Banks Power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Speed Control- Banks Brake, Exhaust Brake System, Late '04-07 For use w_Manual Transmissions - Manual (Page 37)

97232 v.3.0
37
Section 9
Troubleshooting
If the Banks Brake does not pass
the FUNCTIONAL TESTING or ceases
to function properly, re-check all
the connections per the installation
instructions. Make sure that electrical
connections are tight and secure and
that the vacuum hoses are not kinked or
pinched.
If the Brake Enable Switch does not light
up within a few seconds, the following
diagnostic procedures can be carried out
to identify and correct the problem:
1.
With key on and the engine off,
turn the Brake Enable Switch on. If the
Switch does not light up, make sure
the Switch is connected correctly and
check the fuse.
2.
If the Enable Switch is lit solidly,
then inspect all the mechanical
components in the System. With the
engine cold and the hood up, have
someone start the engine. Make sure
the transmission is in neutral and
the parking brake is set. Watch the
actuator arm on the Brake housing.
It should move forward (closed).
Whenever the accelerator pedal
is pressed, the Brake should open
(actuator arm should move back
towards the firewall).
Checking the performance of the
vacuum pump:
WARNING: The Pump must never
be run open to the atmosphere,
as this will damage the Pump
diaphragm. The Pump must
always be connected to the
Vacuum Solenoid or it’s vacuum
nipple must be plugged. The
warranty on the Pump will be
voided if the Pump is allowed to
run open to the atmosphere.
With the vehicle safely in park and
the engine off, disconnect the 5 ⁄
16
”
hose from the Vacuum Solenoid (Port
1, Figure 8). Connect this hose to a
vacuum gauge while keeping the other
end connected to the Vacuum Pump.
Make sure the truck is in park and
start the engine. Measure the vacuum
at 1900 RPM. The Pump should
generate a minimum of 10 psi (20.4”
Hg) of vacuum. Replace the Vacuum
pump if necessary. After testing, turn
off the engine and disconnect the
vacuum gauge and reconnect the
5 ⁄
16
” hose to Port 1 on the Vacuum
Solenoid.
Checking the operation of the
Exhaust Brake:
With the vehicle safely in gear, the
parking brake set, and the engine off,
disconnect the 7 ⁄
32
” hose connection
(Port 2, Figure 8) from the Vacuum
Solenoid. Connect this hose to a
vacuum tester and keep the other
end of the 7 ⁄
32
” hose connected to the
Exhaust Brake Actuator. As vacuum
is generated with the tester, the
Actuator should retract and rotate
the lever arm off it’s stop (as seen
in Figure 7). The lever arm should
travel 81.5 degrees without binding
or sticking. After testing, disconnect
the vacuum tester and reconnect the
7 ⁄
32
” hose to Port 2 on the Vacuum
Solenoid.
If the Exhaust Brake is slow to open,
check the Vacuum Solenoid’s brass
filter. If it is dirty, clean or replace it.
Replacements can be purchased from
Gale Banks Engineering or may be
found at a hardware or automotive
store.
-eND SeCtIoN 9-