Banks Power Pack System

Transcription

1 Banks Power Pack System Compatible with Banks iq Including Stinger System and EconoMind Dodge Cummins Turbo-Diesel Pickups THIS MANUAL IS FOR USE WITH SYSTEMS Gale Banks Engineering 546 Duggan Avenue Azusa, ca (626) Fax (626) Product Information & Sales: (888) bankspower.com 2010 Gale Banks Engineering 08/11/10 PN v.3.0

2 Also Available from Banks Power Dodge 5.9L BigHead Wastegate Banks iq Banks Bullet Banks Billet Torque Converter Monster Exhaust DynaFact Instrumentation Monster-Ram Advanced Diesel Tuners Banks Brake Banks Ram-Air Intake Super-Scoop Techni-Cooler System Banks iq System (P/N ) - 5 touchscreen interface that can control the Banks Diesel Tuner on the fly. - Interchangable gauge display, read and clear codes, monitor engine diagnostics, log data, time your vehicles runs and much more. Banks Monster Exhaust System Single (P/N , 48700, 48701, 48708) Duals (P/N , 48709) Sport (P/N ) - Increases exhaust flow, cuts backpressure, lowers exhaust gas temperatures (EGTs) and increases power. Banks Ram-Air Intake System (P/N 42145) - Increases your airflow over stock. - Adds power, improves fuel economy, lowers EGTs and reduces smoke. Banks Ram-Air Intake Super- Scoop (P/N ) - Adds cooler denser air to the Ram-Air Intake housing, further increasing fuel economy, reducing smoke and lowers EGTs. Banks Monster-Ram (P/N ) - Increased flow from intercooler - Raises boost without increasing backpressure at the turbine Big Hoss Intake Manifold System (P/N 42747) - Increases flow and provides more uniform air distribution to the engine for more available power at a given boost level. Banks Exhaust Brake (P/N ) - Increases the stopping power of your truck and extends the service life of your brakes Banks Smartlock (P/N 55270) - Reduces wear on transmission - Locks Torque converter and raises trans-line pressure - Works with Banks Exhaust Brake Boost and Pyro Gauges (P/N 64507) - Keep your engine safe by monitoring vital engine parameters. Banks Billet Torque Converter (P/N 72515) - Higher torque capacity over stock - Lockup clutch is slip-resistant so transmission fluids stay cooler and transmission life is prolonged. Banks Bullet (P/N ) - Adds power safely to your vehicle - Displays critical engine functions - Engine safeguards - Change power levels on-the-fly Banks Techni-Cooler System (P/N ) - Provides increased air flow to the engine by increasing air density for more increased power, lower EGTs and improved fuel economy. Thermocouple - Add a temperature limiting function to your Diesel Tuner. Banks Speed-loader (P/N 62981) - Furthers the power output of the Banks Six-Gun and provides EGT limiting safety v.3.0

3 Banks BigHead Actuator (P/N 24331) - Achieves a higher peak boost over stock and gives you precise boost control that gives you crisp acceleration and more mid-range pulling power. Banks Stinger Systems (P/N , , ) Contains: - Ram-Air Intake system - Monster Exhaust (single or dual) - EconoMind Tuner w/ Banks iq - Big Head Wastegate Actuator Banks PowerPack Systems (P/N , , ) Contains: - Ram-Air Intake system - Monster Exhaust (single or dual) - EconoMind Tuner w/ Banks iq - Big Head Wastegate Actuator - Monster-Ram - Techni-cooler System Banks Six-Gun Bundle (P/N , , ) Contains: - Ram-Air Intake system - Monster Exhaust (single or dual) - Six-Gun Tuner w/ Banks iq - Big Head Wastegate Actuator Banks Big Hoss Bundle (P/N , , ) Contains: - Ram-Air Intake system - Monster Exhaust (single or dual) - Six-Gun Tuner w/ Banks iq - Big Head Wastegate Actuator - Monster-Ram - Techni-cooler System For More Information please call (888) or Visit us v.3.0 3

4 Tools Required: 1 4 and 3 8 drive ratchets Inch and metric deep sockets Ratchet extension Metric combination or open-end wrenches Phillips and flat blade screwdrivers Standard and needle-nose pliers Pocket or X-Acto knife Clean shop towels or rags Drill bit set Drill motor Tap Handle 1 4 NPT tap 5 16 nut driver Pliers Torx bits Pry-bar Highly recommended tools and supplies: Multimeter or 12-volt test light Heat gun Foot-pound torque wrench Penetrating oil or light lubricant spray Reciprocating saw Inch-pound torque wrench Table of Contents General Installation Practices...5 Section Monster Exhaust System Installation Section Techni-cooler Assembly Installation Section Thermocouple Installation Section Banks Ram-Air Filter Installation Section Banks EconoMind Diesel Tuner Installation Section Mounting and Connecting the Banks iq Section Power Selector Switch Installation Section Optional Gauge cluster Installation Section Transmission Learnng Section Troubleshooting, EconoMind Section clearing Learned Information Section Removal of the EconoMind Diesel Tuner Section Filter Maintance Section Placement of the Banks Power Decals v.3.0

5 General Installation Practices Dear Customer, If you have any questions concerning the installation of your Banks EconoMind Diesel Tuner, please call our Technical Service Hotline at (888) between 7:00 am and 5:00 pm (PT). If you have any questions relating to shipping or billing, please contact our Customer Service Department at (888) Thank you. 1. For ease of installation of your Banks system, familiarize yourself with the procedure by reading the entire manual before starting work. This manual contains 40 pages of copy, illustrations and parts listing. If any pages are missing from this manual please call Gale Banks Engineering immediately for a replacement. 2. The exploded illustrations provide only general guidance, Refer to each and section diagram in this manual for proper instructions. 3. Throughout this manual, the left side of the vehicle refers to the driver s side, and the right side refers to the passenger s side of the vehicle. 4. Disconnect the ground cable from the battery before beginning work. If there are two batteries, disconnect both. 5. Route and tie wires and hoses a minimum of 6 inches away from exhaust heat, moving parts and sharp edges. clearance of 8 inches or more is recommended where possible. 6. During installation, keep the work area clean. If foreign debris is transferred to any Banks system component, clean it thoroughly before installing. 7. When raising the vehicle, support it on properly weight-rated safety stands, ramps or a commercial hoist. Follow the manufacturer s safety precautions. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the front wheels are centered squarely on the topsides; put the transmission in park; set the parking brake; and place blocks behind the rear wheels. Caution! Do not use floor jacks to support the vehicle while working under it. Do not raise the vehicle onto concrete blocks, masonry or any other item not intended specifically for this use. 8. The Banks iq displays a GREEN indicator light when the battery is fully charged. If an ORANGE light is displayed the Banks iq can be charged with the supplied AC outlet wall charger. Locate the supplied AC-outlet wall charger, also located in your kit and plug the charging cord into the Banks iq. Please refer to the Banks iq DashBoard PC, Owner s Manual for additional instructions. Notification The Banks Ram-Air Filter comes pre-oiled and no oiling is necessary for initial installation. Service the filter as specified in the Filter Maintenance Section of this manual. Warning: Below 32 o F (0 o C) or above 140 o F (60 o C), the Banks iq may be susceptible to damage as a result of extended direct exposure to sunlight, heat or extreme cold. It is highly recommended that Banks iq be removed from its mounting location if the vehicle will be subjected to high concentrations of sunlight, heat or cold for an extended period of time. Gale Banks Engineering is not responsible for damage to Banks iq resulting from exposure conditions. 9. Dual exhaust system only. The Dual Exhaust System is designed to accommodate the factory sized spare tire. If the spare tire is oversized, it may need to be removed. 10. Dual exhaust system only. The tip is located for single rear wheel applications. Installation on dually systems is not recommended v.3.0 5

