Banks Power Universal Car & Truck: (Gas or Diesel ’50 - 14 Universal) Water-Methanol: Straight-Shot and Double Shot, Universal applications - Manual (Page 28)

28
97650 v.1.0
45000 Straight-Shot - Methanol-Water Injection System, Low Volume - Universal Application
45000-1 Base System, Methanol-Water Injection - Controller w/ Onboard MAP Sensor 1
45021 Module, Injection Controller-w/MAP Sensor - Methanol-Water Injection 1
45111 Boost Line Kit - Methanol-Water Injection Systems 1
45121 Fitting, 90 Deg Swivel, 1/4" NPTM- 1/4" Push Lock - MWI 1
62001 Cable Tie, Black, 6" - 12
62034 Connector, T-Tap, Red - 22-18 Gauge 1
62038 Fuse Tap, Blade 1
62831 Pump Harness, Water-Methanol Injection Controller 1
62832 Signal Harness, Contoller - Methanol-Water Injection 1
62837 Sub-Harness, Switch, Pump Pressure - Methanol-Water Injection 1
63001 Mounting Panel, One Gauge - Black, W/Fasteners 1
63006 Bracket, Module, Six-Gun/Bullet/WMI - Various Applications 1
91102 Washer, Sae Flat, Zinc - 1/4" 8
91761 Hex Bolt, Flange Head - 6Mm-1.00 X 45MM 4
91771 Nut, Nylock - M6 X 1.0, Zinc 4
91846 Washer, Internal Tooth Lock - #8 2
91868 Hex Nut, Zinc - 8-32 2
97650 Owner's Manual - Methanol-Water Injection System - Universal Application 1
97650-A Addendum, Owner's Manual-Schematic - MWI - Universal Application 1
45031 Pump Assy, Low Volume, Methanol-Water Injection 1
45031-01 Pump, Low Volume, Methanol-Water Injection 1
62480 Housing, 2 Contact Shroud Half - Solenoid Assy, Cbc-04-06 Dodge 1
62481 Terminal, Male 20-18 Ga - Solenoid Assy, Cbc-04-06 Dodge 2
62482 Cable Seal, Green - Solenoid Assy, Cbc-04-06 Dodge 2
45061 Injection Nozzle Kit-1, Methanol-Water Injection Systems 1
45085 Injection Nozzle, Methanol-Water, #4, 30lb/hr @ 100PSI, 100 Degree Full Cone 1
45087 Injection Nozzle, Methanol-Water, #7, 52lb/hr @ 100PSI, 100 Degree Full Cone 1
45122 Fitting, Nozzle, 90 Deg Swivel, 1/4" NPTF- 1/4" Push Lock - MWI 1
91099 Teflon Tape, 1/2" X 100" - 1
45140 Tubing, 0.040" Wall, Nylon 11, Black-Methanol-Water Inj 10
45001 Straight-Shot - Methanol-Water Injection System, High Volume - Universal Application
45000-1 Base System, Methanol-Water Injection - Controller w/ Onboard MAP Sensor 1
45030 Pump Assy, High Volume, Methanol-Water Injection 1
45030-01 Pump, High Volume, Methanol-Water Injection 1
62480 Housing, 2 Contact Shroud Half - Solenoid Assy, Cbc-04-06 Dodge 1
62481 Terminal, Male 20-18 Ga - Solenoid Assy, Cbc-04-06 Dodge 2
62482 Cable Seal, Green - Solenoid Assy, Cbc-04-06 Dodge 2
45062 Injection Nozzle Kit-2, Methanol-Water Injection Systems 1
45085 Injection Nozzle, Methanol-Water, #4, 30lb/hr @ 100PSI, 100 Degree Full Cone 1
45087 Injection Nozzle, Methanol-Water, #7, 52lb/hr @ 100PSI, 100 Degree Full Cone 1
45090 Injection Nozzle, Methanol-Water, #14, 103lb/hr @ 100PSI, 100 Degree Full Cone 1
45122 Fitting, Nozzle, 90 Deg Swivel, 1/4" NPTF- 1/4" Push Lock - MWI 2
45123 Fitting,"Y", Female 1/4" Push-Lock, Black Nylon - MWI 1
91099 Teflon Tape, 1/2" X 100" - 1
45140 Tubing, 0.040" Wall, Nylon 11, Black-Methanol-Water Inj 10
45002 Double-Shot - Methanol-Water Injection System, Low Volume - Universal Application
45000-1 Base System, Methanol-Water Injection - Controller w/ Onboard MAP Sensor 1
