Banks Power Cummins Motorhomes: (Diesel ’93 - 98 B5.9L & C8.3L) PowerPack & Stinger systems w_Twin Ram Manifold 5.9L, 190-210-230-hp rated - Manual (Page 11)

removal. a sharp chisel with an approximately 3 ⁄
8
”
wide blade may be used to chisel a screwdriver
“slot” across the screw head. pass the chisel
between the injector tubes and strike straight
down to create a “v” notch, then use a 5 ⁄
16
– 3 ⁄
8
”
blade screwdriver with moderate downforce to
turn the screw. see Figure 6. an alternate method
is to drive the chisel into the screw head using
blows upon a hand held impact driver tool set in
the “removal” position, such as a snap-On no. piT
160 or equivalent. install a hex or 8-point socket
on the driver that will fit over the shank on the
chisel. another method is to drive a no. T15 (or
in some cases a no. T20) male TOrX bit into the
screw head using either a hammer or hand impact
driver. a center punch may be required to provide
a depression in the top of the screw. When using a
hand impact driver, use light hammer taps to seat
the TOrX bit, and progressively harder blows to
loosen the screw.
Once this screw has been removed, save the
washers and discard the screw, then loosen
and remove the remaining three screws and retain
these for reassembly. remove two fuel shutdown
solenoid bolts and the hairpin style clip from the
solenoid acctuator rod. remove the solenoid and
set it aside. loosen slightly one bolt at the rear of
the injection pump that will allow the fuel shutdown
solenoid and bracket to be swung outboard just
enough to clear the edge of the cam plate cover
so the cover can be removed from the pump. now
remove the cam plate cover and set it aside. (see
Figure. 7)
note the position of the cam plate attached
to the pump body by two screws. Mark a
scribe line in the pump body at the forward edge
of the cam plate where it contacts the pump
body. see Figure 8. This mark can be used as a
reference should the original cam plate need to
be reinstalled.
place the installation guide template
provided over the stock fuel cam plate. This
template will provide the position reference for
the banks OttoMind calibration cam. note: The
guide template will only fit one way. if it appears
to be misaligned or does not seem to fit, flip the
plate over and try again.
using two of the cam cover screws previously
removed, loosely attach the guide template
to the fuel pump body. slide the guide template
toward the rear of the engine so that there is zero
clearance between the front edge of the fuel cam
plate and the guide template. hand tighten the
two screws so that the guide template dOes nOT
move during the remainder of the banks OttoMind
installation.
loosen and remove the two screws holding
the fuel cam plate in place. keep these for
reuse. remove the stock fuel cam plate. keep this
piece in a safe location in case it is needed for
future work on your vehicle.
install the banks OttoMind fuel calibration
cam in the same position as the stock
fuel cam plate, with zero clearance between
the front edge of the calibration cam and the
guide template. replace the two screws to retain
the calibration cam and tighten. remove the
installation guide template and keep it with your
stock fuel cam plate for future use.
Once the banks OttoMind is installed,
replace the cam plate cover on the pump,
swing the fuel shutdown solenoid bracket into
place and reinstall the fuel shutdown solenoid.
Thread the two lower cover screws into the pump
finger tight. install one original screw in the upper
rear bolt hole. install the supplied phillips head
screw in the upper forward bolt hole. This is a
temporary use screw to be replaced by the new
break-off screw, provided, when fuel calibration
is complete.
place the cover in its exact original position,
as indicated by the scribe lines on the
cover and pump body. Maintaining its position,
tighten the cover bolts and rear fuel-shutdown
bracket bolt that was previously loosened.
after engine performance has been
checked, replace the temporary-use
phillips-head screw with the new break-off screw
provided. CAUTION: Failure to install the new
break-off screw when fuel calibration and
performance have been verified can invalidate
your emissions warranty.
reconnect the rubber hose and plastic tube
to the “tee” fitting on the air flow valve
cover, tighten the hose clamp and tube nut.
For PowerPack installation, proceed to step 51.
Note: Before slipping any boost tubes and the
corresponding hoses, into position, ensure that
all connection ends are clean and free of any oil
residue and contaminates. Clean compressor
outlet and all connection points with a non-oil
based solvent such as Acetone, Mineral Spirits,
Denatured Alcohol or Lacquer thinner. Read and
follow the manufactures operation instruction for
non-oil based solvent cleaner.
remove the rags covering the intake
manifold opening and boost tube, then
reinstall the boost tube hose onto the inlet
casting. check that the boost tube hose is properly
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