6 Section 1 MoNSTER ExHAuST SySTEM INSTAllATIoN Figure 1a General Assembly Banks Monster Exhaust ( ) Item Description year P/N Qty 1 Monster Turbine outlet Pipe Front Intermediate Pipe 2 cat conv Systems Non-cat. conv. Systems Rear Intermediate Pipe Extension Pipe Crew Cab Long Bed Crew Cab Long Bed Banks Monster Muffler Muffler Muffler Tailpipe Item Description year P/N Qty 8 Tip, Tailpipe 5 Dual Wall , V-Band Clamp Gasket, Turbine outlet Gasket, Exhaust Flange, (4-bolt) Exhaust Clamp * 13 4 Exhaust Clamp ** 14 Front Muffler Hanger Clamp Rear Muffler Hanger Clamp SAE Washers , Nut, Crimplock x1.50 Hex Bolt, Zinc * cat Models Only **03-05 cclb Models receive three 4 -clamps v.3.0

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8 Figure 1a General Assembly Banks Split Dual Monster Exhaust ( ) Item Description year P/N Qty 1 Monster Turbine outlet Pipe Front Intermediate Pipe 2 cat conv Systems Non-cat. conv. Systems Rear Intermediate Pipe Standard Cab Long Bed / Crew Cab Short Bed Crew Cab Long Bed Extension Pipe Crew Cab Long Bed Monster Muffler y-pipe Tail Pipe 8 Left Driver Side Right Passanger Side V-Band Clamp Item Description year P/N Qty 11 T.o.P Gasket Turbine outlet Gasket (4-Bolt) Exhaust Clamp ** 14 4 Exhaust Clamp * 15 Front Hanger Clamp Rear Hanger Clamp Frame Hanger Bracket x 2 Hanger Plate Rubber Insulator x 4 Hex Bolt SAE Washers *** Crimp lock Nuts **** x 1.25 Hex Bolt Black 5 Cable Ties *04-05 ScLB use one 4 -clamp **03-04 cat conv. Models use three 3.5 -clamp ***04-05 use two (2) washers ****04-05 use one (1) crimp lock nut v.3.0

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10 1. Disconnect the battery ground cables from each of the batteries. Secure the cables so that they do not come in contact with the battery posts during the installation. 2. Raise the vehicle and support it with properly weight rated safety stands, ramps or a commercial hoist. Follow the manufacturer s safety precautions. Take care to balance the vehicle to prevent it from slipping or falling. When using ramps, be sure the front wheels are centered squarely on the topsides; place the transmission in park; set the parking brake and place blocks behind the rear wheels. CAuTIoN: Do NoT WoRK under ANy VEHIClE SuPPoRTED only By A JACK. SEVERE INJuRy MAy RESulT. WARNING! The following step requires the use of a torch and/or saw. Proper safety equipment should be used. Failure to use proper safety equipment may result in severe injury. 3. From under the vehicle remove the factory exhaust system. Starting at the rear of the vehicle, remove tail pipe, muffler and any extension pipes attached to the outlet of the catalytic converter, by either cutting through the pipe near the clamps or by removing the clamps and heating the joints with an oxy-acetylene torch to allow crimped pipes to separate.do NoT CuT or DAMAGE CATAlyTIC CoNVERTER TuBING DuRING THE REMoVAl PRoCESS. Remove the hanger pins from the rubber hangers with a pry bar. (Spray lubricant will ease hanger removal.) Steps 4 thru 10 for Step 11 for Remove the clamp attaching the turbine outlet pipe (T.O.P) to the catalytic converter headpipe (or intermediate pipe if applicable) and remove the catalytic converter assembly or intermediate pipe. 5. Remove the V-band clamp that attaches the turbine outlet elbow to the turbine housing and remove the turbine outlet pipe and elbow from the vehicle. 6. Attach the supplied T.O.P. gasket to the Banks T.O.P. Loosely place the supplied V-band clamp on the Banks T.O.P. Install the Banks T.O.P. to the turbine housing (NOTE: the factory turbine outlet elbow will not be used). Loosely snug the V-band clamp assuring the gasket and T.O.P are aligned properly. 7. For vehicles that are NOT equipped with a catalytic converter, install the supplied Banks front intermediate pipe and supplied gasket onto the previously installed Banks T.O.P. Place a small amount of anti-seize onto the four (4) 7 16 bolts. Loosely install the supplied 7 16 hardware onto the T.O.P. and intermediate pipe flange (see Figure 1). Proceed to Step For vehicles equipped with catalytic converters: With the catalytic converter removed from the vehicle and the headpipe removed from the converter, measure 13 inward from the outlet tubing rim (3-1 2 of tubing from the outlet weld should remain). Using a reciprocating saw or equivalent, vertically cut and remove 13 from the converter outlet tubing (see Figure 2). 9. Install the supplied clamp onto the catalytic converter inlet. Place the catalytic converter onto the previously installed intermediate pipe. Loosely snug the clamp on the catalytic converter inlet. IMPoRTANT: If the vehicle is equipped with a catalytic converter, it should be inspected. Diesel catalysts may become plugged with soot and can cause a restriction to exhaust flow, impeding performance. Shine a powerful flashlight into the inlet end of the converter. observe the light through the other end of the converter. The full circle of the flashlight should be visible without any blockage in the gridwork of the catalyst. If excessive soot is observed, Figure 2 the catalyst may need to be cleaned. TAKE PRECAuTIoNS to avoid blowing soot toward the work area or where it could be inhaled. AlWAyS use breathing protection. Also inspect the catalyst for damage (i.e. chips, bent corners, etc.) to the gridwork. If your catalytic converter is damaged, it may be covered under your vehicle s emissions warranty. 10. Place a supplied 4 clamp onto the front of the supplied rear intermediate pipe. Install the intermediate pipe onto the catalytic converter outlet or the front intermediate pipe. Lightly snug the exhaust clamp near the rim of the intermediate pipe. 11. For 2005 NOTE: The catalytic converter will not be removed from the vehicle. Remove attached intermediate pipe and corresponding clamp(s). Take care not to damage the catalytic converter outlet end. Step 12 thru 20 for Single Tip Step 21 thru 33 for Split Dual For quad cab long bed (160.5 wheelbase) models only: Place a supplied 4 clamp onto the front of the supplied extension pipe. Install the extension pipe hanger pin into the corresponding rubber hanger. Connect the extension pipe onto the intermediate pipe and loosely snug the 4 clamp. 13. For Crew Cab Long Bed (160.5 wheelbase) ONLY, install a 4 exhaust clamp onto the front of the Banks intermediate pipe. Install the intermediate pipe onto the catalytic converter outlet. Install the intermediate pipe hanger onto the corresponding rubber hanger. Loosely snug the 4 clamp v.3.0

