97238-04-05 SpeedBrake Chevy-v2.indd

97238-04-05 SpeedBrake Chevy-v2.indd
InstallationManual
Banks SpeedBrake
For use with Banks iQ
2004-2005 Chevy/GMC 6.6L (LLY)
Turbo-Diesel Pickup
THIS MANUAL IS FOR USE WITH KITS 55437, 55440
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
bankspower.com
©2010 Gale Banks Engineering
04/08/10 PN 97238 v.2.0
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
judgement 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.
2
97238 v.2.0
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
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 the 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.
The Warranty is Limited to two (2) years
from the date of sale and is limited
solely to the Gale Banks Engineering
parts contained within the products kit.
Parts or devises outside the products
kit, are not covered under Gale Banks
Engineering warranty. 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 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.
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.
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.
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-ofpurchase, to the place-of-purchase
within thirty (30) days from dateof-purchase for a full refund.
The installation of this product
indicates that the buyer has read
and understands this agreement
and accepts its terms and
conditions.
Table of Contents
General Installation . . . . . . . . . . . . 4
Practices
Section 1 . . . . . . . . . . . . . . . . . . . . . . 5
Installation of Banks SpeedBrake Wire
Harness
Section 2 . . . . . . . . . . . . . . . . . . . . . 11
Mounting The Docking Station and
Connecting The Banks iQ
Section 3 . . . . . . . . . . . . . . . . . . . . . 16
Updating Banks iQ & Banks SpeedBrake
Software
Section 4 . . . . . . . . . . . . . . . . . . . . . 17
Troubleshooting
Section 5 . . . . . . . . . . . . . . . . . . . . . 20
Placement of the Banks Power Decal
97238 v.2.0
3
General Installation Practices
Dear Customer,
Your new Banks SpeedBrake
is a uniquely designed braking
system with electronic controls,
designed to achieve the optimum
level of braking from your
vehicle’s engine.
If you have any questions
concerning the installation
of your Banks SpeedBrake
System, please call our
Technical Service Hotline
at (888) 839-2700 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.
1. Before starting work, familiarize
yourself with the installation procedure
by reading all of the instructions.
2. The exploded views provide only
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.
7. 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.
general guidance. Refer to each step
and section diagram in this manual for
proper instruction.
8. Save this Installation Manual as a
3. Throughout this manual, the
TOOLS REQUIRED:
left side of the vehicle refers to the
driver side, and the right side to the
passenger side.
4. Disconnect the negative (ground)
cable from the battery (or batteries, if
there are two) before beginning work.
5. Route and tie wires and hoses a
reference for system maintenance and
service.
• 1⁄ 2”
and 3⁄ 8” drive ratchets with inch
and metric sockets and 1⁄ 2” and
3⁄ 8” drive extension
• Inch and metric combination or
open-end wrenches
• Standard & Phillips screwdriver
minimum of 6” away from exhaust
heat, moving parts and sharp
edges. Clearance of 8” or more is
recommended where possible.
• Clean shop towels or rags
6. When raising the vehicle, support
• Utility knife
it on properly weight-rated safety
stands, ramps or a commercial hoist.
4
97238 v.2.0
• Pliers
• Needle nose pliers
• Inch-pound and foot-pound torque
ratchets
Section 1
Installation of Banks SpeedBrake wire harness
Figure 1 Banks SpeedBrake and supplied wiring harness
97238 v.2.0
5
1. Disconnect the negative (ground)
cable from the battery (or batteries, if
there are two) before beginning work.
Secure the cables so that they do not
come in contact with the battery posts
during the installation.
2. Locate the Banks SpeedBrake wire
Note: install the fuse tap in the
Body Control Module (TBC IGN1) spot
closest to the firewall. This is the “hot”
side of the circuit. See Figure 3.
7. Locate the fuse connector wire on
the SpeedBrake wiring harness and
connect it to the mini-blade fuse tap.
harness in your kit. Start By placing
the wire harness near the under hood
fuse box.
8. Replace the fuse box cover and
3. Install the ground ring terminal on
9.Locate the black wire harness
the SpeedBrake wire harness onto the
bolt on the fire wall. See Figure 2.
make sure not to pinch the fuse
connector wire.
4. Remove the fuse box cover to
locking connectors between the brake
fluid reservoir and the air conditioning
compressor. Lift the gray connector
locks and disconnect the 24-pin
connector pair. See Figure 2.
5. Locate mini-fuse for the Body
10.Insert the male 24 pin connector
access the fuses on the electrical
center and set aside.
Control Module (TBC IGN1) and remove
it. See Figure 3.
6. Install the mini-blade fuse tap onto
the removed mini fuse as shown in
Figure 4. Re-install the mini fuse with
the attached blade tap into the fuse
box.
on the SpeedBrake harness into the
female 24-pin connector on the factory
harness. Insert the female 24-pin
connector on the SpeedBrake harness
onto the male 24-pin connector of the
factory harness.
