DPS Turbonator VGT User manual

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Revision Date 6/7/2021 Turbonator® VGT Controller
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DPS
Turbonator® VGT Controller
Installation Manual

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* IMPORTANT *
DO NOT CHANGE THE SOFTWARE SETTINGS AND
TUNING UNTIL YOU HAVE DRIVEN THE VEHICLE
AND EVERYTHING IS WORKING PROPERLY!
DO NOT CLOCK OR LOOSEN ACTUATOR, IT IS PRE-
CALIBRATED! DOING SO WILL MAKE VEHICLE RUN
POORLY!
DO NOT INSTALL CRANK SENSOR WIRE UNTIL
VEHICLE HAS BEEN DRIVEN AND IS FUNCTIONING
PROPERLY!
ACTUATOR MUST NOT BE PLACED ON TOP OF OR
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.

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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. 2007.5-2018 6.7L Trucks Run Pin 20 wire into cab
5. Connect power to battery
6. Connect boost wire to provided sensor.
7. Connect exhaust wire to provided sensor.
8. Do NOT connecting RPM wire yet
9. Either connect ACC wire (ignition wire) to ignition on/off power OR; run into cab.
RUN THE FOLLOWING WIRES INTO CAB
1. USB wire
2. Exhaust Brake Switch wire
3. Ignition/ACC (accessory), unless already connected.
4. Exhaust brake wire (Pin 20 Wire) Only on 2007.5-2018 Trucks run in cab
a. 1998.5-2002 Trucks (Pin 20 wire) does NOT run into cab
INSIDE THE CAB
1. Mount brake switch in dash
2. Connect Ignition/ACC (accessory) wire to an ignition wire on/off ignition source
a. An ignition source is a positive power source which turns on and off with the key.
3. Connect wire (PIN 20 wire) to APP Sensor (Above Throttle Pedal 2007.5-18 Trucks Only)
4. Tie USB cable under dash (for future use)
More detailed instructions are in the following pages.

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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.

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Wiring Harness (Cont.)
1. The harness is very simple to understand and connect.
2. Lay the cords out on a floor and simply connect the same color connector to the same
color connector, (grey to grey) of the same type connector.
a. If two similar connectors have a similar color, match label.
3. Attach battery power as follows: BLACK ring to negative and RED to Positive terminals
of the battery. (2003-07 trucks have a second ground cable to battery negative)
4. Attach the Ignition/ACC wire to your accessories power, to an ignition controlled wire, so
control turns on and off with ignition switch (usually in your fuse panel).
a. Definition: ACC wire = Accessory Power Wire
5. Pull the exhaust brake toggle switch (for exhaust brake) and USB cables into the cab,
through the firewall.
a. 2007.5-2018 Cummins pull wire labeled PIN 20 into the cab as well.
6. Plug in the sensor wires as follows:
a. PURPLE END=Boost Sensor
b. GREY or YELLOW END=Exhaust Sensor
7. Plug actuator wire to the turbo actuator. It’s the only wire which fits the actuator. (DO
NOT BUMP OR BEND THE ACTUATOR, MISALIGNMENT CAN OCCUR).
8. Note: DO NOT LOOSEN OR ADJUST THE ACTUATOR FROM THE HOUSING. It is
calibrated to the housing it comes on. If you to need to reconfigure the actuator please
watch our CALIBRATION video in the instructions section of our website. If Diesel
Power Source, mounted the actuator you should not need to calibrate. But,
CALIBRATION IS ABSOLUTELY NECESSARY if the actuator bolts are ever loosened.
9. Download software from our Website https://www.dieselpowersource.com/installation-
instructions# (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.
Note 1: If you need to adjust the length of the harness connections must be soldered.
Note 2: If any part of the harness is shortened, which is not recommended. The wires must be
soldered, and heat shrunk.
Caution 1: Take caution when cutting the harness. There may be 2 or more wires side by side
with the same color code with different functions. Cutting harness could void warranty.
Caution 2: Only cut one branch at a time, once that branch is completed then move to another.
Cutting more than one branch may cause issues identifying how the branches connected.