11 14. Install the front hanger clamp onto the Monster Muffler inlet. Install the muffler inlet onto the intermediate pipe or catalytic converter if equipped. With the hanger facing the rear of the vehicle, insert the front hanger into the vehicle s rubber grommet. 15. Install the rear hanger clamp onto the Monster Muffler outlet with the hanger pins facing forward. Install the two (2) rear hanger pins into the vehicle s rubber grommets. Orient the Banks Monster logo to be level with the frame rail. Install a 4 clamp onto the muffler outlet. Figure 3 Figure 4 PASSENGER SIDE TAILPIPE DRIVER SIDE TAILPIPE 3.5 CLAMP Y-PIPE REAR HANGER CLAMP 16. Route the tailpipe over the rear axle housing and into the muffler outlet. Install the tailpipe hanger pin into the corresponding rubber hanger. 17. Install the 5 Monster tailpipe tip on the exhaust. Keep the wrapping on until installation is complete. The tip should be rotated so the clamp nut is pointing down. For a fleet-side truck the 5 tip should be hung 1 past the end of the tailpipe. For a dually, the tip should be past the end of the tailpipe or where aesthetically pleasing. ORIENTATION OF MONSTER MUFFLER FRONT HANGER CLAMP 4 CLAMP INTERM PIPE 18. With everything positioned properly, begin to tighten the clamps starting with the ones closest to the turbo and working your way back. Torque the V-band clamp to 80 in-lbs (not ft-lbs). Evenly torque the exhaust clamps to 35 ft-lbs. Torque the 7 16 hardware to 48 ft-lbs. Make sure that each slip is fully inserted (+/- 1 4 inch) and that all mount hangers are in the forward position (see Figure 3). NOTE: Whenever possible, tack weld slip connections to prevent disengagement is recommended. 19. Remove the protective covering from the tailpipe tip. Caution: the protective covering may ignite and burn if not removed prior to running the engine. 20. Monster Exhaust Single tip installation complete, proceed to Section 2. Step 21 thru 33 for Split Dual 21. Install the front hanger clamp onto the Monster Muffler inlet. Install a 4 clamp onto the muffler inlet. Install the muffler inlet onto the intermediate pipe. Insert the front hanger into the vehicle s rubber grommet. 22. Install the rear hanger clamp onto the Monster Muffler outlet with the hanger pins facing forward. Install the two (2) rear hanger pins into the vehicle s rubber grommets. Orient the Banks Monster logo to be level with the frame rail. 23. Install the Banks Y-pipe into the muffler outlet such that the outlets are pointing up. Install a saddle clamps onto each y-pipe outlet (see Figure 4). 24. Install the Banks hanger bracket onto the rear of the driver-side frame rail. Behind the rear shock cross member, place the hanger bracket over the frame rail on the inside. Align the 1 2 hole in the center of the frame with the hanger bracket. Install the 7 16 x 4 bolt & washer through the bracket and frame rail. Secure the bolt on the outside frame rail using the 2 x2 plate, washer and 7 16 nut. Be sure the hanger pin is parallel with the frame rail and torque 7 16 hardware to 48 ft-lb (see Figure 5). FORWARD v

12 25. Install the supplied rubber hanger onto the Banks hanger bracket. 26. Install the driver-side tailpipe into the top Y-pipe outlet. Install the driver-side tailpipe hanger into the vehicle rubber hanger. 27. Install the passenger-side tailpipe into the lower Y-pipe outlet. Install the passenger-side tailpipe hanger into the vehicle rubber hanger. 28. Move the spare-tire to the rear of the vehicle and center between the dual tailpipes. Tighten the spare tire with the manufacture tire tool so that it is retained or in place (See Figure 6). 29. Un-clip the axle vent hose outlet attached to the bed near the spare tire. Re-route the vent hose on top of the fuel tank and attach to the bed away from the driver side tailpipe. Zip tie the vent hose and brake line to the emergency brake cable, away from the tailpipe. 30. Adjust each of the pipes to ensure that all of the hanger pins are parallel with the frame-mounted pins and fully inserted in the vehicle s rubber grommets. 31. Be sure that the two (2) tailpipes are completely engaged into the Y-pipe. Rotate the tailpipe until the hanger pins are parallel with the frame-mounted pin. NOTE: Recommended distance between exhaust tip and body is a half (1 2 ) inch. 32. Beginning with clamps closest to the catalytic converter, and working your way back. Align the saddle clamps at the beginning of the slots (on the 1 2 circle punch) and evenly torque the 2-studs on the clamp. NOTE: Whenever possible, tack weld slip connections to prevent disengagement is recommended. 33. Remove the protective covering from the tailpipe tip. Caution: the protective covering may ignite and burn if not removed prior to running the engine. -END, SECTION 1- Figure 5 Figure 6 7/16 NUT & WASHER 2 X 2 PLATE ADJUST SO THAT SPARE TIRE TO TAILPIPE CLEARANCE IS THE SAME BANKS DRIVER SIDE TAILPIPE ZIP TIE ON VENT HOSE & BRAKE LINE DRIVER SIDE TAILPIPE DRIVER SIDE FRAME HANGER BRACKET 7/16 BOLT & WASHER SPARE TIRE MOVE SPARE TIRE TOWARDS REAR OF VEHICLE BANKS PASSENGER SIDE TAILPIPE v.3.0

13 Section 2 TECHNI-CoolER ASSEMBly INSTAllATIoN Figure 7 Banks Techni-Cooler General Assembly Item Description P/N Qty 1 Techni-Cooler Assembly Boost Tube left Boost Tube Right Hose 3.5 x 3.25 Black Hose Comp out 2.75 x Hump Hose 3.5 x 3.25 Black High-Ram Intake Manifold Gasket Air Inlet Manifold Stud, High-Ram Air Intake x 8MM 1.25 x Stud, High-Ram Air Intake x 8MM 1.25 x Hose Clamp 2.75 Spring loaded Item Description P/N Qty 12 Hose Clamp 3.5 Spring loaded Ground Strap Intake Heater Bracket Mntig Techni-Clr Hex Bolt, M8-1.25x16, Zinc Hex Bolt, S/S x Nut, Hex, M6 x 1.0, Zinc Nut, Nyloc Washers, Flat, Zinc, 6MM Washer, AN, S/S Washer, Thread Sealing v

