BULLY DOG TECHNOLOGIES
UNCOMPROMISED DIESEL PERFORMANCE
ADJUSTABLE PROPANE KIT
P/N# 010800
Bully Dog Propane Charger Installation Instructions
Read the disclaimer before continuing with installation

REMEMDER THIS IS A HIGH PREFORMANCE PRODUCT. BE SURE TO READ AND UNDERSTAND THE DISCLAMER THE INSTALLATION OF THIS PRODUCT INDICATES THAT THE BUYER HAS READ AND UNDERSTANDS THIS AGREEMENT AND ACCEPTS ITS TERMS AND CONDITIONS

IT IS ABSOULUTELY NECESSARY THAT A VAPOR TANK IS USED WHEN RUNNING A BULLY DOG PROPANE CHARGER.

MOUNTING THE REGULATOR

Turn off the vehicle, set the parking brake and remove the keys from the ignition.

Find a suitable place to mount the regulator solenoid setup. (Maximum 20 inches from the intake or turbo charger).

TANK HOSE INSTALLATION

Install the black steel braided hose with the proper fittings from tank to solenoid. (BE SURE THE HOSE DOES NOT HANG DOWN FROM THE FRAME. MAKE SURE THE HOSE IS FAR ENOUGH AWAY FROM THE EXAUST. KEEP THE HOSE AWAY FROM VIBRATING OR MOVING OBJECTS.

SPARGE TUBE INSTALLATION

Install the sparge tube in the intake system between the filter and the turbo charger or intake manifold
  1. On turbo applications, install the sparge tube into the intake hose between the turbo charger and the air filter assembly no closer than 3 inches from the turbo charger.
  2. On non-turbo applications install the sparge tube on the engine side of the air filter assembly.
  3. Drill a ¾ inch hole into the intake hose for the installation of the strain relief.
  4. Install the strain relief into the ¾ inch hole. Reach in the intake hose and attach the washer and nut make sure the teeth part of the nut is facing towards the washer. (Lock tight is recommended as well as sealing around the fitting with silicone).
  5. Different applications may call for some cutting of the copper tubing on the sparge tube. To determine the proper length place the sparge tube into the intake hose the tube should be centered in the hose. If it is to long mark it and cut the excess off.
  6. Place the sparge tube in the strain relief. Point the barb of the sparge tube towards the regulator and tighten the strain relief nut firmly.
BE SURE THAT THE INSIDE OF THE INTAKE HOSE IS CLEAN BEFORE REINSTALLING.

VAPORIZING UNIT

Locate the heater hose that runs from the motor block to the heater core. The stock hose can be used removed or spliced.
  1. If removing the stock hose, run the new hose form the heater core to one side of the regulator the back to the barb on the motor block.
  2. When splicing the stock hose pinch the hose in two positions and cut the hose between the pinched areas. Place the two barb couplers provided in the cut hose ends and tighten securely with hose clamps. Then run the heater hose off each side of the regulator to the two hoses being spliced into.
FEED HOSE

Tighten the end already on the hose to the regulator outlet fitting. Cut the proper length of hose needed to reach from the regulator to the sparge tube. Put the hose end by twisting the bottom part of the hose end counter clockwise until it is tight then thread the top of the fitting it to the bottom going clockwise.

WIRING

AIR PRESSURE SWITCH

Install the air pressure switch on the pressure side of the turbo.
  1. Choose a suitable location for the switch (cold side intercooler hose, or map sensor hose)
  2. If you are using the intercooler pipe, drill a 5/16 inch hole and tap it with a 1/8 inch NPT tap. Screw the pressure switch into the threaded hole, use thread sealant to assure a good seal. BEFORE PUTTING THE PIPE BACK ON, MAKE SURE TO REMOVE ALL LEFTOVER FILINGS.
  3. One side of the pressure switch run a wire to the solenoid. On the other terminal on the pressure switch run a wire to the cab to go on the toggle switch. The other side of the solenoid put to a ground source.
TOGGLE SWITCH

Install toggle switch in a convenient location in the cab.
  1. Run a ground wire to the earth terminal on the toggle switch
  2. Find a power source (such as a radio terminal) with a positive key on power. Attach the power to the supply terminal on the toggle switch.
  3. Run the wire coming from the pressure switch to the load terminal on the toggle switch.
REGULATOR ADJUSTMENT

