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Transcript of Banks Manual
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IMPORTANT
DEAR CUSTOMER:
To obtain optimum performance from your BANKS turbocharger
system, it is necessary to make an ad ju st me nt to the fuel
injection pu mp . This adj ust me nt is easily made by following the
enclosed instructions. However, it is extremely important that the
instructions be followed very ca re fu ll y. Before starting the
injection pump adjustment procedure, please note the following:
The engine must be C.OL_D (preferably overn ight ) before starting
the injection pump adjustment procedure. DO NOT_ attempt to
turn the engine over or adju st the injection pump while the
engine is w a r m.
To gain access to the injection pump adjusting screw, it is
necessary to rotate the engine cr ankshaft, so that the screw
is properly positioned. As noted in the instructio ns, the
crankshaft is rotated by h a n d , IN THE CLOCKWISE DIRECTION
ONLY , by turning the vibration damper mounting bolt using an
appropriate so ck et , extension and breaker bar . ( O n some late
model trucks it may be necessary to remove the front
crankshaft pulley to gain access to the vibration damper
b o l t . ) DO NOT ROTATE THE CRANKSHAFT USING THE STARTER, for
any reason. Even though the fuel solenoid is de-energized,
the engine can still start. This is extremely hazardous and
can result in both severe personal injury and major mechanical
da ma ge . Again when making the injection pump adju stme nt, DO
NOT ROTATE THE CRANKSHAFT WITH THE STARTER.
3 . If you r e m o v e d the fron t crank sha ft pulley to gain access to the
vibration da mpe r b o l t , be sure to reinstall the pulley ( an d
be lt s) before starting the en gin e.
GALE BANKS ENGINE ERIN G
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JUNE 1 2 , 1989
ATTENTION
THIS IS AN ADDENDUM TO ALL GALE BANKS TURBOCHARGER SYSTEM
INSTRUCTIONS. THE INSTRUCTIONS SHOW ( 2 ) 3/8" 16 x 1" HEX
BOLTS TO MOUNT THE OIL DRAIN TUBE. WE HAVE SUBSTITUTED ( 2 )
3/8" 16 X 3/4." HEX BOLTS IN THEIR PLACE. YOUR BILL OF
MATERIALS WILL NOT HAVE THESE BOLTS LISTED.
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IMPORTANT
DEAR CUSTOMER:
To obtain optimum performance from your BANKS turbocharger
system, it is necessary to make an ad ju st me nt to the fuel
injection pu mp . This adj ust me nt is easily made by following the
enclosed instructions. However, it is extremely important that the
instructions be followed very ca re fu ll y. Before starting the
injection pump adjustment procedure, please note the following:
The engine must be C.OL_D (preferably overn ight ) before starting
the injection pump adjustment procedure. DO NOT_ attempt to
turn the engine over or adju st the injection pump while the
engine is w a r m.
To gain access to the injection pump adjusting screw, it is
necessary to rotate the engine cr ankshaft, so that the screw
is properly positioned. As noted in the instructio ns, the
crankshaft is rotated by h a n d , IN THE CLOCKWISE DIRECTION
ONLY , by turning the vibration damper mounting bolt using an
appropriate so ck et , extension and breaker bar . ( O n some late
model trucks it may be necessary to remove the front
crankshaft pulley to gain access to the vibration damper
b o l t . ) DO NOT ROTATE THE CRANKSHAFT USING THE STARTER, for
any reason. Even though the fuel solenoid is de-energized,
the engine can still start. This is extremely hazardous and
can result in both severe personal injury and major mechanical
da ma ge . Again when making the injection pump adju stme nt, DO
NOT ROTATE THE CRANKSHAFT WITH THE STARTER.
3 . If you r e m o v e d the fron t crank sha ft pulley to gain access to the
vibration da mpe r b o l t , be sure to reinstall the pulley ( an d
be lt s) before starting the en gin e.