45031 Pump Assy, Low Volume, Methanol-Water Injection 1
45040 Solenoid Kit, Methanol-Water Injection 1
45035 Solenoid, Methanol-Water Injection 1
45038 Bracket, Solenoid Mount, Single - Methanol-Water Injection 1
45120 Fitting, Straight, 1/4" NPTM - 1/4" Push Lock - MWI 2
91102 Washer, Sae Flat, Zinc - 1/4" 4
91110 Nut, Nylock - 1/4"-20 2
91118 Hex Bolt, Grade 5, Zinc - 1/4"-20 X 1" 2
91725 Screw - Button Head, Socket Cap - 10-32 X 3/8" - 18.8-S/S 2
91826 Washer, Int Tooth Lock, Zinc - #10 2
45050 Check Valve, In-line - Methanol-Water Injection 1
45070 Injection Nozzle Kit-10, Methanol-Water Injection Systems 1
45083 Injection Nozzle, Methanol-Water, #2, 15lb/hr @ 100PSI, 100 Degree Full 1
45085 Injection Nozzle, Methanol-Water, #4, 30lb/hr @ 100PSI, 100 Degree Full Cone 1
45087 Injection Nozzle, Methanol-Water, #7, 52lb/hr @ 100PSI, 100 Degree Full Cone 1
45122 Fitting, Nozzle, 90 Deg Swivel, 1/4" NPTF- 1/4" Push Lock - MWI 2
45123 Fitting,"Y", Female 1/4" Push-Lock, Black Nylon - MWI 2
91099 Teflon Tape, 1/2" X 100" - 1
45108 Thermocouple Kit - Methanol-Water Injection Systems 1
62001 Cable Tie, Black, 6" - 6
63042 Thermocouple, Pyrometer - Chevy, Dodge, Ford Pwr Sys 1
63060 Leadwire, Pyrometer, Electric - Various Applications 1
92273 Weld Bung, 1/4" NPT 1
95015 Box, 6X6X6 - 200# Rsc 1
45140 Tubing, 0.040" Wall, Nylon 11, Black-Methanol-Water Inj 25
45144 Tank Kit, 2.5 Gallon - Methanol-Water Injection 1
45096 Tank, 2.5 Gal, PE, Natural, with 1/4" FPT Fitting weld-on; 2.25" Top Vented Cap, Black, w/8" Tether 1
91103 Washer, Uss, Zinc - 1/4" 8
91110 Nut, Nylock - 1/4"-20 4
91120 Hex Bolt, Grade 5, Zinc - 1/4"-20 X 1 1/8" 4
91590 Strap, Mounting - MWI Tank, Small 2
45003 Double-Shot - Methanol-Water Injection System, High Volume - Universal Application
45000-1 Base System, Methanol-Water Injection - Controller w/ Onboard MAP Sensor 1
45030 Pump Assy, High Volume, Methanol-Water Injection 1
45040 Solenoid Kit, Methanol-Water Injection 1
45050 Check Valve, In-line - Methanol-Water Injection 1
45071 Injection Nozzle Kit-11, Methanol-Water Injection Systems 1
45084 Injection Nozzle, Methanol-Water, #3, 22lb/hr @ 100PSI, 100 Degree Full Cone 1
45087 Injection Nozzle, Methanol-Water, #7, 52lb/hr @ 100PSI, 100 Degree Full Cone 1
45088 Injection Nozzle, Methanol-Water, #10, 74lb/hr @ 100PSI, 100 Degree Full Cone 1
45090 Injection Nozzle, Methanol-Water, #14, 103lb/hr @ 100PSI, 100 Degree Full Cone 1
45122 Fitting, Nozzle, 90 Deg Swivel, 1/4" NPTF- 1/4" Push Lock - MWI 2
45123 Fitting,"Y", Female 1/4" Push-Lock, Black Nylon - MWI 2
91099 Teflon Tape, 1/2" X 100" - 1
45108 Thermocouple Kit - Methanol-Water Injection Systems 1
45140 Tubing, 0.040" Wall, Nylon 11, Black-Methanol-Water Inj 25
45147 Tank Kit, 7 Gallon - Methanol-Water Injection 1
45098 Tank, 7 Gal, PE, Natural, with 1/4" FPT Fitting weld-on; 3.5" Top Vented Cap, Black, w/8" Tether 1
91103 Washer, Uss, Zinc - 1/4" 8
91110 Nut, Nylock - 1/4"-20 4
91120 Hex Bolt, Grade 5, Zinc - 1/4"-20 X 1 1/8" 4
91592 Strap, Mounting - MWI Tank, Large 2
Kits used in more than one injection system (i.e. 45000-1) are listed in full only once . See a previous system for all parts in that kit.