Located on the backside of the regulator there is a adjustment screw. Turning the adjustment screw clockwise will increase the amount of propane. The screw with the lock nut should not be adjusted unless otherwise informed by Bully Dog.
  1. First a jumper wire will need to be placed on the air pressure switch to give a direct connection to the solenoid.
  2. The vehicle will then need to be started.
  3. Make sure the propane tank is full and is in the on position
  4. Turn the toggle switch to the on position.
  5. With the vehicle at an idle, turn the adjustment screw clockwise until the vehicle comes to a rough idle then adjust the screw back about ½ turn.
  6. Remove the jumper wire, and take the vehicle on a test drive.
  7. If no power if felt bring the regulator right up to a rough idle and leave it there. Once you hit seven pounds of boost you should not hear any knocking, pinging. If there is and knocking or pinging when you are on a test drive contact Bully Dog.
  8. If the vehicle will not idle contact Bully Dog
  9. If any pre-detonation (pinging noise) is ever present shut off switch immediately and contact Bully Dog
NOTES

Be sure to install a vapor capable tank using only the VAPOR outlet. Install the tank so that the position allows for the vapor outlet to work properly.

Never overfill tank

If any icing occurs over valve, regulator, or hose, liquid is present instead of vapor. Check tank installation for over filling.

BE SURE TO CHECK THE SYSTEM FOR ANY LEAKS BEFORE USING THE SYSTEM. Your local propane company should be able to assist you with determining the proper tank, tank position, and proper mounting.

Do not use the system until normal engine operating temperature has be reached.

TANK INSTALLATION


BED MOUNTING

Place tank across the front of the bed left to right.

Adjust the mounting brackets with L bracket down so that they raise tank ¼ inch of the floor of the bed and tighten brackets to the tank.

Drill ½ holes trough the bed and use ½ inch bolts. Check underneath the bed to make sure there is nothing in the way that could be damaged.

UNDERBODY MOUNTING

Hold tank underneath the body inside or outside the frame rail. Make sure you are far enough away from the exhaust. Find a place on the frame to put the L brackets use a ½ inch drill bit find a spot to drill make sure that you check where you drill first.

Have tank purged and filled by an authorized propane dealer. Check for leaks. Make sure the hose is clear from any sharp or moving objects.
SUGGESTED SAFETY GUIDELINES FOR PROPANE USE:


OPERATION:
Operate you LP-Gas engine exactly as you did when it ran on gasoline or as recommended by manufacturer. As with any engine a warm-up period of a minute or two at fast idle is advisable. Because an LP-Gas fuel system is simple, it is unlikely that adjustments will be necessary. However, if they are required, see you LP-Gas servicemen.

SAFE HANDLING OF LP-GAS:

These common-sense rules should be observed:
  1. Perform service work on an LP-Gas fuel system in an open, well ventilated area. Never allow the gas to escape in a closed area. LP-Gas is heavier than air and may settle in low places.
  2. Avoid cutting and welding operations near LP-Gas systems.
  3. Handle LP-Gas containers carefully. Do not drop or drag.
  4. Installation and repair should be done only by qualified service personnel.
  5. Never test for leaks with a flame. Use soap suds to test or approved leak detector.
  6. Do not fill tanks improperly labeled for LP-Gas. Do not put propane into tanks with working or service pressure less than 240 psi. Do not tamper with valve or fitting in the LP-Gas system.
IN CASE OF ACCIDENT:

LP-Gas, as all fuels, must be treated with respect and care. On detection of escaping gas take the following steps.
  1. Immediately shut off the tank service valves.
  2. Eliminate all possible outside sources of ignition.
  3. Summon qualified LP-Gas personnel.
IN CASE OF FIRE:
  1. Stop flow of gas as quickly as possible. If fire occurs, never put out flame unless gas can be shut off.
  2. Notify Fire Department and clear immediate area of all people.
  3. When gas flow is stopped, put out the fire. Usually when flow of gas is cut off, fire will automatically stop. Carbon dioxide and dry chemical extinguishers may be used. DO NOT USE CARBON TETRACHLORIDE EXTINGUISHERS (PYRENE, ETC.).
  4. If gas flow cannot be immediately stopped, direct water on tanks to keep them cool, but do not put out fire.
LP-Gas is by nature odorless and invisible. An identifying odor has been added so that the presence of gas can be quickly detected.