14 NOTE: For installation of the Banks Stinger System proceed to Section Disconnect the Inlet Air Temperature/ Pressure Sensor connector located on the air box cover. The connector is shown in Figure Remove the nut that fastens the air filter housing to the radiator cross brace. 3. Loosen the hose clamp that secures the air inlet duct to the turbocharger inlet. Disconnect the inlet duct from the turbocharger. 4. Remove the air box and inlet duct as an assembly. The air box is held in place with re-usable pushin fasteners and can be pulled out vertically. 5. Remove the passenger side boost tube. The boost tubes are the charge air ducting that route air from the turbocharger to the charge Air cooler (cac) and from the cac to the intake manifold. 6. cover the turbocharger inlet and outlet with a clean rag to prevent foreign debris from entering these locations. 7. Remove the bolt the holds the engine oil dipstick to the intake. Save the bolt for re-use. 8. Remove the electric heater wire harness from the stock intake by pulling the plastic pin out. Remove the wire harness brackets that are mounted on the intake by removing the nut and washer. 9. Unbolt and remove the 4 bolts at the base of the stock intake. Remove the stock intake from the vehicle. cover the intake manifold opening with a clean rag to prevent any foreign debris from entering the engine through the heater block. 10. Remove the driver side boost tube. 11. Remove the two upper radiator attachment bolts. 12. Remove the two upper CAC attachment bolts. 13. Remove the 4 bolts (2 per side) that retain the upper radiator cross brace, then remove the upper radiator cross brace. The brace is shown in Figure Remove the 4 hex head bolts that attach the A/c condenser mounting brackets to the cac. 15. Swing the A/C condenser upward as shown in Figure 10, then out away from the vehicle as shown in Figure 11. Caution: Minimize the amount of stress to the A/C condenser fluid lines to prevent damage. An assistant could be helpful to hold the A/C condenser while the stock cac is being removed and the Banks Techni-cooler is being installed. 16. Remove the stock cac from the vehicle. Figure 8. Location of the Inlet Air Temp/ Pressure Sensor Figure 9. Upper radiator cross brace 17. Remove the lower saddle mount rubber bushings from the stock cac and install them on the Banks Technicooler. 18. Remove the upper rubber isolators from the stock cac and install them on the Banks Technicooler. 19. Install the Banks Techni-cooler in the vehicle. 20. Remove the torx head screws that fasten the lower two mounting brackets to the A/c condenser. Discard the stock lower mounting brackets, but retain the torx head bolts for re-use v.3.0

15 21. Relocate the upper driver side condenser mounting bracket as shown in Figure 12. Place the A/c condenser back in front of the Techni-cooler. Install the 5 16 bolts and washers supplied with the Banks Techni-cooler system to fasten the top two A/C condenser mounts to the Techni-cooler. Keep the bolts loose to aid in the alignment of the lower two mounting brackets. Install the lower two A/C mounting brackets supplied with the Banks system. Use the torx head screws that were Figure 10. A/C condenser removal procedure Figure 11. A/C condenser removal procedure previously removed from the vehicle to fasten the brackets to the A/c condenser. Use the 5 16 bolts and washers supplied with the Banks system to fasten the A/c condenser mounts to the Techni-cooler. 22. Tighten the 5 16 bolts at each of the A/c mounting brackets and torque to 19 ft-lbs. 23. Tighten the torx head bolts on both of the lower and the upper A/C mounting brackets. 24. Install the upper radiator cross brace. Leave the bolts loose to aid in the alignment of the cross brace with the radiator and Techni-cooler. 25. Loosely install the upper cac mounting bolts. 26. Loosely install the upper radiator mounting bolts. 27. Tighten the radiator cross brace bolts and torque to 21 ft-lbs 28. Tighten the upper cac mounting bolts and torque to 8 ft-lbs (96 in-lbs). 29. Tighten the upper radiator mounting bolts and torque to 8 ft-lbs (96 in-lbs). 30. Install the passenger side boost tube. The passenger side uses a 2.75 inch diameter straight hose at the turbocharger connection, and a 3.5 inch diameter hump hose at the cac connection. The orientation of the hose clamps should be as shown in Figure 13 to avoid clearance issues. Do not install the straight hose onto the turbocharger, and keep the hose clamps at the cac connection loose until the thermocouple is installed in Section 3. cover the opening of the boost tube to prevent foreign objects from entering the boost tube during the installation. NOTE: Before slipping any boost tubes and the corresponding hoses, into position, ensure that all connection ends are clean and free of any oil residue and contaminates. Clean compressor outlet and all connection points with a non-oil based solvent such as Acetone, Mineral Spirits, Denatured Alcohol or Lacquer Thinner. Read and follow the manufactures operation instruction for non-oil based solvent cleaner v

16 31. Install the driver side boost tube. The driver side tube uses a 3.5 inch diameter straight hose at the intake manifold and a 3.5 inch diameter hump hose at the cac. The orientation of the hose clamps should be as shown in Figure 14 to avoid clearance issues. Keep the hose clamps loose until the High Ram is installed. cover the opening of the boost tube to prevent foreign objects from entering the boost tube during the installation. 32. Remove the three wires on the electric heater block at the intake manifold, then remove the heater block. Save the fasteners for re-use. Caution: Cover the opening in the intake manifold with a clean rag to prevent foreign objects from entering the engine. 33. completely remove the stock gaskets from both sides of the heater block and intake manifold. Take care not to scratch or gouge any of these surfaces when removing the gasket material. 34. Remove the rag that was used to cover the intake. Reinstall the electric heater block onto the intake manifold with one of the supplied gaskets. Reattach the three electrical connections to the heater element. 35. Caution: The High Ram studs have different threads on each end. Make sure the M8 ends go into the engine intake manifold. The shorter studs are placed inboard closest to the valve cover. Apply the supplied thread locking compound to the M8 threaded end of the studs. Hand tighten the studs to the intake manifold. Figure 12. Relocation of the upper driver side A/C condenser mounting bracket Figure 13. Orientation of the passenger side hose clamps to avoid clearance issues v.3.0

17 Figure 14. Orientation of the hose clamps on the driver side. Figure 15. High-Ram stud installation. 1/2 36. Using the two nuts supplied, tighten the studs into the intake by threading both nuts onto the stud, then tighten the nuts against each other with two 1 2 open end wrenches. Tighten and torque the stud to 2 ft-lbs by turning the top nut. Remove the nuts from the stud by using two open-end wrenches to loosen the nuts in relation to each other. Repeat the process for each stud. The process is shown in Figure If your vehicle is NOT equipped with a factory ground strap on the intake heater, install the supplied ground strap from the intake heater to the engine. Put a 6-mm washer onto the bottom intake heater stud, leaving the factory heater nut installed. Next, install the smaller diameter ground strap terminal over the stud and retain with a 6-mm washer and nut. Route the other end of the ground strap to the threaded section on the engine and retain with a SAE washer and M8-1.25x 16 bolt. See Figure Slide the supplied intake gasket over the four studs, then slide the High-Ram over the studs. FACTORY NUTS INTAKE HEATER GROUND STRAP LARGER DIAMETER TERMINAL M6 NUT & M6 WASHERS (2) M8 X 1.25 BOLT SAE WASHER v

