Owner`sManual

Owner`sManual
Owner’sManual
with Installation Instructions
Banks Six-Gun &
Banks SpeedBrake
®
®
For use with Banks iQ
& Compatible with PowerPDA
2008-2010 Ford Power Stroke
6.4L Turbo-Diesel
THIS MANUAL IS FOR USE WITH SYSTEMS 55464-55466, 63919
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
©2012 Gale Banks Engineering
5/14/12 PN 96827 v.6.0
Product available from Banks Power
for the 2008-2010 Ford 6.4L
Banks iQ® System
(P/N 61155)
- 5” touchscreen interface that can
control the Banks Diesel Tuner and/
or SpeedBrake on the fly.
- Interchangable gauge display, read
and clear codes, monitor engine
diagnostics, log data, time your
vehicles runs and much more.
Banks Monster® Exhaust System
(Single and Dual P/N 49780-49787)
- Increases exhaust flow, cuts
backpressure, lowers exhaust gas
temperatures (EGTs) and increases
power.
Banks Ram-Air® Intake System
(P/N 42185)
- Increases your airflow over stock.
- Adds power, improves fuel economy,
lowers EGTs and reduces smoke.
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96827 v.6.0
Banks Techni-Cooler® System
(P/N 25984)
- Provides increased air flow to the
engine by increasing air density for
more increased power, lower EGTs
and improved fuel economy.
Banks Brake®
(P/N 55469)
- Increases the stopping power of
your truck and extends the service
life of your brakes
Banks SpeedBrakeTM
(P/N 55464)
- Allows for controlled hill decent at
a user defined vehicle speed.
Banks Diesel Tuner
Six-Gun® (P/N 63907)
- Adds power safely to your vehicle
- Engine and transmission safeguards
- Change power levels on-the-fly
AutoMind® Programmer
(P/N 66100)
- Contains Banks tunes that boost
your vehicles HP, Torque and MPG.
- Displays a host of critical engine
functions
- Provides “service technician”
diagnostic capabilities
- Has upgradeable functionality, so it
will never be out of date
Six-Gun® Bundle
(P/N 46652-46655)
Contains:
- Monster Exhaust (single and dual)
- Ram-Air Intake
- Six-Gun Tuner w/ Banks iQ
Big Hoss® Bundle
(P/N 46656-46659)
Contains:
- Monster Exhaust (single and dual)
- Ram-Air Intake
- Six-Gun Tuner w/ Banks iQ
- Techni-Cooler
For More Information please call (888) 635-4565
or Visit us online @ www.bankspower.com
96827 v.6.0
3
THIS IS A HIGH PERFORMANCE
PRODUCT. USE AT YOUR OWN
RISK.
Do not use this product until
you have carefully read the
following agreement.
This sets forth the terms and
conditions for the use of this
product. The installation of
this product indicates that
the BUYER has read and
understands this agreement
and accepts its terms and
conditions.
Disclaimer of Liability
Gale Banks Engineering Inc., and its
distributors, employees, and dealers
(hereafter “SELLER”) shall in no way be
responsible for the product’s proper use
and service. The BUYER hereby waives
all liability claims.
The BUYER acknowledges that he/
she is not relying on the SELLER’s skill
or judgment to select or furnish goods
suitable for any particular purpose
and that there are no liabilities which
extended beyond the description
on the face hereof and the BUYER
hereby waives all remedies or liabilities,
expressed or implied, arising by law
or otherwise, (including without
any obligations of the SELLER with
respect to fitness, merchantability, and
consequential damages) whether or not
occasioned by the SELLER’s negligence.
The BUYER is responsible to fully
understand the capability and limitations
of his/her vehicle according to
manufacturer specifications and agrees
to hold the SELLER harmless from any
damage resulting from the failure to
adhere to such specifications.
The SELLER disclaims any warranty
and expressly disclaims any liability
for personal injury or damages. The
4
96827 v.6.0
BUYER acknowledges and agrees
that the disclaimer of any liability for
personal injury is a material term for
this agreement and the BUYER agrees
to indemnify the SELLER and to hold
the SELLER harmless from any claim
related to the item of the equipment
purchased. Under no circumstances will
the SELLER be liable for any damages
or expenses by reason of the use or sale
of any such equipment.
The BUYER is responsible to obey
all applicable federal, state, and
local laws, statutes, and ordinances
when operating his/her vehicle, and
the BUYER agrees to hold SELLER
harmless from any violation thereof.
The SELLER assumes no liability
regarding the improper installation
or misapplication of its products. It is
the installer’s responsibility to check
for proper installation and if in doubt,
contact the manufacturer.
The BUYER is solely responsible for all
warranty issues from the automotive
manufacturer.
Limitation of Warranty
Gale Banks Engineering Inc. (hereafter
“SELLER”), gives Limited Warranty as
to description, quality, merchantability,
fitness for any particular purpose,
productiveness, or any other matter of
SELLER’s product sold herewith. The
SELLER shall be in no way responsible
for the product’s open use and service
and the BUYER hereby waives all rights
except those expressly written herein.
This Warranty shall not be extended
or varied except by written instrument
signed by SELLER and BUYER.
Please see enclosed warranty
information card, or go to
www.bankspower.com/warranty,
for warranty information regarding
your product. All products that are in
question of Warranty must be returned
shipping prepaid to the SELLER and
must be accompanied by a dated proof
of purchase receipt. All Warranty claims
are subject to approval by Gale Banks
Engineering Inc.
Warning: Below 32oF (0oC)
or above 140oF (60oC), the
Banks iQ may be susceptible
to damage as a result of
extended direct exposure to
sunlight, heat or extreme cold.
