Banks-power Dodge Trucks: (Diesel ’03 - 07 5.9L Cummins) Speed Bedienungsanleitung

©2012 Gale Banks EngineeringOwner’sManualwith Installation InstructionsBanks Brake with CBC/SmartLock®Exhaust Brake System2004-2007 Dodge Cummins ISB

10 97055 v.8.0Figure 6Figure 7

97055 v.8.0 11Bill of MaterialsDescription P/N Kit 55225 Kit 55226 Kit 55229Assembly, Brake Housing 55045 1 1 1Vacuum Pump 55176 1 1 1Bracket, Vacuu

12 97055 v.8.0Description P/N Kit 55225 Kit 55226 Kit 55229Hose, 1/4” 9 ft 94121 - - 1Hose, 5⁄16” 5 ft 94129 1 1 1Vent Hose Assembly 94450 - - 1

97055 v.8.0 13Section 2Banks Exhaust Brake Installation1. As a precaution, disconnect the ground of the battery (if there is more than one battery,

14 97055 v.8.02006-07 trucks proceed to Step 5.2004-05 proceed to Step 8.5. For 2006-07 trucks, the heater core tube that is above the exhaust pipe

97055 v.8.0 15Figure 11 Exhaust Brake Orientation Figure 10 Driver Side

16 97055 v.8.011. Slide the V-clamp that is on the Brake assembly onto the turbo outlet. Make sure that the flanges on the Banks Brake and the turbo

97055 v.8.0 17Section 3Vacuum Boost Actuator InstallationIf installing kit 55229 continue with this section, For kits 55225 and 55226 skip to Sectio

18 97055 v.8.0Figure 14Figure 15

97055 v.8.0 197. Remove the mounting bolt from the transmission case and install the line pressure boost actuator and bracket as shown in Figure 16.

2 97055 v.8.0Banks iQ System(P/N 61148-61149)- 5” touchscreen interface that can control the Banks Diesel Tuner on the fly.- Interchangable gauge disp

20 97055 v.8.010. Locate two spring band clamps and slide over the rubber hose that were routed down to the left side of the transmission in step 1.

97055 v.8.0 21Figure 18 Vacuum Boost Actuator Hose connectionsFigure 19 Vent Line with Breather Assembly, Left Side Engine Compartment

22 97055 v.8.01. Locate the rail along the rear of the engine compartment. Remove the push-in retainer that is closest over the exhaust brake with a

97055 v.8.0 23Figure 22Figure 21 For models with no Throttle Valve Assembly (some 2004)

24 97055 v.8.01. Use a 1⁄2” ratchet or breaker bar to loosen the tensioner pulley to create slack on the drive belt. Remove the factory drive belt.2

97055 v.8.0 25Figure 25Figure 24

26 97055 v.8.01. Remove the fuse box cover, located in the front driver’s side of the engine compartment. Locate mini-fuse #50 for 2004-05 trucks (F

97055 v.8.0 27Figure 28 Fuse Tap InstallationFigure 27 2006-07 Models

28 97055 v.8.0Figure 30 2006-07 ModelsFigure 29 2004-2005 Models

97055 v.8.0 29Figure 32 All Models CBC Smartlock Mounting LocationFigure 31 Ground Wire Attachment Location

97055 v.8.0 3Banks Billet Torque Converter(P/N 72515)- Higher torque capacity over stock- Lockup clutch is slip-resistant so transmission fluids stay

30 97055 v.8.04. Attach the Ground wire (Black wire with ring terminal) to an existing bolt by removing the existing bolt and sliding the ring termi

97055 v.8.0 31Figure 34 All Models Vacuum Solenoid Connection Location 8. Route the Wiring Harness along the A.C. hose. Secure it later with cable

32 97055 v.8.0Figure 35 Left side of transmissionFigure 36 Location of Rubber Grommet in Engine Compartment

97055 v.8.0 33If installing kit 55229,Locate the factory C109 connector on the driver side of the transmission. There will be three connectors conne

34 97055 v.8.0CAUTION: Pull gently to avoid damage to the Wiring Harness Connectors or wires. Always pull on the Wiring Harness housing rather than

97055 v.8.0 35Figure 39

36 97055 v.8.0CAUTION: Do not use force when working on plastic parts. Permanent damage to the part might result.NOTES: Before drilling, confirm tha

97055 v.8.0 373. Remove the cluster bezel by first removing the two (2) screws at the top. Gently pull on it and disengage all the clips that attach

38 97055 v.8.0Figure 42 Late 2004 thru 2005 modelsFigure 43 Late 2004 thru 2005 models

97055 v.8.0 392006-2007 Switch install9. Remove the lower dash knee panel from the vehicle by removing the two (2) screws at the bottom corners of t

4 97055 v.8.0Gale Banks Engineering Inc. (hereafter “SELLER”), gives Limited Warranty as to description, quality, merchantability, fitness for any p

40 97055 v.8.0NOTES: It is important that the hole is drilled as close as possible to the recommended location. The switch may not clear the instrum

97055 v.8.0 4116. Remove the chrome bezel nut from the Switch shaft. Insert the Switch shaft into the hole that was drilled in the dash panel. Re-in

42 97055 v.8.0The Banks Brake with CBC/SmartLock has been designed for your truck. It features:Improved torque convertor control • when in the facto

97055 v.8.0 43Section 9Safety and Operation/ Driving TipsCAUTION: Your Banks Brake is NOT a substitute for the hydraulic brakes on your truck. The d

44 97055 v.8.0Your Banks Brake CBC/SmartLock is equipped with diagnostic features that will detect and display certain errors. If the Banks Brake do

97055 v.8.0 45other 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

46 97055 v.8.0This Page Intentionally Left Blank

97055 v.8.0 47Figure 48- 2004-2005 Model Template Location #1Figure 49- 2004-2005 Model Template Location #22004-2005Model Template2004-2005Model Te

48 97055 v.8.0This Page Intentionally Left Blank

97055 v.8.0 49Figure 50- 2006-07 Model TemplateFigure 51- 2006-07 Model Template2006-07Model Template2006-07Model Template

97055 v.8.0 5Figure 2 Engine Compartment Driver SideFigure 1 Driver Side, Top of Transmission

50 97055 v.8.0Notes

97055 v.8.0 51Notes

Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334-1743Product Information & Sales: (888) 635-4565bankspowe

6 97055 v.8.0For some 2004 models, if the diameter of the Turbine Outlet Pipe (T.O.P) is 3½“, call Gale Banks Engineering for a T.O.P replacement.If

97055 v.8.0 7Dear Customer,Your new Banks Brake with CBC/SmartLock is a uniquely designed exhaust brake with electronic controls, designed to achiev

8 97055 v.8.0Tools Required: 1• ⁄2” and 3⁄4” drive ratchets with inch and metric sockets and 1⁄2” and 3⁄8” drive extension1• ⁄2” breaker barInch and

97055 v.8.0 9Section 1General AssemblyFigure 4 Wiring Harness 55406Figure 5