18 39. Install the supplied Stat-O-Seal washers on the two driver side (longer) studs. Driver side studs are longer than passenger side studs. The washers should be installed in a twisting motion to prevent tearing their sealing element. Install the supplied 5 16 flat washer on all studs, then fasten with the supplied nylock nuts. The nuts should be tightened to 12 ft-lbs (144 in-lbs). An exploded view of the High-Ram assembly is shown in Figure Gently bend the engine oil dipstick tube to it s mounting location on the High Ram as shown in Figure 16. Secure the dipstick tube with the factory bolt that was previously removed. 41. Remove rag that was used to cover the boost tube opening. Make the connection between the driver side boost tube and the High-Ram. Tighten all the driver side hose clamps to 5 ft-lbs (60 in-lbs). -END, SECTION 2- Figure 16. Exploded view of the High-Ram assembly v.3.0

19 Section 3 THERMoCouPlE INSTAllATIoN 1. The thermocouple monitors the temperature of the exhaust gases entering the turbocharger at the turbine housing. Installation requires that the exhaust manifold be drilled near the outlet of the manifold adjacent to the turbine housing. For this reason it is essential that the turbocharger be removed from the engine in order to clean out any metal chips from drilling that could cause turbine blade damage. NOTE: The Cummins ISB engine uses a divided exhaust manifold. The thermocouple may be installed to sample exhaust temperature in either exhaust passage. We recommend the rear passage (toward the firewall). 2. If not already done, remove the factory air intake system as described in Section 2 Steps Loosen the upper hose clamp on the turbocharger oil drain-tube hose that is located between the two sections of the oil drain tube. 4. Disconnect the oil supply hose at the turbocharger. Disconnect the compressor outlet hose that goes to the intercooler. 5. Disconnect the turbine outlet pipe by loosening the V-band. Save V-band for re-installation. 6. Remove the turbocharger mounting nuts/bolts and the turbocharger from the exhaust manifold. clean and inspect the Figure 17 exhaust flange mounting surfaces on the exhaust manifold. Make sure the surface is clean and dry. CAuTIoN: Anytime the turbocharger is removed from the engine, take care that no foreign objects enter any of the turbocharger connections on the engine or the turbocharger. Foreign objects entering air, exhaust, or oil connections may cause major damage to the engine and/or turbocharger and is not covered under any warranty. Cover the open end of the intercooler pipe with a clean rag, as this pipe is very susceptible to foreign object entry. 7. Stuff clean shop towels into the compressor outlet and inlet hoses to prevent contamination from entering the pipes. cover the turbo oil drainpipe to avoid contamination. 8. Stuff a small clean shop towel or rag 4 to 5 inches into the rear exhaust manifold passage through the turbocharger mounting flange. This is to prevent chips from entering the manifold while drilling and tapping. 9. Use a 7 16 drill, keeping the drill perpendicular to the manifold surface and drill through the exhaust manifold into the rear passage as shown in Figure Tap the drilled hole with a 1 4 NPT pipe tap. check the thread depth as you tap by periodically removing the tap and screwing the pipe coupling into the tapped hole. The coupling should thread in 3 to turns hand tight. Do not install the probe in place at this time. 11. Remove all loose chips from the exhaust manifold. A shop vacuum or small brush will help. Now remove the rag using a welding rod or coat hanger bent into a hook. Caution! Make sure rags are removed from exhaust manifold prior to reinstalling turbocharger! 12. Install the pipe coupling into the manifold using anti-seize on the threads. CAuTIoN: Remove all the rags that are inside the compressor outlet and inlet hoses and the exhaust manifold before re-installing the turbocharger. 13. Install the new turbine inlet gasket provided and apply a dab of anti-seize compound to the four turbo mounting studs. Install the turbocharger on the exhaust manifold. As the turbocharger is reinstalled, slip the oil drain tube into the drain hose. Tighten the turbocharger mounting nuts to 24 ft-lbs. Tighten the oil drain hose clamp. 14. Reconnect and tighten the turbo oil supply hose. 15. Reconnect the turbine outlet pipe to the turbocharger and secure it with the V-band. 16. Re-install the air box and inlet tube assembly. Secure the air box at the radiator cross brace with the factory nut that was previously removed. Re-connect the Air Inlet Temperature/ Pressure sensor at the air box cover. Re-connect the air inlet duct to the turbocharger inlet. Tighten the hose clamp at the turbocharger inlet to 8 ft-lbs (96 in-lbs). 17. Re-connect the compressor outlet hose that goes to the intercooler and tighten all hose clamps to 5 ft-lbs. -END, SECTION v

20 Section 4 BANKS RAM-AIR FIlTER INSTAllATIoN Notification The Banks Ram-Air Filter comes pre-oiled and no oiling is necessary for initial installation. Service the filter as specified in the Filter Maintenance Section of this manual. 1. Locate the engine air filter box on the passenger s side of the vehicle. Remove the cover by releasing the four (4) clips on the side of the housing and slide the cover toward the engine. 2. Remove the old air filter element from the filter housing and replace it with the Banks Ram-Air filter element. Place the Banks filter element in the right orientation and check the filter seal is seating properly around the housing to ensure no leakage. 3. Slide the tabs on the cover into the slots on the air filter box. Press the cover down gently and re-attach the four (4) clips on the side to securely clamp the cover. -END, SECTION 4- Figure 18 EconoMind and supplied wiring harnesses v.3.0

21 Section 5 BANKS ECoNoMIND DIESEl TuNER INSTAllATIoN Figure 19 Figure 20 Figure Place the EconoMind Diesel Tuner box on top of the fuse box located in the left front side in the engine compartment. See Figure 19. The in-cab cable with the three small connectors will be routed into the cabin via the grommet on the firewall. The other two harnesses will be routed under the intake to their respective locations listed in the following steps. 2. Locate the rubber grommet on the drivers side firewall. Using a utility knife, make a 1.5-inch-long slit in the grommet next to the wire harness. Be careful not to cut or damage the harness. See Figure 20 for the proper location of the required cut. Insert a screwdriver from the engine compartment into the cut hole and gently thrust it through the grommet. 3. Inside the vehicle, remove the lower dash panel beneath the steering column by removing the two (2) screws at the bottom of the panel. Retain the screws for re-installation. NOTE: There are also two (2) clips located at the top corners of the panel, which hold the panel in place. These clips can be released by gently pulling on the corners of the panel. Use caution to avoid damaging the panel during removal. 4. Remove the electrical connector bracket on the left hand side of the support below the steering column in front of the firewall by removing the two (2) bolts. This will allow access to the inner grommet. See Figure Cut the grommet on the firewall inside the vehicle along the hole created by the screwdriver in Step Locate the in-cab cable with the three connectors. From the engine compartment, push the in-cab cable through the hole cut in the firewall grommet. NOTE: Taping the end of the cable to a piece of stiff wire (i.e. coat hanger) may make routing the cable through the firewall a simpler task. The stiff wire should be pushed through the slit in the grommet and then the wires can be attached to the stiff wire and pulled through the hole in the grommet. CAuTIoN: Pull gently to avoid damage to the cable connectors. Always pull on the cable sheath rather than the wires themselves v

