Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Power Systems- Stinger system '03-04 - Manual (Page 19)

OttoMind box connection. Insert the
provided engine rating jumper key
into the OttoMind box thermocouple
connection. See Figure 23.
72.
Turn the key to ON position
(DO NOT start the engine) and wait 5
seconds.
73.
Turn the key to OFF position,
wait 5 seconds and turn the key
to ON position (Do NOT start the
engine) and wait 5 seconds.
74.
Again, turn the key to OFF
position, wait 5 seconds and turn the
key to ON position (DO NOT START
ENGINE) and wait 5 seconds.
75.
When the procedure is
completed correctly, the OttoMind
will flash the red LED once.
76.
Turn the key to the OFF
position and remove the engine
rating jumper key. Re-install the
thermocouple leadwire into the
OttoMind box.
Note: Each time the key is turned on,
the OttoMind will flash the red LED
once at powerup to indicate that it
has calibrated as a 235HP/250HP
engine rating. A 305HP rated engine
calibration does not flash a red
LED. If you have incorrectly used
a 235HP/250HP calibration on a
305HP rated engine, excessive fuel
rail pressure will result and the
OttoMind will automatically adjust
the calibration to the 305HP rated
engine level and red LED will not
flash at powerup. A “4,4” diagnostic
code will be generated and stored in
the OttoMind in the process. A “4,4”
will also be generated and stored in
the OttoMind on a 235HP or 250HP
rated engine if excessive fuel rail
pressure is detected. This “4,4” code
is eliminated and cleared when the
key is turned off and turned back on.
If “4,4” diagnostic code keeps
being generated and stored on
your OttoMind, contact Gale Banks
Engineering Technical Support.
Checking Engine
Performance
Note: The OttoMind requires the
engine coolant temperature (ECT) to
be above 125 degrees before it will
add fuel.
Note: This verification of proper
performance should be performed
prior to permanent mounting of the
OttoMind as illustrated in Steps 77
to 80.
Observe the operation of the boost
and pyrometer on the DynaFact
gauges 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.
Note: Before key-OFF, check tuner
for error codes.
Use your pyrometer gauge to
monitor exhaust gas temperature
(EGT) in the engine. At idle,
exhaust gas temperature will
be very low, perhaps only 300
Degrees Fahrenheit. 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 400 Degrees before the
engine is shut down.
Your OttoMind is calibrated to
maintain a maximum EGT of 1350
Degrees Fahrenheit. You may
experience brief excursions slightly
above 1350 Degrees Fahrenheit
under acceleration. This is normal
and EGT should return to 1350 or
below within a few seconds. If you
find that EGT remains high for any
length of time, check for boost leaks
or a dirty air filter.
9 6 7 6 7 v . 3 . 0
| 19