It is highly recommended that
Banks iQ be removed from its
mounting location if the vehicle
will be subjected to high
concentrations of sunlight, heat
or cold for an extended period
of time. Gale Banks Engineering
is not responsible for damage
to Banks iQ resulting from
exposure conditions.
Under no circumstance shall the
SELLER be liable for any labor charged
or travel time incurred in diagnosis for
defects, removal, or reinstallation of this
product,or any other contingent expense.
In the event that the buyer
does not agree with this
agreement:
The buyer may promptly return
this product, in a new and
unused condition, with a dated
proof-of-purchase, to the placeof-purchase within thirty (30)
days from date-of-purchase for
a full refund, less shipping and/
or restocking fee.
Table of Contents
General Installation Practices . . . 7
Section 1 . . . . . . . . . . . . . . . . . . . . . . 8
Installation of Banks Six-Gun Wiring
Harness
Section 2 . . . . . . . . . . . . . . . . . . . . . 14
Installation of Optional Banks
SpeedBrake Wiring Harness
Section 3 . . . . . . . . . . . . . . . . . . . . . 20
Mounting and Connecting the Banks iQ
Section 4 . . . . . . . . . . . . . . . . . . . . . 24
Automatic Transmission Learning
Section 5 . . . . . . . . . . . . . . . . . . . . . 25
Checking Engine Performance
Section 6 . . . . . . . . . . . . . . . . . . . . . 26
Troubleshooting
Section 7 . . . . . . . . . . . . . . . . . . . . . 32
Clearing Learned Information
Section 8 . . . . . . . . . . . . . . . . . . . . . 32
Removal of the Six-Gun Diesel Tuner
Section 9 . . . . . . . . . . . . . . . . . . . . . 32
Updating Banks iQ/PowerPDA and Banks
Six-Gun/Brake Software
Section 10 . . . . . . . . . . . . . . . . . . . . 34
Placement of the Banks Power Decals
For detailed operation of the
Banks Speedbrake, see the Banks
iQ Owner’s Manual
The installation of this product
indicates that the buyer has
read and understands this
agreement and accepts its
terms and conditions.
Under no circumstances will the SELLER
be liable for any damage or expenses
incurred by reason of the use or sale of
any such equipment.
96827 v.6.0
5
Dear Customer,
If you have any questions
concerning the installation
of your Banks Six-Gun Diesel
Tuner, please call our Technical
Service Hotline at (888) 8392700 between 7:00am and
5:00pm (PST). If you have any
questions relating to shipping
or billing, please contact our
Customer Service Department
at (888) 839-5600.
Thank you.
The Banks Six-Gun Diesel Tuner has six
power levels that you can adjust with
the Banks iQ Dashboard PC.
Banks iQ is a versatile device that gives
you total control of your Banks Six-Gun
Tuner. With a touch of your finger on
the bright, full-color LCD display, you
can adjust power levels on-the-fly,
customize the gauges you view, tune
numerous performance parameters, set
system warnings and alerts, see vital
engine functions at a glance, and more.
Evaluate your changes by running 0-60,
¼ and 1/8 mile performance tests. You
can even scan, read and clear OBDII
diagnostic trouble codes.
Banks iQ doesn’t stop there. It’s a
true in-car PC packed full of extra
functions. Listen to your favorite tunes,
watch videos, play games, review
Windows® Office documents, and more.
Expandable and upgradeable, it comes
fitted with a rechargeable battery and
includes accessory cords. You’ll quickly
discover Banks iQ is the device you’ll
use every day, both inside and outside
your car.
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96827 v.6.0
To prevent damage to the factory
transmission, Banks recommends that
both automatic and manual transmission
vehicles do not exceed Level 4 while
the vehicle is experiencing load (towing,
climbing a steep grade, carrying a load,
etc.).
To use the higher levels of the Six-Gun
Diesel Tuner while towing or climbing,
airflow improvements must be made
to lower the exhaust gas temperature
(EGT) entering the turbo. The EGT should
not exceed 1400º F for more than a few
seconds. Elevated EGT can damage the
turbocharger and the engine.
Attention! Before proceeding
with these instructions, please
carefully read the DISCLAIMER
OF LIABILITY and LIMITATION OF
WARRANTY statement located on
pages 2-3 of this manual.
Tools Required:
• Inch and metric sockets
• Inch and metric combination and
open-end wrenches
• Pliers
• Wire cutters
• Scissors
• Drill motor
• 1⁄ 8” drill bit
• 13⁄ 32” drill bit
General Installation Practices
1. Banks recommends either a
Banks iQ or a Pyrometer (EGT) gauge
and Boost gauge be installed with
the Six-Gun Diesel Tuner to help
monitor performance and exhaust gas
temperature of the vehicle (see part
numbers below). To further increase
engine life by lower EGT’s, Banks also
recommends installing a Monster
Exhaust® system.
2. Before starting work, familiarize
yourself with the installation procedure
by reading all of the instructions.
3. The exploded views provide only
general guidance. Refer to each step
and section diagram in this manual for
proper instruction.
4. Throughout this manual, the left side
of the vehicle refers to the driver side,
and the right side to the passenger side.
5. Disconnect the negative (ground)
cable from the battery (or batteries, if
there are two) before beginning work.
6. Route and tie wires and hoses a
minimum of 6” away from exhaust
heat, moving parts and sharp
edges. Clearance of 8” or more is
recommended where possible.
Follow the manufacturer’s safety
precautions. Take care to balance the
vehicle to prevent it from slipping or
falling. When using ramps, be sure the
front wheels are centered squarely on
the topsides. When raising the front of
the vehicle, put the transmission in park
(automatic) or reverse (manual), set
the parking brake, and block the rear
wheels. When raising the back of the
vehicle, be sure the vehicle is on level
ground and the front wheels are blocked
securely.
