INSTALLATION INSTRUCTIONS FOR PART #49103 Diesel TOW MAX WATER / METHANOL INJECTION SYSTEM DODGE CUMMINS 5.9L/6.7L DIESEL

INSTALLATION INSTRUCTIONS FOR PART #49103 Diesel TOW MAX WATER / METHANOL INJECTION SYSTEM DODGE CUMMINS 5.9L/6.7L DIESEL rprated

CONTENTS Kit Cntents.3 Intrductin.4 Nzzle Chart 4 Installatin Mechanical.5 Installatin Electrical 12 Variable Cntrller Installatin.12 Cntrller Operatin 13 Variable Cntrller Tuning.15 Testing the System..15 Tuning Quick Reference.17 Warranty Infrmatin.....19 Have a questin? FAQ: www.snwperfrmance.net/faqs.php 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.

Kit Cntents 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 1 Brass Hse Barb 5 Duble Sided Tape Diesel TOW MAX Cntrller Temperature Prbe Yellw Temp prbe Cnnectr Mechanical Packets 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/Optins 2.5 Galln Reservir Hse Adaptr r Bung Bst Juice Level Switch Required Tls Electric Drill w/ Drill Bits Utility Knife Screwdriver Phillips Assrted Wrenches 1/8-27 NPT Tap

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 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, 2011. Nte that this infrmatin is subject t change. Please refer t www.snwperfrmance.net fr current infrmatin. The adjustments t the delivery n the fly are accmplished with tw easy-tuse 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. Nte: The prvided rcker switch is used n the cntrller pwer supply. The prng with the piece f plastic cming ut with it cnnects t 12VDC key n pwer, the ther prng cnnects t the RED wire n the cntrller. Nte: The system can use tw nzzles simultaneusly, but this is nt always needed. Refer t the nzzle guide n page 8 fr nzzle selectin. The diagram shws tw nzzles, but ften nly ne is needed. See page 8 fr details.

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. 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. Cntact Us: Phne Office (719) 633-3811 Fax (719) 633-3496 Tech Supprt Line (Tll Free) (866) 365-2762 Web http://www.snwperfrmance.net Email sales@snwperfrmance.net custmerservice@snwperfrmance.net tech@snwperfrmance.net Mail Snw Perfrmance, Inc 1017-A East Highway 24 Wdland Park, CO 80863 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. Nte:

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. 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. 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.* 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. Fr Warranty service: Call and get an RMA #. This # must be displayed n package cntaining returned part alng with a cpy f the riginal invice. 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. 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. 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. Warranty service may be btained by calling 719-633-3811, 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. 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.

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. Maintenance Remve nzzle(s) and clean screen filters at least nce per year saking nzzle fr 10 min in descaler shwer 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. 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. Cautin****** Pump must be shielded frm rad debris and tire wash. Failure t d s will result in pump failure Step 3 Nzzle Selectin Nzzle sizing is a functin f hrsepwer, which apprximates the engine airflw, and bst, which apprximates intake charge heat. Recmmended starting pints: 250-350 WHP 625 ml/min nzzle 400-500 WHP 375 & 625 ml/min nzzle 500-600 WHP 2 X 625 ml/min nzzle Nzzle Identificatin Chart: Nzzle Number Nzzle Size Nzzle Number Nzzle Size 1 60 ml/min 4 225 ml/min 2 100 ml/min 5 375 ml/min 3 175 ml/min 6 625 ml/min 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 finger tight. D nt use Tefln sealants n Snw Perfrmance fittings. Warranty

Crrect Step 4 Nzzle Munting Incrrect 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. Discnnect the silicne bst line frm the bst T n the intake plenum bst line. Using a hand pump, apply 10-20 psig f pressure t the bst line leading t the cntrller. Pump shuld activate, fluid shuld flw, and tank level shuld g dwn. Tuning Quick Reference If cmbustin quench ccurs as evidenced by engine bucking, reduce the injectin quantity. This can be dne by: The nzzle assembly shuld be installed 90 t the directin f airflw. On the 5.9l the preferred lcatin is the back f the air hrn (see pht). Chse and mark munting lcatin Remve selected piece and drill and tap (11/32" pre-drill, 1/8-27 NPT tap) fr ne r tw nzzles. 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. 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 20-30 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 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.

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. Be sure t discnnect cntrller befre htwiring pump. 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. Addendum fr 6.7L Cummins Applicatins: Nzzles are munted in the black plastic tube that cnnects the intercler-t-intake lcated n the driver s side f the engine. Step 1. lsen clamps that attach tube t cast elbw and intercler. 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. Step 2. Pry rubber bts ff intercler and cast piece. Step 3. Slide tube ut frm tp and mark, drill and tap fr nzzles. If pump ges n and fluid level desn't g dwn, there is an bstructin in the tube r nzzle. Activatin f pump fr shrt perids (1-5 sec.) will purge air bubbles frm the system. This can be accmplished during initial use f the system. Tip: Munt nzzles apprx 3 apart s spray is 90º t airflw. Tip: T make sure there is n pling f fluid while injecting, make sure nzzle tip is at least flush with the inside f the tube when tightened. 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. Cntinual insertin and remval frm quick cnnect fittings will mar the end f the tubing. Over time the internal gripping teeth may lse their 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. 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. This is ideal in heavy lad and twing situatins. In this mde, a high gain setting will result in a larger injectin rate. 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 unladed driving where mre immediate injectin is desired. Tggle t Screen 8. Set EGT Cntrl t OFF. 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. Selecting a higher bst range. T adjust gain dwn, tggle t screen 11. Adjust the gain dwn until engine runs smth with n bucking. Testing the System Nte: fr best results, prime pump befre use Munt the Temp Prbe using the 3/16 cmpressin fitting (prvided). T clear air frm the pump and insure that the system is primed: Fill reservir with water apprx ¼ full.

This mde displays the bst, EGT and injectin in English units. 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 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 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 18-25 psig f bst, use MED mde. Fr vehicles making 25+ psig f bst, use HI mde. 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 make a significant difference in injectin. Screen 11 BAR DegC %Injectin EGT Cntrl Change PSI DegF BAR DegC Bst Range Change Injectin Gain Increase 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.

Installatin - Electrical Variable Cntrller Installatin 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 the 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 +12 vlt key n surce with inline switch. 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. Cntrller Operatin The cntrller has an LCD display screen. The display sftware allws fr seven different display mdes and fur cntrl/setup screens. 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 P I T This mde displays the bst pressure and EGT temperature in PSI and ºF. Screen 3 Bst EGT This mde displays the bst pressure and EGT temperature in BAR and ºC. Screen 4 PSI DegF %Injectin