Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) Tuner- Big Hoss Diesel Tuner (does not connect to pump wire) - Manual (Page 13)

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Note: this verification of proper
performance should be performed prior
to permanent mounting of the Big Hoss
Diesel tuner as illustrated in Steps
19-21.
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 tight. Make sure that the wire
harness is not laying in the way of the
brake and gas pedals. Re-connect the
battery terminals. Start the engine and
allow it to warm up. Drive the vehicle
under light load (normal around-town
driving) for 20 to 30 minutes, and
listen for any exhaust leaks or rattles,
or intake boost leaks. Shut off the
engine and re-tighten all intercooler
and turbocharger boost clamps. These
connections may have loosened
with time, and if leaking, will cause
a drop in boost pressure with a loss
in performance. check that clamps
are properly positioned on hoses,
and periodically check tightness of
hose clamps at regular maintenance
intervals, such as when the oil is
changed.
Observe the operation of the boost
and pyrometer gauges (if equipped)
while driving under varying conditions.
Turbocharger boost pressure will
increase as a function of load and
engine RPM, thus the engine will
produce little boost while cruising at
light throttle, with maximum boost
while climbing hills heavily loaded
during acceleration. Note the boost
level seen during hard acceleration
with a given load. If performance
seems to have deteriorated sometime
in the future, the maximum boost
figures may be compared to see if
boost has dropped off. Lower boost
may be caused by turbo ducting
leaks, a malfunctioning wastegate or
fuel injection pump, or dirty air filter.
Typical maximum boost pressure
settings for the Dodge/cummins diesel
will vary considerably with stick or
automatic transmission options, year
model of vehicle and altitude.
Use your pyrometer gauge (if
equipped) to monitor exhaust gas
temperature (EGT) in the engine. At
idle, exhaust gas temperature will
be very low, perhaps only 300°F. As
the engine is accelerated for higher
speeds with greater loads, the EGT
will rise. The highest EGT will be seen
under maximum load at full throttle,
such as climbing a steep grade with a
heavily laden vehicle. Your pyrometer
is color coded to assist in your reading
of the gauge. The red zone indicates
a dangerous level of temperature.
Your engine should not operate in this
range for more than a few seconds.
The blue zone indicates when it is safe
to shut the engine off. To avoid heat
damage to various engine components
it is recommended that the exhaust
gases cool below 400º before the
engine is shut down.
The maximum recommended turbine
inlet EGT (in the exhaust mainfold)
is 1300º F. Use caution to avoid
exceeding 1300º.
If you feel that your Big Hoss Diesel
Tuner is not functioning properly,
some diagnostics can be performed.
Your Big Hoss is equipped with
diagnostic features that will detect
and display certain errors. Turn vehicle
key to ON position. Observe the two
LEDs mounted on the upper corners
of the black connector on the end of
the Big Hoss. If all wire connections
are correct, a steady green light is
illuminated.
If a connection is incorrect or if there
is a problem with the system, when
the key is ON the LEDs will flash in
sequence to identify a diagnostic code.
Section 2
CHECKING ENGINE PERFORMANCE