Kits used in more than one injection system (i.e. 45000-1) are listed in full only once . See a previous system for all parts in that kit.
Kits used in more than one injection system (i.e. 45000-1) are listed in full only once . See a previous system for all parts in that kit.
BANKS
PN BANKS
DESCRIPTION STAMPED
# GAL
/
HR LB
/
HR* CC
/
MIN GAS
(SUPPORTED) DIESEL
(ADDED)*
45081 Nozzle, Water-Methanol Injection, #01 1 0.75 6 47 23 3
45082 Nozzle, Water-Methanol Injection, #02 2 1 7 63 31 4
45083 Nozzle, Water-Methanol Injection, #03 3 2 15 126 63 8
45084 Nozzle, Water-Methanol Injection, #04 4 3 22 189 94 12
45085 Nozzle, Water-Methanol Injection, #05 5 4 30 252 125 16
45086 Nozzle, Water-Methanol Injection, #06 6 5 37 315 156 20
45087 Nozzle, Water-Methanol Injection, #07 7 7 52 442 219 28
45088 Nozzle, Water-Methanol Injection, #08 8 10 75 631 313 40
45089 Nozzle, Water-Methanol Injection, #09 9 12 90 757 375 48
45090 Nozzle, Water-Methanol Injection, #10 10 14 105 883 438 56
*BASED
ON
A
50/50
MIX
OF
METHANOL
AND
WATER
HORSEPOWER
POTENTIAL FLOW
RATE
@
100
PSI
ΔP
Appendix
A:
Nozzle
Flow
Rates
BANKS
PN GAL
/
HR LB
/
HR* CC
/
MIN GAS
(SUPPORTED) DIESEL
(ADDED)*
45030 43.7 327 2757 1250 175
45031 23.3 175 1470 750 90
Appendix
B:
Pump
Flow
Rates FLOW
RATE
@
100
PSI
ΔP HORSEPOWER
POTENTIAL
*BASED
ON
A
50/50
MIX
OF
METHANOL
AND
WATER
BANKS
DESCRIPTION
Pmp
Assy,
High Volume,
Water-­‐Methanol
Inj.
Pmp
Assy,
Low
Volume,
Water-­‐Methanol
Inj.
ERROR
CODE DESCRIPTION TROUBLESHOOT
MAP
ERR1 MAP
sensor
signal
voltage
too
low
or
high
Check
sensor
connecBon
and
harness
leads
for
shorts
or
broken
connecBons.
Refer
to
system
schemaBc
(P/N
97650-­‐A
or
97651-­‐A).
SOL
ERR2
Solenoid
(either
primary
or
2nd
stage)
control
current
too
high
Check
solenoid
harness
connecBons
and
leads
for
shorts
to
ground.
Refer
to
system
schemaBc
(P/N
97650-­‐A
or
97651-­‐A).
FLD
ERR3 Pump
output
pressure
switch
error
Typical
indicaBon
of
low
/
out
of
fluid
state,
check
and
fill
reservoir.
If
condiBon
does
not
correct,
check
connecBon
and
harness
leads
for
shorts
or
broken
connecBons.
Refer
to
system
schemaBc
(P/N
97650-­‐A
or
97651-­‐A).
If
no
connecBon
errors
found,
inspect
downstream
fluid
plumbing
from
pump
for
leaks.
If
no
leaks
found,
increase
starBng
pump
duty
cycle
to
a
higher
value,
as
inadequate
line
pressure
(<40
PSI)
to
trigger
the
pump
output
pressure
switch
may
be
present
-­‐
common
with
larger
nozzle(s).
EGT
ERR4 EGT
sensor
connecBon
problem
Check
sensor
connecBon
and
harness
leads
for
shorts
or
broken
connecBons.
Refer
to
system
schemaBc
(P/N
97650-­‐A
or
97651-­‐A).
STAT
ERR5
System
Status
output
line
connecBon
problem
Check
harness
connecBon
and
leads
for
shorts
to
ground.
Refer
to
system
schemaBc
(P/N
97650-­‐A
or
97651-­‐A).
PUMP
ERR6
Pump
overcurrent
problem
Check
pump
harness
connecBon
and
leads
for
shorts
to
ground.
Refer
to
system
schemaBc
(P/N
97650-­‐A
or
97651-­‐A).
Appendix
C:
Error
Codes
&
Trouble
Shoo6ng