Caution: Do not use floor jacks to
support the vehicle while working
under it. Do not raise the vehicle
onto concrete blocks, masonry
or any other item not intended
specifically for this use.
8. During installation, keep the work
area clean. Do not allow anything to
be dropped into intake, exhaust, or
lubrication system components while
performing the installation, as foreign
objects will cause immediate engine
damage upon start-up.
9. Save this Owner’s Manual as a
reference for system maintenance and
service.
7. When raising the vehicle, support it
on properly weight-rated safety stands,
ramps or a commercial hoist.
Additional Equipment:
Gauge Assembly,
Boost and Pyro ...........................64507
96827 v.6.0
7
Section 1
Installation of Banks Six-Gun Wiring Harness
Figure 1: Six-Gun and supplied wiring harnesses
If you have previously installed a
Six-Gun and are adding the Banks
Brake, Skip to Section 2.
If you are installing the Banks SixGun for the first time, continue to
Step 1
Six-Gun Installation
1. Locate the Six-Gun Powertrain
Control Module (PCM) Harness. See
Figure 1. Place harness over the
driver side fuse box. Route the PCM
connectors from the driver side fuse
box along the rail on the rear of the
engine compartment to the passenger
side of the vehicle. See Figure 2.
2. Locate the Factory Powertrain
Control Module (PCM) on the
8
96827 v.6.0
passenger side firewall in the engine
compartment. See Figure 2.
3. Disconnect the left connector from
the PCM by opening the locking tab as
shown in Figure 3.
4. Insert the male connector on the
Six Gun Tuner PCM harness into the
female connector on the factory
harness. Insert the female connector
on the Six Gun Tuner PCM harness
onto the male connector on the
factory PCM. Lock the connection by
closing the locking tabs. Secure the
connectors behind the oil reservoir
and away from any heat source.
5. Secure the Six-Gun Tuner PCM
harness along the rail on the firewall
with the supplied cable ties.
Figure 2: Six-Gun Harness routing
Figure 3: PCM Location on Passenger side.
96827 v.6.0
9
Note: Do not connect the Six-Gun
PCM harness to the tuner. It will be
connected in step 17.
6. Locate the Six-Gun Turbo/In-cab
harness. Place the harness over the
driver side fuse box. Route the turbo
actuator connector on the Turbo/
in-cab harness along the rail on the
rear of the engine compartment to the
turbo.
7. Unplug the turbo actuator
connector shown in Figure 4. The
turbo actuator cable connector can
be unplugged by sliding the red safety
slide down, pressing the locking
button, and then pulling on the
connector.
8. Plug the female Six-Gun turbo
actuator connector into the male
factory turbo actuator connector.
Plug the female factory turbo actuator
connector into the male Six-Gun turbo
actuator connector.
9. Secure the Six-Gun turbo actuator
connector wires to the firewall rail
using the supplied zip ties. Secure the
wires away from any heat source.
WARNING: The use of Banks Brake
is for use with installed Six-Gun
Tuner Package.
10. Remove the bottom steering
column panel by pulling out to release
the retaining clip. See Figure 5.
Installing harness through firewall.
11. Locate the rubber grommet on the
driver’s side of the vehicle firewall. The
grommet is about 3” in diameter. Make
a 1” x 1” cross-shaped (X) incision in
the grommet. Be careful so you do not
cut the factory harness.
12. From inside the cab locate the
grommet on the firewall and make
another 1” x 1” cross-shaped (X)
incision on the grommet, opposite the
spot that was cut from the outside.
Figure 4: Turbo Actuator Connector
10
96827 v.6.0
Figure 5 Ford (08-09)
Figure 6: Rubber Grommet on driver side Fire wall
96827 v.6.0
11
Now, feed the Six-Gun In-Cab cable on
the Turbo/In-cab harness through the
incision made in the firewall grommet
and into the cab See Figure 6.
Note: Some thick putty may be used
to provide additional sealing around
the In-Cab cable and the grommet.
If also installing Banks Brake wait
until after Section 2, step 5 to use
putty.
Mounting The Six-Gun Diesel Tuner
13. If equipped, remove the vacuum
pump from its mounting location by
turning the thumb screw and lifting the
pump aside. See Figure 7.
14. Clean the area on top of the fuse
box cover.
NOTE: Make sure the entire mounting
surface is clean and free of dirt and
oil before mounting the Six-Gun Diesel
Tuner. Clean and dry as required using
a cloth damped in rubbing alcohol or
similar cleaning solution.
Figure 7
12
96827 v.6.0
15. Locate the two (2) dual-lock
fasteners in your kit. Peel the protective
backing off from one side of the hook
and loop interlocking fasteners and
attach to the recess area on the back of
the tuner module.
16. Peel the protective backing off
the other side of the hook and loop
interlocking fasteners on the back of
the tuner module and affix the tuner to
the top of the fuse box cover as shown
in Figure 8. Apply light pressure to the
Six-Gun Diesel Tuner module by hand
for 60 seconds to create a strong bond
between the fuse box and hook & loop
interlocking fasteners.
17. Connect the PCM and Turbo/
In-Cab harness connectors to the
correct Six-Gun module connection. The
connections are keyed differently so
make sure to connect the correct one
into the appropriate connection. See
Figure 8.
Figure 8 Mounting location of Six-Gun tuner to Fuse box, driver side.
18. If previously removed, reinstall
the Vacuum Pump in place and secure
with the factory thumb screw.
19. Go over all connections. Check all
connections under the hood and keep
wires away from heat sources when
possible.
END, SECTION 1-
96827 v.6.0
13
Section 2
Installation of Optional Banks SpeedBrake Wiring Harness
If you are not installing Optional
SpeedBrake Skip to Section 3.
