahrenheit. Propane is heavier than air and will settle in low laying areas. 7. Always consult the vehicle s owner s manual in regards to vehicle/power train warranty programs whenever adding aftermarket products. 8. Always consult your local Propane Professional for tank mounting and line fabricating practices. Thank you for your purchase!
Page 18 Diesel Magnum Page 3 35. Take the vehicle to your local Propane Professional and have the tank filled. Ask the Propane Professional to check all the connections for leaks at this time. Leak Check can be obtained form your local Propane Professional for future use. 36. Start the vehicle and energize the system with the Diesel Magnum switch. The green LED fuel gauge or flashing red LED indicates the system is powered up. The yellow LED above the push button is the MIL (malfunction indicator lamp). The MIL should not light unless there is a problem with the system. Consult your Dealer or Master distributor if the MIL is illuminated at any time during testing. 37. The system should now be ready for road testing and then years of trouble free operation. Be sure the end user or customer receives an owner's manual (supplied with kit) and perform a finale inspection of all lines fittings and wiring. INTRODUCTION Congratulations on your purchase of our Digitally Controlled Propane Injection System for Diesel Engines the DIESEL MAG- NUM. We believe this product to be the safest and most dependable system of it s kind on the market today. It is highly recommended that the installing technician read the installation literature included within (in it s entirety) prior to the actual commencement of the installation. Propane when injected into a Diesel Engine enhances combustion by evening out the normally violent explosion that commonly occurs in the Diesel Combustion chamber. This evening and slowing effect provides a more complete burn, a cleaner burn and a less violent burn resulting in more power, more torque, fewer emissions, less engine wear and the system pays for it self with increases in fuel mileage! Each Diesel Magnum is pre-assembled and vehicle specific preprogrammed by the manufacturer. Only the manufacture and authorized dealers have the capability to re-program a Diesel Magnum. Any tampering of the product will void the warranty and release the manufacture from any and all liability. The Propane tank and LPG fuel line to deliver fuel from the motor fuel tank must be purchased separately and must meet Federal DOT and NFPA 58 requirements as well as State and local requirements that apply. Information is available at your local Propane Professional which can be located by visiting www.usepropane.com. FIG 17 This product is to be installed by trained and certified technicians only following safe work and installation habits in accordance with NFPA pamphlet 58. No warranty or liability will be assumed by Dynamic Fuel Systems Inc. on systems installed by anyone other than trained and certified technicians. This product was designed with the very best materials and products available with fail safes engineered into the product to provide the end user with years of trouble free operation. It is imperative that it is installed correctly!
Page 4 Diesel Magnum Page 17 Parts Included & SpecialtyTools Parts Included 1- Diesel Magnum Assembly** 1- Diesel Magnum Switch & Harness** 1- Diesel Magnum Regulator** 1- Fuel Lock* 1- Venturi Adapter** 1- Silicone Intake Hose* 2- Hose Clamps* 1- Oil Pressure Safety Switch* 1- Thermal Couple** 2- LPG Hose Fittings* 4- Feet LPG Hose* 1- Small Parts Bag (fittings)* 4- Feet Boost Signal Hose* 2- Coolant Y Connectors* 1- Filter Assembly* 1- Owner s Manual** 1- Weatherpack Pig Tail** 33. Plug in the Diesel Magnum weather pack connector to the fabricated harness and check all connections and hoses making sure they are secure (FIG16). Remember it is good practice and it is recommended by Dynamic Fuel Systems Inc. to enclose all wiring in protective poly loom. 34. After all wiring has been double checked re-connect the battery. Specialty Tools Required 1- High Impendence Multi-Meter 1- Soldering Gun or Torch 1-1/8 NPT Pipe Tap w/ correct drill bit 1-20mm Drill Bit or Hole Saw 1- FIG 16 (*) Available from Master Distributors. (**) Available from Master Distributors ONLY.
