Subscribe to Our Youtube Channel
Related Manuals for DPS Turbonator VGT
Summary of Contents for DPS Turbonator VGT
- Page 1 Page 1 of 25 Turbonator® VGT Controller Installation Manual Revision 2.6 Revision Date 6/7/2021 Turbonator® VGT Controller www.dieselpowersource.com...
- Page 2 ABOVE THE TURBO OR EXHAUST MANIFOLD! HEAT RISES AND CAN RUIN THE ACTUATOR! THE SOFTWARE, TUNING, AND ACTUATOR POSITION ARE ALREADY CUSTOMIZED AND PROGRAMMED FOR YOUR APPLICATION. DPS CHARGES $150 PER HOUR FOR CUSTOM TUNING. CHANGES MADE TO SOFTWARE SETTINGS AND TUNING BY UNQUALIFIED INDIVIDUALS MAY RESULT IN POOR VEHICLE PERFORMANCE.
-
Page 3: Under The Hood
Page 3 of 25 QUICK START GUIDE **READ FIRST** UNDER THE HOOD 1. Connect harness to VGT controller (control unit) 2. Connect harness to turbo actuator 3. Secure VGT Controller to the vehicle 4. Connect exhaust wires to vehicle ECU (1998.5-2007 Trucks Only) a. -
Page 4: Wiring Harness
Page 4 of 25 Wiring Harness Step 1: Lay the main harness out on the floor, it is pre-connected (Figure 1). Wire colors may differ from the picture. Revision 2.6 Revision Date 6/7/2021 Turbonator® VGT Controller www.dieselpowersource.com... - Page 5 (choose “DPS Turbonator® Software) which can tune and control the actuator, but the control is pre-programmed for your vehicle from DPS, and is not required to connect to a computer to operate properly. a. Install BOTH the DRIVER and the APPLICATION files. Install both files.
- Page 6 Page 6 of 25 Exhaust Brake Wiring 2003-2007 Dodge 5.9 Common Rail ONLY ____________________________________________________________________________ 1. Locate the wires shown in Figure 4, which have the relay, two loose wires, and a ground wire. If these wires have PIN labels, follow those labels. Otherwise: Yellow=PIN B42; White=PIN B39;...
- Page 7 Page 7 of 25 Exhaust Brake Wiring 1998.5-2002 Dodge 5.9 VP44 ONLY ______________________________________________________________________ 1. Locate the ECM on the drivers side of the engine, remove bolt, disconnect the connector from the ECM. 2. On the inside of the plug at pin 20 there is a small piece of plastic to keep water out. Use needle nose pliers and pull the plastic piece out.
- Page 8 Page 8 of 25 Exhaust Brake Wiring 6.7 Cummins 2007.5-2018 ONLY _____________________________________________________________________ 1. Connect the single wire shown in figure 5, labeled PIN 20 into the wiring harness. 2. Run the wire labeled PIN 20 through firewall into the cab. 3.
- Page 9 Page 9 of 25 APP Sensor Signal Wires **Note: Although pictures show two connectors you will only tap one wire.** 2007.5-2009 | Brown/White Wire 2010-2012 | Brown/Light Green Wire 2013-2014 | Brown/Light Green Wire 2015-2018 | Brown/White Wire Revision 2.6 Revision Date 6/7/2021 Turbonator®...
- Page 10 Page 10 of 25 Exhaust Brake Wiring 12 Valve Cummins & Universal Kit ____________________________________________________________________________ Universal 2-wire kit can be used on 12 Valve non-electronic trucks. The 2 loose wires can be shorted together to trigger the brake, after the brake switch is turned on. To use with a micro-switch on 12V engines: Do not connect these wires to anything but each other through a switch The goal is for the pedal to close the circuit to engage the exhaust brake.
-
Page 11: Exhaust Brake Switch
Page 11 of 25 _________________________________________ Exhaust Brake Switch Step 1: Identify a desirable spot to mount the exhaust pressure switch Revision 2.6 Revision Date 6/7/2021 Turbonator® VGT Controller www.dieselpowersource.com... - Page 12 Page 12 of 25 Engine RPM Wiring (Optional) 1998.5-2018 Dodge Trucks Only ______________________________________________________________________ **DO NOT HOOK UP WIRE LABELED RPM UNTIL UNIT IS INSTALLED AND FUNCTIONING FIRST. The Engine RPM Wiring is NOT necessary to connect to achieve correct VGT operation. But it is used for cold start help with warm up, and for the idle ENGINE SPEED BRAKE DISENGAGE.