If an existing Six-Gun Tuner has
been previously installed, verify that
the Tuner has the latest version
firmware. Check and compare to
the current version available on the
Banks website. Banks Brake may not
function properly if Six-Gun Tuner
firmware is not up to the current
version. If the Tuner is not to the
latest version refer to section 9.
Installing Banks Brake Wire Harness
1. From inside the engine
compartment, locate the factory
brake pressure sensor connector on
the brake master cylinder. The brake
pressure sensor will be the connector
farthest away from the firewall. See
Figure 9. Disconnect the factory brake
pressure sensor connector.
2. Locate the Brake Pressure Sensor
harness in your kit. See Figure 10.
Connect the female connector on the
Brake Pressure Sensor harness to the
Figure 9 Brake Pressure Sensor
14
96827 v.6.0
factory male connector. Connect the
male connector on the Brake Pressure
Sensor harness to the factory female
connector.
3. Route the 2-pin connector on
the Brake Pressure Sensor harness
following the six-gun in-cab cable
through the fire wall. Secure the wiring
harness with the supplied cable ties
away from any heat source or moving
parts.
4. From inside the vehicle, continue
to pull the cable through the firewall
until it is approximately 22” inside the
cab. Secure the cable to the lower
access panel area. Take precaution to
leave the three connectors accessible
for usage further in the installation
process.
5. From under the dash, pull the 2-pin
connector on the Brake Pressure
Sensor harness through the fire wall.
Note: Some thick putty may be used
to provide additional sealing around the
In-Cab cable and the grommet.
6. Locate the Banks Brake Wire
Harness and connect the 2-pin male
connector on the Brake Pressure
Sensor harness to the 2-pin connector
on the Banks Brake wire harness.
If you have previously installed a
PowerPDA or Banks iQ, continue to
Step 7.
If you have not previously installed a
PowerPDA or Banks iQ, skip to Step
10.
Removing a Previously installed
Banks OBD II Interface Cable
7. Disconnect Banks OBD II interface
cable from the vehicle OBD II
connector.
A. For PowerPDA: Disconnect the
RJ12 connector from the docking
station.
B. For Banks iQ: Disconnect the
RJ12 connector from the Banks iQ
Bridge Module.
8. Disconnect the 8-pin connector
from the OBD II interface cable from
the 8-pin connector on the Six-Gun incab cable.
9. Remove the OBD II interface cable
from the vehicle.
Figure 10: SpeedBrake and supplied wiring harnesses
96827 v.6.0
15
Installing Banks Brake Wire Harness
10. Connect the Banks Brake Wire
Harness OBD II connector to the
vehicle’s OBD II connector. Use a cable
tie, as shown in Figure 11 to secure
the Banks Brake Wire Harness to the
vehicle’s OBD II connector.
11. Connect the 8-pin connector from
the Banks Brake Wire Harness to the
8-pin connector on the Six-Gun In-Cab
Cable.
12. Locate the Foot Brake position
switch connector under the dash. See
Figure 12. Disconnect the foot brake
position switch connector.
13. Locate the Brake Position
Switch intercept connectors on the
Banks Brake Wire Harness. Connect
the female connector on the Brake
Position Switch intercept connectors
to the factory black brake position
Figure 11 OBDII Connector
16
96827 v.6.0
switch connector. Connect the male
connector on the Brake Position Switch
intercept Connectors to the factory
female brake position connector that
was disconnected.
14. From under the steering column,
loosen the screws that hold the
steering column panel covers in place.
15. Move the steering column down
to the lowest possible position to aid
in removal of the top steering column
panel. Remove the top steering column
panel. See Figure 13.
CAUTION: Be careful when
removing the top steering column
panel or damage may result.
16. Locate the tow haul connector
towards the top rear of the steering
column. See Figure 14.
17. Disconnect the tow haul
connector.
Figure 12 Brake Position Sensor location under dash
Figure 13 Remove top column panel cover
96827 v.6.0
17
18. Locate the tow haul intercept
connector on the Banks Brake Wire
harness. Route the Tow Haul intercept
connectors under the dash towards the
front of the vehicle and up to the top
of the steering column following the
factory harness to the factory tow haul
connector. Make sure the connectors
and wires are free of rotation from the
steering column. Connect the female
connector on the Tow Haul intercept
connectors to the factory male tow
haul connector. Connect the male
connector on the Tow Haul intercept
connectors to the factory female tow
haul connector. Secure the connectors
and wires with supplied cable ties.
19. Connect the Brake module 10-pin
connector on the Banks Brake wire
harness to the Brake module. The
connector will be the only one with a
label.
NOTE: Make sure the correct connection
is made to the Tuner and the Banks Brake
before proceeding.
20. Secure Brake Module under the
dash to any dash frame support or
main wiring harness using the supplied
cable ties. Use the cable tie support
loops on the side of the Brake Module
to securely fasten it under the dash.
See Figure 15.
NOTE: Make sure to mount the Brake
Module under the dash away from
moving parts or where it can obstruct
feet movement.
Figure 14 Tow Haul Connector on steering column, under main harness
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96827 v.6.0
21. Install the top steering column
panel back in place.
22. Reinstall the factory screws to
fasten the steering column plans back
together.
WARNING: Take care to keep any
cables away from the pedals
or where they could become
tangled.
-END, SECTION 2-
23. Go over all connections. Secure
the wire harness with the supplied ties
under the dash.
Figure 15 Banks Brake Module mounting location
96827 v.6.0
19
Section 3
Mounting and Connecting the Banks iQ
If installing a Banks SpeedBrake with
a PowerPDA. Proceed to step 7.
WARNING: Below 32oF (0oC) or
above 140oF (60oC), the Banks iQ
may be susceptible to damage as a
result of extended direct exposure
to sunlight, heat or extreme
cold. It is highly recommended
that the Banks iQ be removed
from its mounting location if the
vehicle will be subjected to high
concentrations of sunlight, heat
or cold for an extended period of
time. Gale Banks Engineering is not
responsible for damage to Banks iQ
resulting from exposure conditions.