22 7. From inside the vehicle, continue to pull the in-cab cable through the firewall until it is approximately 22 inside the cab. Secure the cable to the lower access panel area. Take precaution to leave the three connectors accessible for usage further in the installation process. 8. Locate the Banks OBDII Interface cable and 11 cable tie in your kit. connect the OBDII Interface cable to the vehicle OBDII connector. Use the 11 cable tie as shown in Figure 22 to secure the Banks interface cable to the vehicle OBDII connector. Now, connect the 8-pin connector from the Banks OBDII Interface cable to the 8-pin connector on the EconoMind Tuner in-cab cable. NOTE: If you are not installing the optional Banks IQ then coil up and secure the cable with the RJ12 (telephone style) connector end. 9. In the engine compartment find the Fuel Rail Pressure (FRP) sensor on the fuel rail. It is located on the drivers side of the engine. Unplug the factory connector and plug it into the corresponding male FRP sensor connector on the EconoMind harness. Plug the EconoMind s female FRP sensor connector into the sensor. See Figure Locate the Manifold Pressure (MAP) sensor on top of the intake manifold. Unplug the factory connector and plug it into the corresponding male MAP sensor connector on the EconoMind harness. Plug the EconoMind s female MAP sensor connector into the sensor. See Figure 23. CAuTIoN: The Camshaft Position (CMP) sensor and the Crankshaft Position (CKP) sensor have the same type of connectors and they are in close proximity to one another. Make sure the right connectors are used when installing these connections. Refer to Figure 24. for their locations on the EconoMind Diesel Tuner wire harness. Figure 22 Figure 23 Figure v.3.0

23 Figure 25 Figure 26 Figure Locate the crankshaft Position (CKP) sensor on the lower front left side of the engine. It is behind the engine crankshaft pulley (engine harmonic balancer). Unplug the factory connector and plug it into the corresponding male ckp sensor connector on the EconoMind harness. Plug the EconoMind s female ckp sensor connector into the sensor. Take care to route the wire harness away from the power steering pump pulley and secure it with the supplied cable ties. See Figure Locate the camshaft Position (CMP) sensor below the fuel injection pump between the timing gear cover and the EcM. Unplug the factory connector and plug it into the corresponding male cmp sensor connector on the EconoMind harness. Plug the EconoMind s female cmp sensor connector into the sensor. See Figure Attach the supplied thermocouple lead wire extension to the previously installed thermocouple with the supplied nuts and bolts. The YELLOW extension wire attaches to the YELLOW thermocouple wire, and the RED extension wire attaches to the RED thermocouple wire. 14. Route the thermocouple lead wire extension along the factory harness to the driver s side and connect it to the EconoMind harness. Cover both joints with the supplied heat shrink tubing and heat until the tubing conforms to the joint. Make sure the entire joint is insulated. 15. Remove the fuse box cover, located in left front side of the engine compartment. Locate the mini-fuse #50 and remove it. Install the miniauto blade tap onto the removed mini fuse as shown in Figure 27. Re-install the mini fuse with the attached blade tap into location #50 as shown in Figure 28. NOTE: Install the mini-auto blade tap on the terminal leg closest to the firewall. This is the hot side of the circuit. Caution: It is very important that you select the proper fuse. The Banks EconoMind Diesel Tuner will not function properly if installed incorrectly v

24 16. It is recommended to cut a small notch in the fuse box cover as shown in Figure 29, to avoid a crimped or stressed wire. Locate the RED/WHT wire with the Power Terminal on the EconoMind tuner wire harness and connect it to the mini-fuse blade tap. Replace the fuse cover and make sure not to pinch the RED/WHT power wire. 17. In the engine compartment, locate the BLACK Ground wire with the ring terminal on the EconoMind Diesel Tuner wire harness. Install this ring terminal onto the fender ground stud, over the ring terminals already there, and re-install the nut. See Figure 30. NOTE: Go over the entire installation as a precautionary check to ensure that all clamps are tight, wiring and hoses are properly routed, and connections are correct and tight. Make sure that the EconoMind wire harness is not lying in the way of the brake and gas pedals, or any moving parts. 18. (Engine compartment) After confirming all of the system connections are correct, make sure the entire mounting surface is clean and free of dirt and oil before mounting the EconoMind Diesel Tuner. clean and dry as required using a cloth dampened with rubbing alcohol or a similar cleaning solution. CAuTIoN: Do not spray fluid directly onto any electrical equipment, or equipment damage may result. Mount the EconoMind Diesel Tuner on the top of the fuse box cover as shown in Figure 19, by peeling the protective backing off the adhesive tape on the back of the EconoMind Diesel Tuner. 19. Hold the EconoMind Tuner against the fuse box cover for approximately 1 minute while applying pressure to allow the adhesive to properly adhere to the surface. -END, SECTION 5- Figure 28 Figure 29 Figure v.3.0

25 Section 6 MouNTING AND CoNNECTING THE BANKS iq If not installing the optional Banks iq, skip to Section 7. WARNING: Below 32 o F (0 o C) or above 140 o F (60 o C), the Banks iq may be susceptible to damage as a result of extended exposure to sunlight, heat or extreme cold. It is highly recommended that the Banks iq be removed from its mounting location if the vehicle will be subjected to high concentrations of sunlight, heat or cold for an extended period of time. Gale Banks Engineering is not responsible for damage to Banks iq resulting from exposure conditions. Figure 31 Attaching Banks iq to window mount CAuTIoN: Do not use force when working on plastic parts. Permanent damage to the part might result. 1. Locate the Window Mount Assembly in your kit. 2. Assemble the Banks iq docking station to the Universal mount by inserting and sliding the Universal mount tab into the docking station groove. Hand tighten the nut behind the docking station to hold the docking station in place. 3. Attach the window mount to your Banks iq. See Figure 31. Align and place the two (2) lower tabs on the window mount to the corresponding slots on the bottom of Banks iq first then snap the top of Banks iq into place. NOTE: There may be a snug fit when installing the Banks iq into the window mount. Take care not to force this process. 4. Find a suitable place on the windshield for ease of access and viewing of Banks iq. Use location shown in Figure 32 as a reference for mounting Banks iq in your vehicle. Loosen the knob and move the swivel suction plate to achieve desired viewing angle of the Banks iq screen. Do a test fit and note the angle necessary to achieve the correct viewing angle. 5. Make sure the suction cup and the mounting area on the windshield are clean and dry. With the suction lever in the up position, ensure the suction cup is flat against the windshield, and then push the suction lever down to secure in place. 6. Next, remove and set the side dash access panel aside. 7. Locate the RJ12 cable (similar to telephone connector) previously secured behind the knee panel. Remove the knee panel to gain access to the RJ12 cable. See Figure Locate Banks iq Bridge Module and connect the RJ12 connector into the Bridge Module. See Figure 34. Figure 32 Mounting location for Banks iq v

