Which Smarty for my setup?

[BryanSmith]

I'm trying to sort out if a Smarty Jr will work with my setup, or if I should purchase the Sr. I have an early 2004 305/555 with a built auto trans with low stall converter and 15%/50hp injectors (3.73 gearing).

I've read that the Jr is for stock injectors. If this is true, I'm guessing I'd should go with the Sr. Just trying to verify if the extra cost is necessary.

I usually drive in the 1500-2000 rpm band. I try to stay in the 17-1900 band cruising, saving the 2100+ for long climbs.

Most of my driving these days is at around 10,500 lbs with my cab over camper without a trailer in tow. I do haul horses and feed 4-10 times a year over long mountain grades up to 7000 feet elevation.

I'm interested in the Smarty for better pedal response and some quicker spool up of my stock turbo. Also hopeful for a bump in fuel economy. I used to avg 16mpg with the camper and stock injectors. I now get 13-14 mpg with the 50hp injectors, so hoping to gain back a little of what I lost. Mpg hand calculated. I'm looking for efficiency and driveability, not high rpm power.

Any experience and input is appreciated.

Happy Thanksgiving,

Bryan

 

[petersonj]

I have limited knowledge regarding Smarty on an early 3rd generation truck, but I think the Smarty Junior has canned performance levels (three, I think). I don't think that you can change timing, fuel duration, or torque management. I believe all that changes with a Smarty S06. Many more tunes and I believe that you can custom set timing, fuel duration, and torque management like my Smarty S03.

I have been using a Smarty S03 on my 2002 truck for about 140,000 miles now. The first 50,000 miles were with stock injectors, then I went to RV275's (about a 30 hp bump for me). The Smarty adapted well. I just tuned with less fuel duration and set the torque management to reduce smoke for low rpm spool up. I keep smoke in check with my right foot. It's actually easy to drive without smoking.

I think you are like me - I want good performance at low rpm's to get the load moving and I am not interested in high horsepower at high rpm's since the engine spends 95% of its time in the 1500-2000 rpm range.

Good move on getting a lower stall speed converter.

- John

 

[BryanSmith]

Thanks for sharing your experience John. Sounds as though it'll be worthwhile to spend the extra money so I can adjust the fuel parameters.

I have no interest in the high hp tunes (160 & 210hp), only the 30 and 60 hp tunes. As you said, it's about getting the load moving. And I'm still hoping to get back some of the fuel efficiency I lost.

Happy Thanksgiving!

 

[Jim W]

Hi Bryan,
I have a 2008, truck with the S67 SR, on the truck. On my Sr there are 9 different settings that will add different performance levels. I am running number three which adds 60 HP with increase additional timing. (but no fuel economy).

My truck when I tow the trailer under ideal conditions, I may see 11 MPG's. In the mountains I could calculate the fuel milage to be around 8 to 10MPG's depending on speed and wind resistance on the trailer. Normal fuel mileage without the trailer max would be 15 MPG still is.

But I think the S67 SR will not work on your truck. You should use the Smarty S06 for your year of truck or something similar. A different programmer that would be compatible with the 5.9L engine in your truck.

I may be wrong but with additional HP from your injectors which means more fuel being added to the engine the milage will likely be lower.

Just saying.

 

[BryanSmith]

Hi Jim. Thanks for taking the time to share your experience. You are correct - the S06 is the Smarty that's compatible with my 2004. And as you pointed out, more fuel through my injectors will equate to lower fuel economy.

 

[petersonj]

Here is a link to the Smarty S06 User Guide. Page 11 shows that you can set individual custom parameters for torque management, timing, and fuel rail pressure. This basically works the same as my Smarty S03 with exception that the Smarty S03 controls fuel duration, not fuel pressure. You would have to experiment with these settings on a specific software setting for you to come up with the best combination for your application. In the end, your fuel economy could improve.

http://www.madselectronics.com/downloadfiles/Smarty06PodUserGuide.pdf

In my application (I know - comparing 2nd gen 24v to 3rd gen 24v) my fuel economy increased about one mile per gallon with stock injectors and the Smarty S03. When I replaced the injectors with RV275's, I slightly de-fueled and kept stock timing with the Smarty. Fuel economy did not change. Low end torque is excellent.

- John

 

[BryanSmith]

Thanks for sharing that link. That gave me the direction I needed to find the J06 user manual so I could compare optional parameters each unit can adjust. The S06 adds rail pressure and the speed limiter to the adjustable parameters for my early 2004 305/555 engine.

This is my first common rail. I presumed it would be better to keep fuel duration at the stock setting with the extra fuel my 50hp injectors provide. So I've been trying to find a Smarty allowing me to adjust that parameter.

I don't understand the cause and effect of the rail pressure parameter. And I'm wary of messing with the rail pressure as I fear it could compromise the pressure relief valve or the actuator. I need to read up on the rail pressure design and operation so I can determine if this is something I want to play with. Otherwise, it looks as though the J06 is the proper tool.

I also sent an email to Mads North America to see what they recommend for my truck.

The only other modification that may happen in the future is a slightly bigger turbo when my stock 341 needs replaced. I'm between the 60/60/9 or a 62/65/12. I spend so much time in hill country with long grades, up to 7000 foot elevations, it doesn't seem advantageous to go any larger.

Thanks again John.

- Bryan

 

[AH64ID]

The SJR uses stock duration for all 3 of its power levels, the different in horsepower is based on how much of the stock duration tables is used.

The S06 also does this at the same power increase levels.

Both the SJR and S06 can adjust rail pressure, with the S06 being more aggressive if needed.



With 50hp injectors I would really consider custom tuning. For how you described you use your truck you want more advanced timing similar to the 90/100hp tunes, but don’t need the duration that’s associated with them.

Too much rail pressure will shorten injector life.

Despite popular belief I had better fuel economy results with lower rail pressure when I was tubing my 05, I also generally ran lower peak pressure for longevity.

For example I ran 03-04 style pistons and injectors with 30% over stock flow with less than 85% of stock duration but made 415rwhp and my EGT’s were much cooler than stock.

Long story short, I don’t like any of the box tunes for 5.9 HPCR’s with larger injectors, just my 0.02 based on lots of tuning with Smaty/MADS products for many trucks.

 

[BryanSmith]

Thanks AH64ID. It sounds as though I should revisit custom MM3 tuning so fuel duration can be adjusted on account of my injectors.

Thanks also for letting me know I should leave rail pressure and rail peak pressure stock, unless I want to try lowering those for efficiency and system longevity. It's good to hear it from somebody who's done plenty of tuning and is familiar with this generation.