Figure 2 Grounding location & 24-Pin Intercepting Connectors
6
97238 v.2.0
Figure 3 Electrical Center Fuse Tap Location
Figure 4 Fuse Tap Installation
97238 v.2.0
7
Note: If vehicle is equipped with a
Banks Tuner, disconnect the 24-pin
connection between the factory 24-pin
connectors and the Banks Tuner
24-pin connectors. It is not important
if the intercepting connection is made
before the Banks Tuner connection
or after. This will not affect the
performance of the Banks Tuner or
SpeedBrake. Insert the male 24 pin
connector on the SpeedBrake harness
into the female 24-pin connector on
the factory harness or Banks Tuner’s
harness. Insert the female 24-pin
connector on the SpeedBrake harness
onto the male 24-pin connector of
the factory harness or Banks Tuner’s
harness.
If a Banks Diesel Tuner has been
previously installed, skip step 12.
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
incision in the grommet. See Figure
5. Now from inside the cab locate the
grommet on the firewall and make
another 1” x 1” cross-shaped incision
on the grommet.
12.Locate the In Cab Cable on Banks
SpeedBrake wire harness and feed the
single connector cable through the
incision made in the firewall grommet
and into the cab.
13.With the SpeedBrake Module
positioned on top of the fuse box, peel
the protective backing from the hook
and loop interlocking fasteners and
attached to the SpeedBrake Module.
Position the SpeedBrake module to
the edge closest to the engine of the
fuse cover then press the adhesive
onto the outside of the fuse box cover.
Apply light pressure to the SpeedBrake
Module by hand for 60-seconds to
create a strong bond between the
fuse box and hook & loop interlocking
fasteners.
Note: make sure the fuse box cover
is clean and free of any oil residue and
contaminates. Clean fuse box cover
with a non-oil based solvent such as
Acetone, Mineral Spirits, Denatured
Figure 5 Driver Side Firewall, Rubber Grommet
8
97238 v.2.0
Figure 6 Placement of Banks Tuner on top of the Fuse Box.
Figure 7 Placement of Banks Tuner on side of the Fuse Box.
97238 v.2.0
9
Alcohol or Lacquer Thinner. Read and
follow the manufactures operation
instruction for non-oil based solvent
cleanser.
If vehicle is equipped with a Banks
Tuner, detach the Tuner from the top
of the fuse box cover and reattach
on the fuse box side or on top of the
fuse box along with the SpeedBrake.
See Figure 6 & 7. If placing the Tuner
on top of the fuse box along with
the SpeedBrake module there may
be some over hang from the tuner.
Secure the tuner so that it stays in
place. Use the supplied hook & loop
interlocking fasteners to make the
necessary adjustment to attach the
SpeedBrake to the top of the fuse box
cover and Banks Tuner to the fuse box
side or top.
Figure 8
10
97238 v.2.0
Warning: Make sure to place
the SpeedBrake Module as shown
in Figure 8 to avoid a clearance
issue when closing the hood.
Mount the SpeedBrake Module
as close to the inside edge of the
fuse cover as possible.
14.Insert the SpeedBrake 20-pin
Module Connector on the wire harness
to the SpeedBrake Module. Using the
supplied cable ties, secure the wire
harness away from any heat sources
(i.e. Driver side exhaust manifold) or
moving components.
-END, SECTION 1-
Section 2
Mounting and Connecting the Banks iQ
WARNING: Below 32oF (0oC) or
above 140oF (60oC), the Banks iQ
may be susceptible to damage
as a result of extended 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 9
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 9. 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: Due to the snug fit, use caution
when installing the Banks iQ into the
window mount.
4. Find a suitable place on the
windshield for ease of access and
viewing of Banks iQ. Use location
shown in Figure 10 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
97238 v.2.0
11
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 fuse
access panel aside. See Figure 11.
7. 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 12 to secure the Banks
interface cable to the vehicle OBD II
connector.
8. Next, connect the 6-pin connector
on the Banks OBD II interface cable
to the 6-pin connector on the Six-Gun
Tuner harness.
Figure 10
12
Note: If your vehicle is equipped
with a Banks Diesel Tuner, Optional
Tuner-to- SpeedBrake cable will be
needed (P/N 55411). See Figure
13. Disconnect the 6-pin terminal
connections between Banks OBD
II Interface Cable and Banks Diesel
Tuner. Connect the OBD II 6-pin male
connector to the optional Tuner-toSpeedBrake 6-pin female connector.
Connect the three (3) wire 6-pin male
connector to the Diesel Tuner female
6-pin connector and connect the five
(5) wire 6-pin male connector to the
SpeedBrake female 6-pin connector.
9. Locate the RJ12 Cable (similar to
telephone connector) on your Banks
OBDII interface cable. See Figure 14.
