“Pittsburgh
Power” installation instructions for Cummins Engines
By Diesel Injection of
Pittsburgh
Note: These instructions are for general information. Please use the documentation that comes with your Pittsburgh Power for actual installation. The Caterpillar/Detroit unit is very similar to install as the Cummins although you DO NOT drill the manifold on the Cat, ISX or DD-V Detroit.
Congratulations on the purchase of your “Pittsburgh Power” performance computer. The only product of it’s kind! These installation instructions will guide you through the process required to make your engine perform like a winner. Aside from basic hand tools you will need the following:
1 3/8" hole saw 1/4" pipe tap
1/2" drill 1/8" & 7/16" drill bit.
1). Mounting the “Pittsburgh Power ” computer. Find a suitable location inside the cab around the dash area for the computer. It can be mounted in any orientation making sure you will have access to the connections on the one end and the on-off switch on the other. The computer can be securely mounted to any flat surface with screws inserted through the two holes provided on the ends of the unit or it can be held in place with Velcro or wire ties as the situation permits.
2). Preparing to install the new harness. Inspect the firewall for accessibility and, using a hole saw, drill a 1 3/8" hole (see figure 1) in a location that will allow you to pass the wiring harness through. This harness will be attached to the injector connectors on the drivers side of the engine and the “Pittsburgh Power” computer that is located inside the vehicle. After drilling the hole remove any burrs from the area with sandpaper or a small file.
3). Installing the new harness. Being careful not to damage the connectors, feed the main wiring harness (double round black connector end) through the hole from the engine side towards the inside of the vehicle. Pull enough through so the leads for the EGT sensor (see figure 2) are inside the vehicle and the injector plugs, on the forward most part of the harness, align with the factory injector connectors. Carefully insert the supplied grommet into the pass-through hole in the firewall and around the harness (see figure 3).
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Figure 1 |
Figure 2 |
Figure 3 |
4.) Attach the new harness to the computer. Align the pins and push each black connector (small & large) on to the receptacles of the “Pittsburgh Power ” computer. Turn the lock nut till you feel it "click". Do not over tighten.
5.) Connect the new harness to the injector connectors. Remove the male plug of the factory wiring harness from the #6 (rear) female injector connector. It is located on the drivers side of the engine towards the top-rear. To remove the male plug, push down on the release mechanism (see figure 4) and gently pull the plug from the female connector. Insert the male plug on the new harness into the original connector and insert the original male plug (removed at the beginning of this step) into the connector on the new harness (see figure 5). Repeat this procedure with the remaining 5 connectors.
6.) Connect the power leads. There are two wires that brake out of the new harness in between cylinder numbers 3 and 4 injector plugs. Run the wire marked 12V hot inside the cab and hook it to the accy. side of the ignition switch terminal (not the shut down solenoid ) and the wire marked PWR GND to one of the shut down solenoid magnet mounting screws (see figure 6). Do not interchange. Serious computer damage could result.
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Figure 4 |
Figure 5 |
Figure 6 |
7.) Connect the new harness to the boost sensor. The sensor is located at the rear of the intake manifold (see figure 7). Remove the male plug from the sensor. Find the wires that brake out of the new harness at the #6 injector area. Plug the male connector from the new harness into the boost sensor. Next, plug the original male connector, removed previously, into the female connector of the new harness (see figure 8).
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Figure 7 |
Figure 8 |
8.) Drill and tap the exhaust manifold and install the EGT sensor (thermocouple). If you purchased our turbo upgrade this is best done after the old turbo is removed. However, if you are not removing the turbo, you can still drill and tap without concern. Drill a 1/8" pilot hole approximately 1" towards the engine from the edge of the turbo mounting flange. Referring to figures 9&10, notice there is a divider in the center of the exhaust opening. The EGT sensor should be located in the center of the rear port opening. After the pilot hole is drilled re-drill with a 7/16" bit to open the hole to accept a 1/4" pipe tap. Run the tap in and thread the hole. Use caution not to turn the tap in to deep as this will open the hole beyond specifications. Use the EGT sensor as a guideline by removing the tap and checking for a proper fit. After the hole is tapped, install the sensor into the manifold. It is recommended to use anti-seize on the sensors threaded areas.