CAUTION: Do not use force
when working on plastic parts.
Permanent damage to the part
might result.
1. Locate the Window Mount
Assembly in your kit.
2. Assemble the Banks iQ docking
station to the Universal mount by
inserting and sliding the Universal
mount tab into the docking station
Figure 16
20
groove. Hand tighten the nut behind
the docking station to hold the docking
station in place.
3. Attach the window mount to your
Banks iQ. See Figure 16. Align and
place the two (2) lower tabs on the
window mount to the corresponding
slots on the bottom of Banks iQ first
then snap the top of Banks iQ into
place.
Note: There may be a snug fit when
installing the Banks iQ into the window
mount. Take care not to force this
process.
4. Find a suitable place on the
windshield for ease of access and
viewing of Banks iQ. Use location
shown in Figure 17 as a reference
for mounting Banks iQ in your
vehicle. Loosen the knob and move
the swivel suction plate to achieve
desired viewing angle of the Banks
iQ screen. Do a test fit and note the
angle necessary to achieve the correct
viewing angle.
Attaching Banks iQ to window mount
96827 v.6.0
5. Make sure the suction cup and the
mounting area on the windshield are
clean and dry. With the suction lever
in the up position, ensure the suction
cup is flat against the windshield, and
then push the suction lever down to
secure in place.
6. Next, remove and set the side dash
access panel aside.
If installing a Banks SpeedBrake use
step 7 and skip steps 8-10.
If not installing SpeedBrake, use
steps 8-10 and skip step 7.
7. RJ Connector with SpeedBrake
Banks iQ: Locate Banks iQ Bridge
Module and connect the RJ12 connector
from the Banks SpeedBrake wire Harness
into the Bridge Module. See Figure 20.
PowerPDA: Connect the RJ12
connector from the Banks SpeedBrake
wire Harness into the leftmost receptacle
on the bottom of the Docking Station.
For Banks SpeedBrake with a
PowerPDA. Skip steps 8-12.
8. RJ Connector without SpeedBrake
Locate the Banks OBD II Interface
Cable in your kit. This cable has
three connection points. Connect
the RED OBD II connector on the
Banks interface cable to the vehicle
OBD II connector. Use a cable tie as
shown in Figure 18 to secure the
Banks interface cable to the vehicle
OBD II connector. Next, connect the
6-pin connector on the Banks OBD II
interface cable to the 6-pin connector
on the Six-Gun Tuner harness.
9. Locate the RJ12 Cable (similar to
telephone connector) on your Banks
OBDII interface cable. See Figure 19.
10. Locate Banks iQ Bridge Module and
connect the RJ12 connector into the
Bridge Module. See Figure 20.
11. Route the Banks iQ USB interface
cable from the Banks iQ Bridge Module
under the dash and out through the
fuse access panel opening. The cable
can be slid under the door frame’s seal
and run up to the top of the dash. Pull
enough cable to reach the Banks iQ
Figure 17 Suggested Mounting location for Banks iQ
96827 v.6.0
21
Figure 18 OBD II connection
Figure 19 Banks iQ System
22
96827 v.6.0
Figure 20 Banks Bridge Module
and connect it to the USB receptacle
on the left side of Banks iQ. See
Figure 16. Snap the fuse access panel
back in place making sure not to pinch
the wire.
WARNING: THE CHARGING CABLE
CONNECTED TO THE BANKS iQ IS
DESIGNED TO SUPPLY A CONSTANT
LOW-VOLTAGE POWER SOURCE
(+5VDC) TO THE BANKS iQ AND IS
“LIVE” AS LONG AS THE SYSTEM’S
OBD II INTERFACE CABLE OR BANKS
WIRING HARNESS IS COMPLETELY
INSTALLED AND THE USB CABLE
CONNECTOR IS PLUGGED INTO
BANKS iQ. ALTHOUGH THIS
CHARGING CABLE IS SHORT AND
ITS CIRCUITRY IS FUSE-PROTECTED,
THE USER IS EXPECTED TO TAKE
APPROPRIATE MEASURES TO
PREVENT SMALL CHILDREN AND/
OR PETS FROM CONTACT WITH ANY
PART OF THIS SYSTEM.
12. Secure Banks iQ Bridge Module
under the dash to any dash frame
support using the supplied cable ties.
Use the cable tie support loops on the
side of the Bridge Module to securely
fasten it under the dash.
13. Route all wiring away from any
pedals or other moving components.
Using the cable ties supplied, secure the
wiring under the dash.
14. Reinstall the lower knee panel
back in place with the factory
hardware. Tuck any excess cable
behind it for a clean appearance.
-END, SECTION 3-
96827 v.6.0
23
Section 4
Automatic Transmission Learning (for six-gun only)
The 6.4L Ford Trucks equipped with
the TorqShift™ 5-speed automatic
overdrive transmission use an adaptive
shift control logic. This will require
the transmission to learn how to cope
with the additional power created by
the Banks Power products before it
will shift properly. Additionally, the
Banks Six-Gun Diesel Tuner will require
a short learning curve to characterize
the transmission in order to optimize
fueling during gear change events. The
following sequence must be followed
to allow for collaborative learning
between the Banks Six-Gun and the
transmission’s control system. Failure
to follow the sequence can result in
damage to the transmission.
Perform the following sequence
at a location where it is safe to
accelerate to 60 mph without
exceeding the posted speed limit.
1. Start the truck and allow the
engine to reach normal operating
temperature.
2. Set the Banks IQ to power level 2.
3. Accelerate with the pedal to the
floor, from a standing start to 60 mph.
Repeat three (3) times.