10. Locate Banks iQ Bridge Module and
connect the RJ12 connector into the
Bridge Module. See Figure 15.
Mounting location for Banks iQ, Chevy LMM Shown.
97238 v.2.0
Figure 11
Figure 12
97238 v.2.0
13
Figure 13 Optional Tuner-to-SpeedBrake Cable
Figure 14 Banks iQ System
14
97238 v.2.0
Figure 15 Banks Bridge Module
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
and connect it to the USB receptacle
on the left side of Banks iQ. See
Figure 10. 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 2-
97238 v.2.0
15
Section 3
Updating Banks iQ & Banks SpeedBrake Software
System Info
To view your System Information,
press the ‘System Info’ button in the
‘Adjustments’ menu. See Figure 16.
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 SpeedBrake
1. Go to www.bankspower.com/
downloads and check for the Banks
Power Tuner or SpeedBrake 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 SpeedBrake’
Highlight the appropriate file name from
the available list.
5. Press ‘Update SpeedBrake’ 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.
2. Go to www.bankspower.com/
downloads and click on ‘Check for
Updates’.
3. Follow the on-screen directions on
your PC to update your Bank iQ with the
latest software updates.
button in the ‘Adjustment’ menu.
4. Press the ’Check For Updates’ button
and available SpeedBrake updates will
appear in the window. See Figure 17.
Figure 16
16
97238 v.2.0
-END, SECTION 3-
Figure 17
Section 4
TroubleShooting
Check the Banks iQ’s Status indicator for
the “OK” icon on the upper left corner
of the iQ Environment screen. Any
SpeedBrake fault will be indicated by the
“SpeedBrake Caution” icon (see Figure
18) and its cause can be investigated by
running a ‘SpeedBrake Diagnostic’ from
the Diagnostic menu.
Figure 18
SpeedBrake
Caution Icon
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 21.
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 iQ icon on the lower left of
1. In the Environment select menu
press on the ‘Diagnostics’ button. See
Figure 19.
2. In the Diagnostics menu press on the
‘SpeedBrake Diagnostics’ button to run a
tuner diagnostics. See Figure 20.
3. The ‘Self Diagnostic’ screen displays
a log of diagnostic events related to the
Tuner. The ‘Logged Events’ list takes a
moment to update each time this screen
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.
-END, SECTION 497238 v.2.0
17
Figure 19
Figure 20
Figure 21
18
97238 v.2.0
Table 1 - (For 04-05 model years)
Flash
Code
PDA Error Message
Corrective Action- LLY
1.1
Code 11: VGT control input
out of range
Turn ignition OFF and check the 24-Pin connector.
Turn ignition back ON and re-check for presence of
code.
1.2
Code 12: Vane Position
Sensor input out of range.
Turn ignition OFF and check the 24-Pin connector.
Turn ignition back ON and re-check for presence of
code.
1.3
Code 13: Rear wheels
slipping.
None required. When traction is regained, error will
clear after 30 seconds.
1.4
Code 14: Low power
voltage detected.
Turn ignition OFF and check the Fuse Tap and the
Ground O-ring. Turn ignition back ON and re-check for
presence of code.
2.1
Code 21: VGT control
output malfunction.
Turn ignition OFF and check the 24-Pin connector.
Turn ignition back ON and re-check for presence of
code.
2.2
Code 22: VGT control
output overcurrent.
Turn ignition OFF and check the 24-Pin connector.
Turn ignition back ON and re-check for presence of
code.
2.3
Code 23: Low relay voltage
detected.
Turn ignition OFF. Turn ignition back ON and re-check
for presence of code.
2.4
Code 24: Vane Position
Sensor voltage output
malfunction.
Turn ignition OFF and check the 24-Pin connector.
Turn ignition back ON and re-check for presence of
code.
3.1
Code 31: OBD
communication error.
Turn ignition off and check the OBD connector
and cable. Turn ignition back ON and re-check for
presence of code.
3.2
Code 32: Internal module
malfunction or intermittent
power.
Turn ignition OFF. Turn ignition back ON and re-check
for presence of code.
3.4
Code 34: CAN
communication input error.
Turn ignition OFF and check the 24-Pin connector.
Turn ignition back ON and re-check for presence of
code.
4.2
Code 42: Torque Converter
Clutch slippage detected.
Turn ignition OFF. Turn ignition back ON and re-check
for presence of code.
4.4
Code 44: Internal memory
malfunction.
Turn ignition OFF. Turn ignition back ON and re-check
for presence of code.
If problem persists, call Gale Banks Engineering Tech Support.
97238 v.2.0
19
Section 5
PLACEMENT OF THE BANKS POWER DECALS
Gale Banks Engineering
546 Duggan Avenue • Azusa, ca 91702
(626) 969-9600 • Fax (626) 334-1743
Product Information & Sales: (888) 635-4565
bankspower.com
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