- Page 13 Page 13 of 25 Crankshaft and/or Camshaft Sensor Wire/Pin Guide: (The Blue or Purple single wire connects to the truck Crank/Cam Sensor) 1998.5-2002 Dodge Cummins 5.9L 24V Camshaft Sensor ECM Pin 17 Grey Wire 2003-2004 Dodge Cummins 5.9L Common Rail Crankshaft Sensor ECM Pin 8 Grey/Black Wire 2004.5-2005 Dodge Cummins 5.9L Common Rail Crankshaft Sensor ECM Pin 22 Light Blue/Brown Wire...
- Page 14 Page 14 of 25 ____________________________________________________________________________ Exhaust Pressure Sensor Mounting Bracket Installation Instruction **Actuator Style May Vary** _____________________________________________________________________________________ 1. The exhaust sensor will mount to the provided bracket, which connects to the compressor housing. 2. Mount the bracket to the compressor housing using the provided (longer) bolt. 3.
- Page 15 Page 15 of 25 Suggested Configuration for 2007 or older trucks single turbo application S300 Suggested Configuration for 2007.5-2018 trucks single turbo application S300 Revision 2.6 Revision Date 6/7/2021 Turbonator® VGT Controller www.dieselpowersource.com...
- Page 16 Page 16 of 25 Suggested Configuration for Ram trucks Compound Turbo application S300 Suggested Configuration for Fummins Compound turbo application S300 Revision 2.6 Revision Date 6/7/2021 Turbonator® VGT Controller www.dieselpowersource.com...
- Page 17 Page 17 of 25 S400 Turbo Exhaust Sensor Location Exhaust sensor bracket will mount to the same bolt as the actuator bracket (see picture) Make sure that you only loosen the one bolt, not the second bolt or actuator will need recalibrated.
- Page 18 Page 18 of 25 Software Download the latest software version and driver from the website: https://www.dieselpowersource.com/installation-instructions Install both files on your computer. The one file is the driver, the other file is the Application. To troubleshoot, adjust the brake, tuning, etc. you will need to have the software downloaded and on a laptop computer that can be in the truck when running.
-
Page 19: Troubleshooting
Page 19 of 25 Troubleshooting If after everything is connected the actuator isn’t responding, or if it feels sluggish, or feels like the exhaust brake is stuck on, check the following: While observing the actuator on the turbo, have someone cycle the ignition from the off to the on position. - Page 20 Page 20 of 25 3. Open the VARIABLE RATIO tab. Check that the starting position is between 25- 50 depending on truck and actuator. Default Starting Position (under Variable Ratio Tab): Med Duty Actuator: 41 for 5.9L, and 48 for 6.7L Cummins). o Make sure that the FEEDBACK is within 3 numbers of the COMMANDED.
- Page 21 They should unplug each wire and check the pins as well as checking the wires going into the plugs. DPS Troubleshooting Version 1.01 May 20, 2021 o Warn them to NOT pull on the wires but only the plug.
- Page 22 A better “crimp” needs made into the APP sensor wire on truck On the DPS wire harness unplug the exhaust brake wire from the main harness and probe the inside pie that coincides with the incoming wire. With truck key turned on the voltage should read approx.
- Page 23 Under INPUT VOLTAGES make sure when switch is on idle voltage is approx.. 0.45 V. o Connect software and use data log feature. Email us the data log. DPS Troubleshooting Version 1.01 May 20, 2021 o If brake actuates and doesn’t have enough pressure refer to (Exhaust Brake Pressure not high enough) ...
- Page 24 Actuator can NOT manually be extended/retracted when power is present o If actuator moves then power is properly connected. DPS Troubleshooting Version 1.01 May 20, 2021 o If actuator has power it will hum and vibrate very slightly o Make sure both the DRIVER and APPLICATION are installed on the computer. They are two separate files.
- Page 25 Page 25 of 25 DB@DieselPowerSource.com Mechanical Version: See video: https://www.youtube.com/watch?v=W1s5BKKipOg&list=UU9aRgqW_hezn7wbk1RyFV3A&index=23 Remove e-clip from linkage (spring loaded be careful not to lose) Adjust half turn either way and drive if it gets better continue adjusting in that same direction. If it performs worse turn it the opposite direction until you find the “Sweet Spot”...
Need help?
Do you have a question about the Turbonator VGT and is the answer not in the manual?
Questions and answers