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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; Purple=PIN B42; Brown=PIN B39; Notice the PIN numbers have
Bank A or B on it. Bank B is the rear bank.
2. Locate the ECM on the drivers side of the engine, remove bolt, disconnect the connector
from the ECM, which contains the pins shown on the provided wires (see above picture).
3. On the inside of the plug at the pin location there is a small piece of plastic to keep water
out. Use needle nose pliers and pull the plastic piece out.
4. Push the two new pins into the connector until they click.
5. Plug connector back into the ECM and tighten bolt.

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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.
3. Push the single wire labeled PIN 20 into the plug from the wire side, until it clicks.
a. This wire should look like the other wires entering into the ECM plug.
4. Plug connector back into the ECM and tighten bolt.

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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. Locate the factory Accelerator Pedal Position (APP) plug located just above the
accelerator pedal. (See pictures )
4. Unplug the factory APP connector by pressing the release button.
5. Carefully peel back the protective sheathing to expose about 1½ inch of wires. If using a
razor blade be very careful to not cut into the insulation on the individual wires.
6. On the factory APP plug, locate the factory wire (see next page for wire identification),
and use the provided wire tap to crimp into that wire.
7. Connect the single wire labeled PIN 20 to the wire tap.
8. Plug the factory connector back into the APP plug.
9. When you’re done you should be able to unplug the opposite end of this PIN 20 wire
from our main wire harness and using a voltage probe detect approx. 0.4 volts from the
pedal at idle, and when depressed voltage should read 4.5 volts.

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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

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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. You can verify the
pedal voltage in the software under Gauges / Voltages.
There are multiple ways you can do this
1. Attach a normally open, momentary microswitch, under your accelerator pedal. The
pedal must press on the switch when your foot is off the accelerator. Then release the
switch when your foot presses on the pedal.
2. Attach a microswitch to your injection pump, the injection pump must have a lever
attached to your accelerator pedal and must follow the same description as in option 1.
3. Attaching a momentary switch to your manual transmission shifter. Attaching
4. Set software to “Normally High” under the EXHAUST BRAKE tab
a. Set voltage to 7.0 v under the EXHAUST BRAKE tab as well.

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_________________________________________
Exhaust Brake Switch
Step 1: Identify a desirable spot to mount the exhaust pressure switch

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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.

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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
2006-2007 Dodge Cummins 5.9L Common Rail
Crankshaft Sensor ECM Pin 22 Brown/Light Blue Wire
2007.5-2009 Dodge Cummins 6.7L Common Rail
Crankshaft Sensor ECM Pin 31 Brown/Light Blue Wire
(In Software choose 2003-2007.5 Crank Sensor)
2010-2012 Dodge Cummins 6.7L Common Rail
Crankshaft Sensor PCM Pin 69 Brown/Light Blue Wire
PCM is located Right Rear of Engine Compartment
Or Access actual crankshaft sensor next to vibration dampener, driver side, wire is
Brwn/Lgt Blue Wire #3
(In Software choose 2003-2007.5 Crank Sensor)
2013-2014 Dodge Cummins 6.7L Common Rail
Crankshaft Sensor ECM Pin 31 Brown/Light Blue Wire
(In Software choose 2003-2007.5 Crank Sensor)
2015-2018 Dodge Cummins 6.7L Common Rail
Crankshaft Sensor ECM Pin 31 BN/BU color Wire
(In Software choose 2003-2007.5 Crank Sensor)

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____________________________________________________________________________
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. Make SURE the fitting that comes out of the turbine housing is installed facing UP so
water can drain into the exhaust housing.
4. Bend the new Stainless Tube and route it in such a way that water continually drains
down towards the turbine housing. Condensation can occur in the tube and must be
routed to drain the water away from the sensor. See the photos below for suggested
routing.
Example of the tube continually sloping downwards

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Suggested Configuration for 2007 or older trucks single turbo application S300
Suggested Configuration for 2007.5-2018 trucks single turbo application S300

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Suggested Configuration for Ram trucks Compound Turbo application S300
Suggested Configuration for Fummins Compound turbo application S300

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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.

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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.

