Banks Power Ford Trucks: (Diesel ’94 - 97 7.3L Power Stroke) Power Systems- PowerPack, Stinger-Plus & Stinger '94-98 3-1_2

Start the engine and allow it to warm up.
Drive the vehicle, listening for any exhaust leaks
or rattles. Adjust and tighten clamps or reposition
the piping if required. When positioning of piping
is finalized, it is a good practice to place tack
welds at any slip joints in the exhaust system to
prevent slippage. NOTE: The exhaust may smoke
slightly after initial startup. This is normal and will
go away shortly as the grease used in the bending
process burns off the inside of the piping.
CHECKING ENGINE PERFORMANCE
Observe operation of the boost and pyrometer
gauges while driving under varying conditions.
Turbocharger boost pressure fluctuates as a
function of load and rpm. The engine produces
lower boost while cruising at light throttle.
Maximum boost occurs while climbing hills and
heavily loaded during acceleration. Note the boost
level during hard acceleration with a given load. If
future performance declines, the maximum boost
figures may be compared to see if boost has
decreased. Lower boost can be caused by turbo
ducting leaks, a malfunctioning fuel injection
system, or dirty air filter. Maximum boost pressure
settings for the Power Stroke turbo-diesel
vary considerably, due to manual or automatic
transmission options, vehicle year and model, and
altitude. Boost readings may vary between 15 and
22 psi. NOTE: Vehicle performance may be erratic
and improper if the module connections are not
properly cleaned.
Use your pyrometer gauge to monitor exhaust gas
temperature (EGT) in the engine. At idle, EGT will
be very low, perhaps only 300°F. As the engine
accelerates and is under load, the EGT rises. The
safe maximum for the EGT is 1050°F. The highest
EGT occurs under maximum load at full throttle,
such as climbing a steep grade with a heavily
laden vehicle. If the vehicle reaches maximum
EGT during these conditions, downshift to reduce
the load, or back off the throttle. CAUTION:
Exceeding 1100°F can cause engine damage.
We recommend that engine oil temperature not
exceed 250°F. Optimum oil temperature is around
230°F.
NOTE: An optional oil temperature gauge is
available from Gale Banks Engineering.
SERVICE TIPS
If the need should arise for you to have your
vehicle serviced, the Banks OttoMind should be
removed from the engine control unit (ECU). It
is common for the service provider to connect a
computer diagnostic link to the vehicle regardless
of the type of service being performed. When the
OttoMind is installed, the computer will return
a code that indicates a memory fault with the
vehicle ECU. The suggested repair for a fault of
this type is replacement of the ECU.
The operation of the OttoMind is such that
the computer is directed to reference certain
information in the OttoMind rather than the ECU.
Therefore, the memory fault that occurs is not
an ECU failure, but rather the presence of an
electronic device that the diagnostic computer
cannot identify.
To avoid confusion about whether or not an
ECU is properly functioning, simply remove the
OttoMind from the ECU before having the vehicle
serviced, and reinsert the plastic cap in the ECU
access port. The OttoMind can be easily accessed
from inside the truck by removing three 13 mm
hex nuts from the emergency brake assembly and
pulling the assembly away from the side panel of
the vehicle. The OttoMind may be reinstalled after
the service is complete. Be sure to reinstall with
duct tape to firmly retain the OttoMind.
It is also not uncommon for a service provider
to update the program in the vehicle ECU. If this
occurs, it is possible that the programming in the
OttoMind will no longer match the ECU program.
If you experience any difficulty with the operation
of the Banks OttoMind after service, check with
the service provider to determine if an update
was performed. Then contact customer service at
Gale Banks Engineering for an updated OttoMind,
if necessary.
94.
21 P.N. 96322 v.7.0