4. Cruise at 30 mph, then press the
accelerator to the floor to cause the
transmission to downshift. Continue
accelerating to 60 mph.
5. Repeat steps (2) and (3) for the
next power setting.
6. Continue to increase the power
setting and drive cycle until the desired
power setting is achieved.
24
96827 v.6.0
The TorqShift™ 5-speed automatic
transmission will continually adapt
to the power output of the engine to
optimize shift quality. This will result
in the transmission un-learning how to
cope with the higher power settings
of the Six-Gun Diesel Tuner, if the
Six-Gun Diesel Tuner is returned to
a lower power setting. The rate that
the transmission un-learns how to
cope with the higher power levels,
when switching to a lower power
level, depends on the driving cycle.
The transmission will quickly adapt
to the power setting if the driving
cycle includes regular gear changes
at high loads. The transmission
learning procedure will need
to be repeated when switching
back to the higher power settings
once the transmission adapts to
the lower power settings. It will
be apparent when the transmission
adapts to the lower settings by
monitoring the feel of the gearshift.
Gear changes will be noticeably harder
when initially switching from a higher
to lower power setting. This will soften
as the transmission adapts to the new
setting.
For example: If the transmission has
adapted to level 3 and it is desired to
go to level 6, the transmission learning
procedure can start at level 3.
IF TRANSMISSION SLIP IS DETECTED
DURING THE TRANSMISSION LEARN
PROCESS, REDUCE THE POWER
LEVEL BY ONE, AND START OVER AT
STEP 3.
-END, SECTION 4-
Section 5
Checking Engine Performance
The Six-Gun Diesel Tuner requires the
engine coolant temperature (ECT) to
be above 110º before it will add fuel.
If the optional Banks iQ or DynaFact®
gauges are installed, observe the
operation of the boost and pyrometer
(EGT) gauge values 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 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 Banks iQ or EGT 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.
To avoid heat damage to
various engine components it is
recommended that the exhaust gases
cool below 400º before the engine is
shut down. Your Six-Gun Diesel Tuner
is calibrated to maintain a maximum
EGT of 1350°F. You may experience
brief excursions slightly above 1350°F
under acceleration. This is normal and
EGT should return to 1350°F 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.
-END, SECTION 5-
96827 v.6.0
25
Section 6
Troubleshooting
If a Tuner has been previously
installed, verify that the Tuner has
the latest version firmware. Check
your version to the current version
available on the Banks website.
SpeedBrake may not function
properly if Tuner/Brake firmware is
not up to the current version.
For PowerPDA, use PowerPDA
manual for TroubleShooting
instructions.
Six-Gun & Brake Troubleshooting
Using The Banks iQ
Check the Banks iQ’s Status indicator
for the “OK” icon on the upper left
corner of the iQ screen. Any Tuner fault
will be indicated by the “Banks Engine”
icon (see Figure 21) and its cause can
be investigated by running a ‘Tuner
Diagnostic’ from the Diagnostic menu.
Banks Engine
Icon
1. In the Environment select menu
press on the ‘Diagnostics’ button. See
Figure 22.
96827 v.6.0
the ‘Tuner Diagnostics’ button to run a
tuner diagnostics. See Figure 23.
3. The ‘Self Diagnostic’ screen displays
a log of diagnostic events related to
the Power Tuner. The ‘Logged Events’
list takes a moment to update each
time this screen is opened. Once
the list is updated, the most current
event will appear at the bottom of
the list. Each event has an associated
timestamp and description, which will
be displayed below the list when that
event is highlighted. Each key cycle
of the vehicle produces a minimum
of two logged events. See Figure 24.
Table 1 lists the common diagnostic
codes and the suggested course of
action for each.
4. Use the arrow buttons to scroll
through the recorded events
5. Touch the Banks iQ icon on the
Figure 21
26
2. In the Diagnostics menu press on
lower left of the screen to return to the
environment screen or the return icon
to return to the Diagnostics menu.
6. A pop-up “Log-File” screen will
appear asking you if you want to erase
the contents of the log. Press ‘No’ to
keep the contents on Log-file or ‘Yes’,
to erase the Log-files.
Figure 22
Figure 23
Figure 24
96827 v.6.0
27
Six-Gun & Brake Troubleshooting
(Using Tuner LEDs).
If you feel that your Brake and/or SixGun Diesel Tuner are not functioning
properly, some diagnostics can be
performed. Your Brake and Six-Gun
Diesel Tuner are equipped with
diagnostic features that will detect
and display certain errors. Remove the
Brake and Six-Gun Diesel Tuner from
there mounting locations while keeping
all connectors plugged in. Turn the
vehicle key to the ON position. Observe
the two LEDs mounted on the Tuner.
• A steady GREEN LED will illuminate
If all wire connections are correct,
the engine is running and the engine
coolant temperature is within its
normal operating range.
• The GREEN LED will flash if all wire
connections are correct, the engine
is running, but the engine coolant
temperature is not within its normal
operating range. The GREEN LED will
stop flashing once the engine coolant
temperature is with normal operating
range. Power will not be added if the
coolant temperature is not within its
normal range (not to be confused with
Speed-Loader flash on power up).
• None of the LEDs will illuminate if the
fuse on the Six-Gun wiring harness is
blown or the power supply hook-up is
not properly connected. If the power
connection and fuses are okay, contact
Banks Technical Service.
• The RED LED will flash if a connection
is incorrect or if there is a problem
with the system, when the engine
is running. The RED LED will flash in
28
96827 v.6.0
sequence to identify a particular fault
code. A Six-Gun Diesel Tuner’s fault
code is comprised of 2 digits. Each
code is expressed in a sequence of 2
sets of the flashing RED LED separated
by a brief flashing of the GREEN LED.
