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| TOTAL SOLUTION FOR DIESEL VEHICLES - Diesel Fuel Saver System |
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General Installations Instructions
Step 1: Tee into the boost pressure gauge port, with the boost pressure line brass adapter tee. Label hose attach to top of regulator. If no boost gauge port is present, locate a proper boost source or determine inter-cooler entry points, drill and tap 1/8 inch pipe threads into inter-cooler, approx. one inch forward of boost tube and hose clamp assembly. Install 1/8 inch pipe to 1/4 inch hose fitting (included), attach hose going to the top of the regulator to this fitting. * * * IMPORTANT * * * Remove boost tube and clean to remove any metal particles from drilling and tapping before proceeding to Step 2. Vehicles without inter-cooler, determine best boost source and drill and tap 1/8” pipe threads.
Step 2: Run 2 hoses from under the vehicle hood to truck bed. Do not cut hoses to equal length, one will be longer, run boost pressure line first.
* * * IMPORTANT * * * MARK HOSES AT BOTH ENDS AS FOLLOWS: ONE-LP FUEL THE OTHER-BOOST PSI Attach BOOST PSI hose to adapter fitting “tee”. At the tank, attach boost PSI line to the top of the regulator. Attach Fuel line to the end of the regulator fuel out fitting
Step 3: Remove air filter cover and air filter indicator, being sure to keep the rubber grommet. Run the fuel hose through the grommet making the fuel hose run down the inlet hose approximately 1 foot toward the turbo.
(*Note - If truck is equipped with Mass airflow sensor, route the hose around the sensor.) Reinstall air filter cover.
Step 4: Run wire from fuel regulator in the bed of the truck, under the dash. Ground the black wire under the dash. Hook the white wire to the switch. Run power wire from ignition switch located on the steering column to the fuse holder. Attach the ground wire from the lock off valve and power switch to a proper ground. Hook yellow wire to white wire from lock off valve. (See diagram below)
THIS POWER SUPPLY MUST TURN ON AND OFF WITH THE IGNITION SWITCH. 12 VOLT POWER WITH KEY ON, NO POWER WITH KEY OFF.
The dual switches under the dash will be used to turn system on and off and must be re-activated each time the vehicle is started by the momentary rocker switch. Power switch is illuminated when system is activated.
Step 5: Secure all lines to frame rail keeping them clear of any moving parts. Leave a slight amount of slack in the hoses and wires leading from the bed of the truck to under the cab area. Truck beds are independent of cabs and can and do move.
Step 6: * * * VERY IMPORTANT * * * ALWAYS SECURE A VERTICAL TANK IN THE UPRIGHT POSITION ONLY! NEVER ALLOW THE TANK TO TIP OVER. THIS WILL ALLOW FOR THE FEED OF LIQUID PROPANE DIRECTLY TO THE ENGINE. DAMAGE CAN OCCUR. CHECK SYSTEM FOR ANY LEAKS BEFORE INITIAL VEHICLE OPERATION AND CHECK HOSES AND WIRES PERIODICALLY.
*Note: This propane kit is intended to optimize the performance of your turbo-charged diesel engine. It is not recommended to operate a diesel engine at maximum power for extended periods. Improper use of propane injection may cause damage to the engine and/or void the manufacturer’s warranty coverage. As with any aftermarket performance product designed to increase torque and horsepower, the user and purchaser assumes all risks and liabilities associated with and resulting from the installation and use of this product.
CUSTOMERS WITH UNDER-VEHICLE TANKS - USE CAUTION WHEN REFILLING YOUR TANK TO AVOID OVERFILLING WHICH COULD LEAD TO LIQUID PROPANE ENTERING THE REGULATOR.
Your propane injection system has been shipped to you preset for your vehicle and to the specifications indicated when you placed your order. Your starting time and flow rates are noted on the packaging. No initial adjustments should be necessary after installation. Just install it and go!
ADDITIONAL ADJUSTMENTS (IF NEEDED)
If you need to change the settings for another application, (such as towing, which generally requires a later start time than the stock setting) please follow the instructions here.
THE BLACK TEE HANDLE REGULATOR IS PRESET AT 40 PSI AND REQUIRES NO ADJUSTMENTS.
It is normal for the lock-off valve solenoid to become very hot when in operation.
Starting pressure adjustments: The stock system setting is normally set at a 5lbs start time unless a custom calibration was requested when ordering. For example, a performance setting comes in at 2-3lbs boost while a towing only setting comes in at around 10lb boost.
To set for Performance Gains – (set level to lowest start time setting):
Remove both hoses from the regulator. Turn the system on; loosen the 1" jam nut located on the top of the GS2K. Apply a minimum of 2 PSI with air pressure, which will simulate boost pressure to the bottom of the GS2K. Screw this assembly out until you hear gas escaping. Then, turn the assembly in until the gas stops flowing. This is the lowest setting of the regulator (approximately 2 PSI start time). Tighten the 1” jam nut to lock this setting. This adjustment is very sensitive. It is recommended to mark the factory setting for future reference.
To set for Propane and Fuel Economy (Towing):
Follow the procedure above, EXCEPT, screw in (right) for a later start time, (up to 15 PSI boost) or screw out (left) for an earlier start time (down to 2 PSI boost).
For the best fuel economy while towing: Set regulator start pressure 2-3 PSI lower than average boost pressure when running on flat grade.
To reset to stock setting or any other start pressure setting, you can use a low pressure adjustable regulator or a Mighty Vac® pump that reads pressure to simulate boost pressure and apply it to the bottom of the Diesel Fuel Saver System follow the steps above, (turn system on, remove hoses) and adjust to the starting boost pressure you desire. The slightest flow indicates start time. Tighten the 1” jam nut to lock setting in.
Flow Limit Adjustments: The Diesel Fuel Saver System does not contain fixed orifices but has an easy adjustment screw for regulating the flow for your specific needs. (i.e. towing, propane economy, performance, etc). To adjust the flow of LP fuel-loosen 7/16” nut (located next to the American Alternative Fuel / Diesel Fuel Saver System engraving) turn this screw in for less LP flow. This is recommended to increase propane and fuel economy. Turn this screw out for more LP flow. The maximum adjustment is six turns out. Make these adjustments in 1/4" turn increments. The maximum flow rate is not recommended for vehicles with extreme performance enhancements such as computer modules/chips or fueling boxes (over 100 HP). Please use caution when making these adjustments. Listen for any signs of engine knocking or rattling when increasing the flow. Turn system off immediately and readjust to the stock setting if any engine knocking or rattling occurs. This can indicate engine detonation, caused by excessive LP flow.
* * * IMPORTANT * * * These adjustments should only be made in well-ventilated areas only. *Propane is extremely flammable*
REMOTE MOUNTING OF THE DIESEL FUEL SAVER SYSTEM UNIT WILL REQUIRE THE USE OF HIGH PRESSURE PROPANE HOSE BETWEEN THE TANK AND THE DIESEL FUEL SAVER SYSTEM REGULATOR. THE LOCK-OFF VALVE AND BLACK TEE HANDLE REGULATOR MUST REMAIN AT THE TANK.
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