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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. Actuator should cycle and move.
If it moves, skip to the “Software” section below.
If actuator does not move continue reading.
Wiring:
If actuator doesn’t cycle when powered on:
The most common problem, is the actuator connector isn’t connected tightly. Make sure plug
clicks into place.
If actuator still doesn’t cycle, check all plugs to make sure each plug is connected to it’s proper
mate. If plug fits, count the number of wires going into plug and out of the mating connector. 5
wires in = 5 wires out. Also, unplug each plug and make sure the pins inside are not bent.
1. Make sure the black is grounded to the battery negative side. The red to the battery
positive side. The white ACC wire must be connected to an ignition power (something
that turns on and off with the key).
a. On 2003-2007 5.9 Cummins engines, there is a second ground wire on the
Exhaust Brake branch that must also be connected to the battery negative.
Software:
After every setting change, you must hit “SAVE” and wait 10 seconds to update.
Engine acts like the exhaust brake is on or is very sluggish.
Engine must be running or at least the ignition must be on:
1. In the software, open the EXHAUST BRAKE tab.
 During troubleshooting make sure to check the box “DISABLE ENGINE
BRAKE DISENGAGE”
 Make sure the exhaust brake pressure is set to 35 PSI.
 Make sure
 Or if you have not connected the crank or cam sensor to monitor the
engine RPM’s, you will want to check the box “DISABLE ENGINE
BRAKE DISENGAGE”.
 Turn OFF all COLD START settings until troubleshooting is over.
2. After Troubleshooting: If the crank or cam sensors are hooked up, make sure
that it is reading the correct RPM through the GAUGES tab. After checking the
RPM’s are correct, open the EXHAUST BRAKE tab. Uncheck the “ENGINE
SPEED BRAKE DISENGAGE”, turn the RPM’s to 900. This is the RPM that the
brake will release, when the engine goes to idle. Make sure 30-38 PSI is put for
the exhaust brake pressure.

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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. If FEEDBACK is dramatically different than
the COMMANDED, check the plug connections, especially
the actuator tab. If FEEDBACK is reading 100 or 0 when
COMMANDED is higher or lower, it generally means than
the actuator isn’t connected.
 Heavy Duty Actuator 1: 26 to 28
4. If the STARTING, COMMANDED and FEEDBACK are all where they should be,
test that the actuator is moving, have someone physically watch the actuator
while performing this test.
 Change the starting position to 80, then hit the SAVE SETTINGS button,
wait 10 seconds and rev the engine twice. The actuator should jump to
the 80 position.
 The FEEDBACK should also show 80 (or really near this value). If the
actuator moves, then reenter the initial starting position, and hit SAVE
SETTINGS again, wait 10 seconds and rev the engine 2 times.
Congratulations it’s working. Now if something isn’t working right it’s
probably just a setting in the software.
 Exhaust Brake Settings:
 2007.5-2018 Cummins 6.7: ACTIVE LOW, set voltage to 0.60
 1988-2007 Cummins 5.9: ACTIVE HIGH, set voltage to 10.00
 SAVE SETTINGS from this EXHAUST BRAKE screen after
adjusting the voltage.
5. Check all voltages under the GAUGES, VOLTAGES tab.
 .42-.45 volts should be present at boost (map) and exhaust sensors
Tubonator® VGT Troubleshooting:
Key Things:
 Before calling tech support on the software and electronics please do the following:
 Make sure you have the latest version of the Turbonator® VGT software installed on your computer.
o Install BOTH files. The software and the driver.
 USING “CONTROL PANEL” ALWAYS UNINSTALL THE OLD SOFTWARE BEFORE INSTALLING THE NEW
SOFTWARE OR IT WON’T INSTALL CORRECTLY.
Other Import Items About the Turbonator® VGT:
 Always Hot Torque all bolts after vehicle has been ran for approximately 100 miles, while it is hot
(wear gloves)
o Hot Torque the eight bolts going around the Turbonator® VGT Exhaust housing to 150
inch/pounds
Emergency Situations Only (Truck is Stuck)
VGT
 Loss of Power, exhaust brake feels stuck on
o Step 1: Cycle power of tuck off and back on, If that doesn’t work