Each set of a number of RED LED
flashes represents a digit. A longer
flashing of the GREEN LED separates
the sequences. The LEDs will continue
to flash to display all the errors, and
then repeat.
Table 1 lists the Six-Gun Tuner fault
codes.
Table 2 lists the Banks Brake fault
codes.
For example, if a faulty thermocouple
is detected (code 2,3) by the SixGun Diesel Tuner, the following RED
and GREEN LED flashing sequence is
observed when the key is ON:
(1) Two times flashing RED LED
(2) One time quick flashing GREEN LED
(3) Three times flashing RED LED
(4) One time longer flashing GREEN
LED
The above flashing sequence will
repeat continuously. When the problem
is corrected, the fault code will be
eliminated and replaced with a steady
Green LED. Note: If multiple codes are
set, they will be displayed in a series
separated by the longer flashing GREEN
LED. When reading codes, make sure
to watch the entire series until you see
the first code repeat.
-END, SECTION 6-
Table 1: Banks Six-Gun Fault Codes
Code
Event
Course of Action
1,1
Fuel Rail Pressure
(FRP) Input Voltage
Out of Range.
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
1,2
Manifold Absolute
Pressure (MAP)
Input Voltage Out
of Range.
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
1,3
Six-Gun Switch
Input Value Out of
Range.
Turn ignition OFF and make sure either Banks IQ or Six-Gun
switch is connected to Six-Gun tuner. If Six-Gun switch is
connected (no Banks IQ), check 2-pin connection on tuner’s
in-cab cable. Turn ignition back ON and re-check for presence
of code.
1,4
Exhaust Back
Pressure (EBP)
Input Voltage Out
of Range.
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
2,1
Fuel Rail Pressure
(FRP) Output
Voltage Out of
Range.
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
2,2
Turn ignition OFF and check the 96-pin male and female PCM
Manifold Absolute
connectors. Turn ignition back ON and re-check for presence
Pressure (MAP)
of code. If code does not re-appear at key ON, start engine
Output Voltage Out
and check for presence of code both at engine idle and under
of Range.
varying driving conditions.
2,3
Mass Air Flow
(MAF) Signal Fault.
2,4
Turn ignition OFF and check the 96-pin male and female PCM
Exhaust Back
connectors. Turn ignition back ON and re-check for presence
Pressure (EBP)
of code. If code does not re-appear at key ON, start engine
Output Voltage Out
and check for presence of code both at engine idle and under
of Range.
varying driving conditions.
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
If code/problem persists, note conditions when code appears and call Gale Banks Engineering Tech
Support.
96827 v.6.0
29
Table 1: Banks Six-Gun Fault Codes (Continued)
Code
Event
Course of Action
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
3,1
Engine Position
Sensor Fault.
3,2
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
Internal Module
of code. If code does not re-appear at key ON, start engine
Malfunction or
Intermittent Power. and check for presence of code both at engine idle and under
varying driving conditions.
3,3
EGR Valve Position
(EGRP) Input
Voltage Out of
Range.
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
3,4
OBDII CAN
communication
error
Turn ignition OFF and check the 4-pin male and female turbo
actuator connectors. Turn ignition back ON and re-check for
presence of code. If code does not re-appear at key ON, start
engine and check for presence of code both at engine idle and
under varying driving conditions.
4,1
EGR Valve Position
(EGRP) Output
Voltage Out of
Range.
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under
varying driving conditions.
4,2
Transmission
Slippage Detected.
Transmission is slipping excessively. Code will automatically
clear once transmission stops slipping (repaired).
4,3
Turn ignition OFF and check the 96-pin male and female PCM
connectors. Turn ignition back ON and re-check for presence
Internal Module
of code. If code does not re-appear at key ON, start engine
Malfunction or
Intermittent Power. and check for presence of code both at engine idle and under
varying driving conditions.
4,4
Internal Memory
Malfunction.
Turn ignition OFF. Turn ignition back ON and re-check for
presence of code. If code does not re-appear at key ON, start
engine and check for presence of code both at engine idle and
under varying driving conditions.
If code/problem persists, note conditions when code appears and call Gale Banks Engineering Tech
Support.
30
96827 v.6.0
Table 2: Banks Brake Fault Codes
Code
Event
Course of Action
1, 1
Insufficient power
supply to brake
module
Turn Ignition OFF and check connection at fuse tap, 10-pin connection to
module and 8-pin connection to Tuner. Turn ignition back ON and re-check
for presence of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under varying
driving conditions.
1, 2
Brake signal
malfunction while
brake is on
Turn Ignition OFF and check connections at 5-pin male and female brake
pedal connector. Turn ignition back ON and re-check for presence of code.
If code does not re-appear at key ON, start engine and check for presence
of code both at engine idle and under varying driving conditions.
1, 3
Insufficient voltage to
tow-haul switch
Turn Ignition OFF and check connections at 3-pin male and female towhaul switch. Turn ignition back ON and re-check for presence of code. If
code does not re-appear at key ON, start engine and check for presence
of code both at engine idle and under varying driving conditions.
1, 4
Brake Signal
malfunction while
brake is off.
Turn Ignition OFF and check connections at 5-pin male and female brake
pedal connector. Turn ignition back ON and re-check for presence of code.
If code does not re-appear at key ON, start engine and check for presence
of code both at engine idle and under varying driving conditions.
2, 1
No response to
generated OBD ISO
messages
Turn Ignition OFF and check connections at OBD II connection. Turn
ignition back ON and re-check for presence of code. If code does not
re-appear at key ON, start engine and check for presence of code both at
engine idle and under varying driving conditions.
2, 2
Turn Ignition OFF and check connections at 2-pin male and female brake
pressure sensor intercept connector and 2-pin in-cab cable connector.