Page 16 Diesel Magnum Page 5 32. It is necessary for the installing technician to fabricate high pressure LPG hose. One length is needed for fuel delivery from the Diesel Magnum to the Venturi Adapter at the Turbo Charger. The other line(s) are needed to supply fuel from the motor fuel tank through the supplied filter assembly and on to the Diesel Magnum via the Fuel Lock. FIG 15 shows a typical LPG hose assembly with protective wrap for fuel delivery to the venturi adapter. It is extremely important that the installing technician follow the hose manufacture s recommendation as well as any DOT and NFPA 58 requirements pertaining to tank installations and hose installations. Installation Instructions 1. Disconnect negative battery terminal(s) and post vehicle disabled sign in cab. 2. Remove all assemblies and components from shipping carton and lay out on a bench in order to make sure everything that was listed was shipped. If anything is missing call your Dealer or Master Distributor for assistance. 3. Find a suitable location for the Diesel Magnum unit that is away from excessive heat and protected from road debris such as pictured (see FIG1). There are 4 tapped mounting holes (1/4x20) on the back plate of the unit and it is recommended that all 4 be utilized. This may require fabricating a bracket or drilling holes in an existing bracket such as the coolant overflow bracket pictured in FIG 1. Keep in mind the wiring harness, the Propane Out port and the Propane In blue hose in that they are unobstructed and clear of moving parts. FIG 15 FIG 1
Page 6 Diesel Magnum Page 15 4. Find a suitable location to mount the Diesel Magnum Regulator. The Regulator comes with two mounting studs. Keep in mind the location of the coolant ports, the fuel lock and the Propane Out port making sure that they are unobstructed (see fig 2). The blue Propane hose that connects the Diesel Magnum unit to the Diesel Magnum regulator may be shortened but can not be lengthened so the regulator must be close to the Diesel Magnum unit.. The orange and black wires are not used and the vent port protruding from the top cover of the regulator must be left open and vented to atmosphere (do not plug or cap). 31. Dynamic Fuel Systems Inc. supplies a short pig tail harness to connect to the weather pack pig tail at the unit.. It will be necessary to add wire to the pigtail in order to complete all the wiring procedures. When adding wire it is recommended that the same color wires be used Red (12 volt +), Blue (to fuel lock) and Black (chassis ground). Please see fig 14 below for assistance with the wiring procedures. FIG 2 5. Make sure Regulator is free and clear from any moving parts and protected from road debris. Extremely Important:: When assembling the fuel lock to the regulator, make sure the port stamped IN receives the fuel line from the motor fuel tank. Reversing the flow in the fuel lock will damage it and eliminate a fail safe! FIG 14 NOTE:: THE ORANGE ANDBLACK WIRES ON THE REGULATOR ARE NOT USED AND SHOULD BE PROPERLY SECURED
Page 14 Diesel Magnum Page 7 22. Plug in the harness to the Diesel Magnum Switch and install running the harness through a grommet in the fire wall or equivalent protecting the wires from damage 23. Solder connect the red wire to +12 volts Switched power that comes on with the ignition ROUTED THROUGH the OIL PRESSURE SAFTY SWITCH. The oil pressure safety switch can be mounted at an oil galley fitting or OEM oil pressure switch location or at the turbo oil feed line utilizing a T fitting if necessary. Using the oil pressure safety switch eliminates the risk of the propane system being energized when the engine is not running. This step is extremely important for safety! 6. Remove the fresh air inlet hose at the Turbo Charger and pull aside (see FIG 3). 7. Install the Diesel Magnum Custom Venturi Adapter with the supplied silicone hose and clamps. Make sure the Propane line fitting is properly positioned and secure the unit with the clamp. 8. Re-install the fresh air inlet hose onto the Venturi Adapter and secure with the supplied clamp (see FIG 4). 24. Connect the black wire to a known good chassis ground. 