26 Figure 33 Banks iq System Figure 34 Banks Bridge Module 9. Route the Banks iq USB interface cable from the Banks iq bridge module under the dash and out through the side access panel opening. The cable can be slid under the door frame s seal and run up to the top of the dash. Pull enough cable to reach the Banks iq and connect it to the USB receptacle on the left side of Banks iq. See Figure 32. Snap the side access panel back in place making sure not to pinch the wire. WARNING: THE CHARGING CABlE CoNNECTED To THE BANKS iq IS DESIGNED To SuPPly A CoNSTANT low-voltage PoWER SouRCE (+5VDC) To THE BANKS iq AND IS live AS long AS THE SySTEM S obd II INTERFACE CABlE or BANKS WIRING HARNESS IS CoMPlETEly INSTAllED AND THE usb CABlE CoNNECToR IS PluGGED INTo BANKS iq. AlTHouGH THIS CHARGING CABlE IS SHoRT AND ITS CIRCuITRy IS FuSE-PRoTECTED, THE user IS ExPECTED To TAKE APPRoPRIATE MEASuRES To PREVENT SMAll CHIlDREN AND/oR PETS FRoM CoNTACT WITH ANy PART of THIS SySTEM. 10. Secure Banks iq bridge module under the dash to any dash frame support using the supplied cable ties. Use the cable tie support loops on the side of the bridge module to securely fasten it under the dash. 11. Route all wiring away from any pedals or other moving components. Using the cable ties supplied, secure the wiring under the dash. 12. Reinstall the lower knee panel back in place with the factory hardware. Tuck any excess cable behind it for a clean appearance. -END, SECTION v.3.0

27 Section 7 PoWER SElECToR SWITCH INSTAllATIoN Not needed if Banks IQ is installed. CAuTIoN: Do not use force when working on plastic parts. Permanent damage to the part might result. 1. The Power Level Selector switch will be installed on the drivers side of the instrument panel (IP) next to the steering column. See Figure Remove the headlamp switch bezel on the drivers side by gently pulling on it. Disconnect the electrical connector once the bezel is removed. Figure To remove the center bezel, open the ashtray and cup holder and remove the retaining screw. Gently pull on the center bezel to disengage all the clips that attach the bezel to the dash. Disconnect the four (4) electrical connections after the bezel is removed. Keep the screw for reinstallation. 4. Remove the cluster bezel by first removing the two (2) screws at the top. Gently pull on it and disengage all the clips that attach the bezel to the dash. Retain the screws for reinstallation. 5. cut out the supplied template (see Figure 36) and align the template onto the front of the cluster bezel by placing its left edge against the cluster rib, and its bottom edge against the cluster bottom edge. Use masking tape to securely hold down the template. NOTE: Do not tape over the markings on the template. 6. Using a 3 8 Uni-bit, center the bit onto the 3 8 drill location on the template and slowly drill through the IP. Using a 1 8 drill bit, center and drill through the 1 8 location on the template. Remove and discard the template and any plastic shavings. NOTE: It is important that the hole is drilled at the recommended location. The switch may not clear the instrument panel structure if the hole is shifted to another location. 7. Align the label onto the previously drilled hole. Make sure the entire mounting surface is clean and free of dirt and oil before mounting the label. clean and dry as required using a cloth dampened with rubbing alcohol or similar cleaning solution. CAuTIoN: Do not spray fluid directly onto any electrical equipment, or equipment damage may result. Mount the EconoMind Diesel Tuner switch label onto the cluster bezel by peeling the protective backing off the adhesive tape on the back of the switch label. Hold the label against the panel for approximately 20 seconds while applying pressure to allow the adhesive to properly adhere to the surface. Figure 36 Template v

28 8. Remove the nut and internal tooth washer from the Power Level Selector switch. Rotate the shaft counter clockwise until the shaft stops. Verify that the locating washer tab is inserted into the #6 position on the switch (see Figure 37). NOTE: If the washer is in any position other than the #6, your EconoMind Diesel Tuner will not select power levels correctly. 9. After confirming the locating washer is in the #6 location, install the switch through the 3 8 hole on the backside of the bezel. The alignment pin should rest in the 1 8 hole and with the switch fully rotated counter clockwise; the shaft s flat side should be facing the steering column. Secure switch with internal tooth washer and nut. Snug the nut. Be careful not to over torque the nut and damage the plastic threads. 10. Install the knob onto the shaft facing the #1 Level on the EconoMind label. On the knob, snug the two (2) set screws with the supplied hex key wrench. 11. Reinstall the cluster bezel by pressing on it to ensure all the clips are engaged. Secure it with the original a two (2) screws. 12. Reconnect the electrical connector to the headlamp switch bezel. Reinstall this bezel by gently pushing on it until all clips are engaged. 13. Reconnect the four (4) electrical connections to the center bezel. Reinstall this bezel by pushing on it to engage all the clips. Open the ashtray and cup holder and reinstall the original screw. 14. Route the Power Level Selector switch wires down to the steering column. 15. Route the Power Level Selector switch s cable to the wire harness that was routed into the passenger compartment from the EconoMind module, and plug the 2-pin connector into the corresponding connector on the EconoMind harness. 16. Route all wiring away from any pedals or other moving components. Using the cable ties supplied, secure the wiring under the dash. -END, SECTION 7- Figure 37 EconoMind switch, orientation of the tab on the washer v.3.0