Brake pressure switch
Turn ignition back ON and re-check for presence of code. If code does not
signal malfunction
re-appear at key ON, start engine and check for presence of code both at
engine idle and under varying driving conditions.
3, 1
Rear wheel slip during Module has detected rear wheel slipping. Code will automatically clear 30
braking
seconds after traction regained.
3, 2
Power Up Error or
Internal Module
Malfunction
Turn Ignition OFF and check connection at fuse tap, 10-pin connection to
module and 8-pin connection to Tuner. Turn ignition back ON and re-check
for presence of code. If code does not re-appear at key ON, start engine
and check for presence of code both at engine idle and under varying
driving conditions.
3, 3
Internal Module
Malfunction
Turn Ignition OFF and check connection at fuse tap, 10-pin connection to
module and 8-pin connection to Tuner. Turn ignition back ON and re-check
for presence of code. If code does not re-appear at key ON, start engine and
check for presence of code both at engine idle and under varying driving
conditions.
4, 3
Exhaust Back Pressure
(EBP) Input Voltage Out
of Range
Turn Ignition OFF and check the 96-pin male and female PCM connectors.
Turn ignition back ON and re-check for presence of code. If code does not
re-appear at key ON, start engine and check for presence of code both at
engine idle and under varying driving conditions.
4, 4
Communication failure
to brake module.
Turn Ignition OFF and check connections at 10-pin brake module, 8-pin Tuner,
and OBD II connector. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine and check for
presence of code both at engine idle and under varying driving conditions.
5, 1
Internal Module
Malfunction
Turn Ignition OFF and check connections at 10-pin brake module, 8-pin Tuner,
and OBD II connector. Turn ignition back ON and re-check for presence
of code. If code does not re-appear at key ON, start engine and check for
presence of code both at engine idle and under varying driving conditions.
96827 v.6.0
31
Section 7
Clearing Learned Information
If the Six-Gun Diesel Tuner has been
moved to a different vehicle, or you are
instructed to do so by Banks Technical
Staff, it is possible to reset all of the
parameters that the Six-Gun has ‘learned’
- presence of an EGT thermocouple or
Speed-Loader, etc.
CAUTION: The following procedures
can only be carried out with the
engine OFF!
1. Turn the vehicle key to ON but DO
NOT start the engine.
2. Fully depress the throttle pedal and
then release it completely. Repeat 5
times. The GREEN LED will flash when
this is completed successfully.
3. Turn the key OFF. Wait 30 seconds, or
until the GREEN LED goes off and stays
off. Turn the key back to the ON position
but DO NOT start the engine.
4. Fully depress the throttle pedal and
then release it completely. Repeat 5
times.
-end, section 7-
Section 8
Removal of the Six-Gun Diesel Tuner
If the Six-Gun Diesel Tuner should ever
need to be removed from the vehicle,
perform the following:
4. Disconnect the 3 small connectors
Note: The ignition must remain in the
OFF position throughout the removal
process.
5. Remove the Six-Gun Diesel Tuner,
1. Disconnect the Six-Gun’s PCM
connector from the left connection on
the PCM.
2. Re-connect the vehicle’s PCM
connector back into the left connection
on the PCM.
3. Disconnect the Six-Gun’s turbo
actuator connector from the vehicles
turbo actuator connection and harness.
Re-connect the vehicle’s turbo actuator
connector.
on the ‘In-Cab Cable’ and gently pull the
cable back through the firewall.
PCM harness and Turbo/In-cab harness
from the vehicle.
Failure to follow the above instructions
when removing the module will result in
a “Check Engine” light on the dash and a
Diagnostic Trouble Code being stored in
the factory computer, in addition to the
engine not running.
Note: Banks Brake will not function
without the Six-Gun Tuner installed.
-END, SECTION 8-
Section 9
Updating Banks IQ/PowerPDA & Banks Six-Gun/Brake
Software
If a Tuner has been previously
installed, verify that the Tuner has
the latest version firmware. Check
your version to the current version
available on the Banks website.
SpeedBrake may not function
properly if Tuner/Brake firmware is
not up to the current version.
To update your PowerPDA go to
www.bankspower.com/downloads and
follow the updating instructions.
32
96827 v.6.0
System Info
To view your System Information,
press the ‘System Info’ button in the
‘Adjustments’ menu (Refer to your
Banks iQ Owner’s Manual to open
the ‘Adjustment’ menu). See Figure
25. Use this info to verify that you
are downloading the correct update/
upgrade version for your Banks iQ. Press
the ‘Return ‘ icon to go back to the
‘Adjustment’ menu.
To update Banks Six-Gun/Brake
1. Go to www.bankspower.com/
downloads and check for the Banks
Power Tuner or Brake updates.
2. Download them onto your Micro-SD
card (sold separately) and insert it into
the port on your Banks iQ.
3. Press the ‘Update Six-Gun/
5. Press ‘Update Six-Gun/Brake’ to
download updates into Banks iQ.
NOTE: A warning message will appear if
the chosen file is the same or older then
the file currently in use.
To update Banks iQ Software
1. Plug Banks iQ into your PC using the
supplied USB cable.
SpeedBrake’ button in the ‘Adjustment’
menu.
2. Go to www.bankspower.com/
and available Brake updates will appear
in the window. See Figure 26. Highlight
the appropriate file name from the
available list.
3. Follow the on-screen directions on
4. Press the ’Check For Updates’ button
Figure 25
downloads and click on ‘Check for
Updates’.
your PC to update your Bank iQ with the
latest software updates.
-END, SECTION 9-
Figure 26
96827 v.6.0
33
Section 10
Placement of the Banks Power Decals
Figure 27: Placement of the Banks decals
34
96827 v.6.0
Notes
96827 v.6.0
35
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
Customer Support: (888) 839-5600
Installation Support: (888) 839-2700
bankspower.com
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