25. Connect the white wire to a 0-90ohm motor fuel tank sending unit for the fuel gauge on the switch to function. If a functional fuel gauge is not desired secure this wire and cover the end with heat shrink tube or equivalent (the gauge green LED bars or flashing red LED when a 0-90ohm tank sender is not used or motor fuel tank is empty are the indicator that the unit is powered up). 26. Connect the green wire to the diesel magnum units red wire via the supplied weather pack connector (it maybe necessary to extend some wires from the switch harness) 27. Connect the black/white wire utilizing a T TAP solider connection to the blue wire from the Diesel Magnum. At the same time connect the Blue wire from the Diesel Magnum to the fuel lock off wire black (either one). Connect the other black wire from the fuel lock to a good chassis ground. FIG 3 28. The yellow wire is not used and should be cut and secured with shrink tube or equivalent to protect it. 29. Connect the black wire from the Diesel Magnum to a known good chassis ground via the weather pack connector. 30. Properly seal and secure all connections with heat shrink tube or equivalent and it is highly recommended to use poly loom on all wiring. FIG 4
Page 8 9. Cut to length and install the blue propane line from the Diesel Magnum to the Diesel Magnum Regulator. Make sure the line is free from moving parts, away from excessive heat and does not have any excessive bends that could cause a kink (see FIG 5.) 10. A soapy water solution can be used to help slide the hose over the fitting. Diesel Magnum Page 13 21. Install the Diesel Magnum switch by selecting a suitable location keeping in mind that the unit protrudes in about 65mm so make sure there is adequate room behind the panel selected for the mounting. Drill a 20mm hole for the unit. A snug fit is important for the switch so a good practice maybe drilling the hole slightly smaller than 20mm and use a tapered reamer to achieve the correct fit. (see FIG 13) 11. Secure the hose with a gear type hose clamp. FIG 5 FIG 13
Page 12 Diesel Magnum Page 9 12. Install the supplied coolant Y connectors in-line in the heater hoses. It is very important to install them in the correct direction of flow as outlined in FIG 6. Failure to install them correctly can result in low-flow or no-flow conditions. 13. Use a good quality 5/8 heater hose to connect the coolant Y connectors to the regulator. The coolant flow through the regulator should enter in the lowest port and exit through the upper most port in order to help prevent an air lock situation. 14. Make sure the hoses are routed well and secured avoiding any moving parts. NOTE: If necessary the regulator coolant ports can be plumbed in series with an available coolant line. FIG 11 FIG 6 FIG 12
Page 10 15. Connect the turbo boost signal line from the Diesel Magnum to a suitable location in the air ductwork from the turbo charger to the intake manifold. Some manufactures will have a test port with a plug. Remove the plug and install a barbed fitting. Secure the line with a small nylon tie strap if necessary (see FIG 8). 16. If no test port is available it will be necessary to drill and tap a hole in the turbo air discharge duct at a suitable point. Remove the duct work before drilling and tapping and then remove any debris before re-installing. If the vehicle you are working on has an OEM MAP sensor it is acceptable to use a tee fitting in the boost line to the OEM sensor and install the Diesel Magnum signal line at that location. Diesel Magnum Page 11 18. Install the Exhaust Gas Temperature Sending Unit as close as possible to the Turbo Charger outlet. Drill a hole in the exhaust pipe in a suitable location and tap the hole with a 1/8 NPT pipe tap (see FIG 10). 19. It is IMPORTANT to NOTE that the yellow wire for the Exhaust Gas Temperature Probe coming from the Diesel Magnum unit must be secured properly along the frame of the vehicle or any other available metal structure. It is not acceptable to leave this wire exposed or hanging or drooped over other components (especially electrical components such as the alternator as this could distort the signal). Dynamic Fuel Systems also recommends that protective poly loom be utilized on this wire (see FIG 11). 20. Connect The Exhaust Gas Temperature Probe to the yellow wires coming from the Diesel Magnum unit utilizing the supplied heat shrink tube (see FIG 12). FIG 8 FIG 9 FIG 10