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Figure 9 |
Figure 10 |
9.) Connect the EGT sensor lead wire to the EGT sensor. Attach the longer red lead wire to the shorter red wire on the EGT sensor and the shorter yellow lead wire to the longer yellow wire on the EGT sensor. Run the sensor lead wire through the grommet installed in step 3. Referring back to figure 3, slide the supplied heat shrink tubing over each of the connections. Using the supplied screws and nuts, attach the EGT lead wires to the new “Pittsburgh Power” harness following the yellow and red markings on the wires of the new harness. Finish this step by shrinking the tubing. Slide the shrink tube over each connection and, with a heat gun or suitable heat source, warm it up enough to shrink it around the connections so they are protected.
10.) Using the supplied wire ties, fasten the EGT lead wire and the “Pittsburgh Power ” harness at several locations under the hood and under the dash to prevent vibration. Be sure to route all wiring away from any heat source.
11.) Install the remote control unit. Using the supplied Velcro, attach the remote to a convenient location. Route the wire from the remote unit to the “Pittsburgh Power ” computer and plug it into the jack on the side of the computer. Use wire ties were necessary to hold the lead in place.
“Pittsburgh Power”operating instructions
All driver interaction will be done through the remote unit. You will have eight different power level settings starting at level zero. Each level above zero will add approximately 25 horsepower to your stock setting for a total of 175 additional ponies. The level setting can be changed at any time under any type of driving condition.
The remote also displays important monitoring information. It will show, in real time, power level setting, exhaust gas temperature, manifold pressure and the approximate horsepower being developed. On power levels 6 and 7 a red LED will blink indicating the high level setting. If the exhaust gas temperature (EGT) rises above 1300 degrees the “Pittsburgh Power” will start to cut the power back in order to maintain a safe operating condition. There is also a safety feature built in that will prevent added horsepower if the EGT is below 400 degrees. If there is a problem with the signal coming from the EGT sensor/wiring, no power will be added.
On the side of the computer there are 6 LED's and an on-off switch. The LED's indicate when cylinders 1 through 6 are firing with enhanced power and will blink with every power stroke of the engine. They will also get brighter as more power is applied. If you have a miss that is ECM or “Pittsburgh Power” related you may be able to tell what cylinder it is. The corresponding light for the problem cylinder will not light while under load. If this occurs, check the fuses in the “Pittsburgh Power” computer. To do so, you will see the fuse holders located on the side of the unit. Push in and turn the screw counter clockwise. Remove the fuse and inspect. Replace if necessary. If the miss is downstream from the ECM or “Pittsburgh Power” the light will still blink. This could indicate a possible problem with an injector or an internal engine malfunction.
The yellow MAP light is an indicator that the “Pittsburgh Power” is seeing a signal from the boost sensor and will get brighter with higher manifold pressure readings. The red power light indicates whether or not the switch is turned on.
Use the on-off switch to enable or disable the unit. With the switch turned off, no power will be added regardless of where the remote is set. The display on the remote will continue to function normally in both modes.
WARRANTY AND DISCLAIMER
Diesel Injection of Pittsburgh Inc. warrants that its “Pittsburgh Power” computer will be free of functional defects and will perform as advertised provided they are used on engines that are in good mechanical condition. It is mandatory that the pyrometer sending unit be properly connected to the “Pittsburgh Power” or severe engine damage may result.
Diesel Injection of Pittsburgh does not warrant the engine, drivetrain or balance of the vehicle in any way. The operator is solely responsible for the proper use of this product.
Diesel Injection of Pittsburgh shall not be held responsible for any misuse or unsafe acts performed by the customer, whether directly or indirectly resulting from the increase in engine power.
The original manufacturer may void its warranty on the engine and/or drivetrain when stock power is altered.
Any repair/alteration of the “Pittsburgh Power”, unless conducted by Diesel Injection of Pittsburgh or one of its factory trained and authorized dealers, will void any and all warranties of the product. A copy of the original sales receipt from Diesel Injection of Pittsburgh or one of its authorized dealers must accompany all products submitted for warranty consideration.
For all technical support related issues call 724-360-4080