INSTALLER’S SAFETY REQUIREMENTS

NFPA 58

“STANDARD FOR THE STORAGE AND HANDLING OF LIQUIFIED PETROLEUM GASES”

Chapter 8 Engine Fuel Systems

8-1.1 This section applies to fuel systems using LP-Gas as a fuel for internal combustion engines. Included are provisions for containers, container appurtenances, carburation equipment, piping, hose and fittings, and provisions for their installation. This section covers engine fuel systems for engines installed on vehicles for any purpose, as well as fuel systems for stationary and portable engines. It also includes provisions for garaging of vehicles upon which such systems are installed.

8-1.4 In the interest of safety, each person engaged in installing, repairing, filling, or otherwise servicing an LP-Gas engine fuel system shall be properly trained in the necessary procedures.

It is suggested that all installations be made in compliance with NFPA Standard 58 and/or applicable State, Federal and Local regulations. Only equipment approved as required by NFPA Standard 58 and/or applicable State, Federal and Local regulations will be used in installations or servicing vehicles. The installer maintains and will continue to maintain the minimum level of product liability insurance required by the jurisdiction in which his facility is located as long as he makes propane carburetion installations and repairs.

To obtain this book contact: National Fire Protection Association Batterymarch Park Quincy, MA 02269
WARNING: IMPROPER INSTALLATION OR USE OF THIS PRODUCT MAY CAUSE SERIOUS INJURY AND/OR PROPERTY DAMAGE.

SERVICE TECHNICIANS AND USERS

SHOULD CAREFULLY READ AND ABIDE BY THE PROVISIONS SET FORTH IN NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #37 FOR STATIONARY ENGINES. #52 FOR CNG VEHICULAR FUEL SYSTEMS OR #58 FOR LPG SYSTEMS.

INSTALLERS

LPG INSTALLATIONS IN THE UNITED STATES MUST BE DONE IN ACCORDANCE WITH FEDERAL, STATE, OR LOCAL LAW, WHICHEVER IS APPLICABLE AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #58. STANDARD FOR STORAGE AND HANDLING OF LIQUEFIED PETROLEUM GASES TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION WITH FEDERAL, STATE, OR LOCAL LAW.

IN CANADA REFER TO CAN/CGA-B149.2 PROPANE INSTALLATION CODE.

CNG INSTALLATIONS IN THE UNITED STATES MUST BE DONE IN ACCORDANCE WITH FEDERAL, STATE, OR LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPHLET #52. COMPRESSED NATURAL GAS (CNG) VEHICULAR FUEL SYSTEMS TO THE EXTENT THESE STANDARDS ARE NOT IN VIOLATION WITH FEDERAL, STATE, OR LOCAL LAW.

IN CANADA REFER TO CAN/CGA-B149.1 CNG INSTALLATION CODE.

LPG AND/OR NATURAL GAS INSTALLATIONS ON STATIONARY ENGINES MUST BE DONE IN ACCORDANCE WITH FEDERAL, STATE, OR LOCAL LAW AND NATIONAL FIRE PROTECTION ASSOCIATION PAMPLET #37 STATIONARY COMBUSTION ENGINES AND GAS TURBINE ENGINES. TO THE EXTENT THESES STANDARDS ARE NOT IN VIOLATION WITH FEDERAL, STATE, OR LOCAL LAW.

FAILURE TO ABIDE BY THE ABOVE WILL VOID ANY WARRANTY ON THE PRODUCTS AND MAY CAUSE SERIOUS INJURY OR P\ROPERTY DAMAGE.

DUE TO THE INHERANT DANGER OF GASEOUS FUELS THE PRODUCTS SHOULD NOT BE INSTALLED OR USED BY PERSONS NOT KNOWLEDGEABLE OF THE HAZARDS ASSOCIATED WITH THE USE OG GASEOUS FUELS.