Banks Power Dodge Trucks: (Diesel ’98 - 02 5.9L Cummins ISB) Tuner- Big Hoss Diesel Tuner (connects to pump wire) - Manual (Page 19)

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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. 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 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 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 indicate 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°F before the
engine is shut down.
your Big Hoss Module is calibrated
to maintain a maximum EGT of
1300°F. You may experience brief
excursions slightly above 1300°F under
acceleration. This is normal and EGT
should return to at or below 1300°
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.
If you feel that your Big Hoss Module
is not functioning properly, some
diagnostics can be performed.
Remove the Big Hoss Module from
its mounting location while keeping
all three connectors plugged in.
Observe the two LED’s mounted on
the programming port. The upper
left LED will indicate red when the
key is on. Once the engine is started
and idling, the red LED will go out
and the upper right LED will indicate
green. As load increases, the red LED
will progressively grow brighter as
fuel delivery is increased. If LED’s do
not indicate as suggested check all
connections to ensure that they are
proper.
-END, SECTION 3-
Section 3
CHECKING ENGINE PERFORMANCE