29 Section 8 optional GAuGE CluSTER INSTAllATIoN If not installing optional gauges, Skip to next section. 1. choose a suitable location under the lower edge of the dash for the mounting of the instrument panel provided where the driver can conveniently view it. Note: Molded pillar mount and additional gauges are available through Gale Banks Engineering. Figure Using the panel as a template, drill two 3 16 diameter holes in the dash and mount the panel with the supplied machine screws, nuts and star washers provided. 3. Locate the supplied EconoMind wire loom with the 4-pin connector. connect the 4-pin connector on the EconoMind wire loom to the connection labeled DYNAFAcT Gauges on the EconoMind wiring harness. See Figure Install the DynaFact boost and pyrometer gauges in the mounting panel using the clamps and thumbnuts provided. Plug the BLAcK wire lead to the male spade terminal on the BLACK wire of each gauge wire harness. Plug the YELLOW wire into the Yellow wire of the boost gauge wire harness and the RED wire into the RED wire of the pyrometer gauge wire harness. The ORANGE wire remains unused. 5. connect the 4-pin connector of each gauge into the back of its corresponding gauge. a. crimp the remaining Black and RED wires from each 4-pin connector gauge harness to the butt connectors as shown in Figure 38. b. Strip one end of the RED wire and crimp it to the butt connector containing the RED wires from step a. c. Strip one end of the BLACK wire and crimp it to the butt connector containing the BLACK wires from step a. d. Route the RED wire to the fuse box. Locate the appropriate fuse for instrument lighting in the owner s manual. Cut the RED wire as required and strip the end. crimp the push on connector to the RED wire and connect to the fuse as shown in Figure 38. Alternatively, locate power wire to dimmer switch and install T-tap. Cut the RED wire as required and strip the end. crimp the push on T-tap connector to the RED wire and connect to T-tap on dimmer power wire. e. Locate a metal surface that will serve as an acceptable chassis ground. Cut the BLACK wire to a sufficient length that will allow it to reach the chassis ground and strip the end. crimp the ring terminal to the BLACK wire as shown in Figure 38. f. Drill a 1 8 hole, if required, to attach the ring terminal to the chassis ground. Caution: If drilling, check the backside to make sure there are no components that may be damaged by drilling. g. Use the supplied self-tapping screw to secure the ring terminal to the chassis ground. -END, SECTION v

30 Section 9 TRANSMISSIoN learnng Your EconoMind Diesel Tuner displays the 4,3 diagnostic code (refer to TROUBLESHOOTING in Section 10 on how to read codes) when it needs to learn your transmission configuration. This always occurs when the EconoMind Diesel Tuner is first installed on the truck. The EconoMind Diesel Tuner is equipped with advanced safety features to preserve your automatic transmission. One of them is the capability to detect the occurrence of transmission slip, and it will automatically de-rate the engine output power accordingly. Before this safety feature can take effect, the EconoMind Diesel Tuner needs to learn that your truck is equipped with an automatic transmission. 1. The following driving test shall be performed in an area where speeds over 55mph are safe and traffic is light. For a vehicle with a manual transmission, follow Step 2. For a vehicle with an automatic transmission, follow Step 3. While driving, listen for any exhaust leaks or rattles, or intake boost leaks. After the engine cools, re-tighten clamps and hoses if leaks are detected. 2. (Manual trans) To teach the EconoMind Diesel Tuner that your truck is equipped with a manual transmission, drive the truck at a speed over 55 mph for at least 2 minutes. The 4,3 diagnostic code will be eliminated. Repeat if necessary to eliminate code. Proceed to Section (Auto Trans) To teach the EconoMind Diesel Tuner that your truck is equipped with an automatic transmission drive the truck at a speed over 55mph until the torque converter is locked (the toque converter is usually locked at speeds over 55mph). With the torque converter locked and with turbo boost below 10psig (ie, light load), maintain the attained speed steadily for at least 30 seconds. Once the transmission is learned, the 4,3 diagnostic code will be eliminated. Repeat if necessary to eliminate code. -END, SECTION 9- Section 10 TRouBlESHooTING, ECoNoMIND EconoMind Troubleshooting using The Banks iq Check the Banks iq s Status indicator for the OK icon on the upper left corner of the iq screen. Any Tuner fault will be indicated by the Banks Engine icon (see Figure 39) and its cause can be investigated by running a Tuner Diagnostic from the Diagnostic menu. Figure 40 Figure 39 Banks Engine Icon 1. In the Environment select menu press on the Diagnostics button. See Figure In the Diagnostics menu press on the Tuner Diagnostics button to run a tuner diagnostics. See Figure The Self Diagnostic screen displays a log of diagnostic events related to the Power Tuner. The Logged Events list takes a moment to update each time this screen is opened. Once the list is updated, the most current event will appear at the bottom of the list. Each event has an associated timestamp and description, which will be displayed below the list when that event is highlighted. Each key cycle of the vehicle produces a minimum of two logged events. See Figure 42. Table 1 lists the common diagnostic codes and the suggested course of action for each. 4. Use the arrow buttons to scroll through the recorded events. 5. Touch the Banks iq icon on the lower left of the screen to return to the environment screen or the return icon to return to the Diagnostics menu. 6. A pop-up Log-File screen will appear asking you if you want to erase the contents of the log. Press No to keep the contents on Log-file or Yes, to erase the Log-files v.3.0

31 Figure 41 Figure 42 Diagnosing EconoMind error codes without the Banks iq. If you feel that your Banks EconoMind Diesel Tuner is not functioning properly, some diagnostics can be performed. Your EconoMind Diesel Tuner is equipped with diagnostic features that will detect and display certain errors. Remove the Banks EconoMind Diesel Tuner from its mounting location while keeping all connectors plugged in, and position it in such a way that you can view the top of the EconoMind housing that contains the LEDs. Turn the vehicle key to the ON position. Observe the two LEDs mounted on the end of the Banks EconoMind Diesel Tuner: A steady GREEN LED will illuminate if all wire connections are correct, the engine is running, and the engine coolant temperature is within its normal operating range. The GREEN LED will flash if all wire connections are correct, the engine is running, but the engine coolant temperature is not within its normal operating range. The GREEN LED will stop flashing once the engine coolant temperature is within its normal operating range. No LEDs will illuminate if the fuse on the EconoMind wiring harness is blown or the wiring harness is not properly connected. If the fuse and all connections are okay, contact Banks Technical Service. The RED LED will flash in a certain sequence if a connection is incorrect of if there is a problem with the system this sequence will identify one or more diagnostic codes. A Banks EconoMind Diesel Tuner s diagnostic code is comprised of 2 digits. Each code is expressed in a sequence of 2 sets of the flashing red LED separated by a brief flashing of the green LED in between. Each set of a number of red LED flashes represents a digit. A longer flashing of the green LED separates the sequences. The LEDs will continue to flash to display all the errors, and then repeat. Table 1 lists the common diagnostic codes. For example, if a faulty thermocouple is detected (code 2,3 ) by the Banks EconoMind Diesel Tuner, the following red and green LED flashing sequence is observed when the key is on: (1) Two times flashing RED LED (2) One time quick flashing GREEN LED (3) Three times flashing RED LED (4) One time longer flashing GREEN LED The above flashing sequence will repeat continuously. When the problem is corrected, the diagnostic code will be eliminated and replaced by a steady green light. NOTE: If multiple codes are set, they will be displayed in a series separated by the longer flashing green LED. When reading codes, make sure to watch the entire series until you see the first code repeat. -END, SECTION v