GALE BANKS ENGINE ERIN G
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I M P O R T A N T
In order to protect your engine from water damage, Ford Motor
Company recommends that the air inlet duct be disconnected from
the air filter housing when fording streams. This warning can
be found on both ends of the air inlet duct ( i t does not appearon some very early models). Removing this duct allows the
engine to draw air into the air filter from a higher
elevation, reducing the risk of water entering the engin e.
The duct should be replaced when fording is completed.
This air inlet duct is reused with your BANKS 6.9/7-3L turbo
kit. You should continue to follow the fording instructions
after the turbo kit is installed.
-G B E -
1/25/89
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GALE BANKS ENGINEERING
INSTALLATION INSTRUCTIONS
GENERAL INSTALLATION PRACTICES
1. For ease of installation and trouble-free operation of your
BANKS turbocharger s ystem, PLEASE READ THIS ENTIRE INSTRUCTION
PACKAGE BEFORE STARTING ANY WORK. (This package contains 15
pages of instr uc tions, 12 sheets of illustrations, and two
sheets of parts listing. If any pages are missing from this
package, please call GALE BANKS ENGINEERING immediately for a
repl ac em en t. ) Become thoroughly familiar with all components
and phases of the installation before starting any wo rk.
2. Inspect all components supplied for any foreign material thatmay have entered during shipping and handling. Wash all fuel and
oil hoses with solvent and blow dry with compressed air before
assembly. Inspect all castings for damage resulting from
shipping. Check all machined surfaces for nicks or other
damage. Clean all castings with solvent and blow dry with
compressed air prior to assembly.
3- Any time the vehicle is raised off its wh eels, it should be
supported by jack stands or ramps of adequate capacity for the
ve hi cl e's weight. NEVER PERFORM ANY WORK UNDER A VEHICLE
SUPPORTED ONLY BY ITS BUMPER OR A HYDRAULIC J A C K .
4- Use the Teflon tape provided on all pipe thread co nnections.Hold tape back from the first two threads of the fitting so tape
will not flake off into the fluid. (This is especially critical
on oil lines.)
5- Any threads to be secured with Loctite must be clean, dry and
free of any oil or grease. Clean threads with lacquer thinner
as required.
6. Pay particular attention to the rou ti ng of all hoses and
wiring. Keep them away from exhaust heat, moving parts and
sharp edges that may cause cuts or other damage. Route or tie
hoses away from critical areas as re quired. Keep all hoses a
minimum of 1" from hot exhaust, pa rts, 1 - 1 / 2 " or more is
recommended whenever possible.
5/18/89 73TA01 Rev.8 Page 1 of
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7 . Collet stainless steel locknu ts a re used on the studs in the
turbine mounti ng bra cke t. The locknuts should be installed as
shown in f i g . 3- The nuts will spin on fre ely and lock only when
tightened.
8. Muffler and exhaust piping are not included wit h this k i t .
An exhaust parts kit cont ain ing these components is ava ila ble
separately from GALE BANKS EN GI NE ER IN G, or you may have a localmuffler shop fabricate the exhaust sy s t e m . The BANKS 3"
exhaust system is REQUIR ED for emissions legal installations.
NO TE : If you have a muffler shop fabricate the exhaust
s y s t e m , or if you comple te the system your se lf , it is highly
re comm ende d that you install a BANKS 3" core muffler to realize
the full benefits of your BANKS turbo sy s t e m .
9- General assembly diagrams are provided in addition to the
specific step or section diagrams in the text. General
assembly diagrams show relationships of individual componen ts
for ref ere nce ; h ow ev er , numbered step-by-step procedures should
be followed for proper assembly s eq uenc e.
1 0 . Right-hand and left-hand designations refer to the d r i v e r ' s
right or le ft , as seated in the ve hi cl e, ( i . e . : Right-hand
refers to the passenger side of the vehicle , unless noted
otherwi se . " F W D " in sketches refers to " f o r w a r d " , or front of
vehicle.
1 1 . All BANKS components are de si g ne d, tested and manufactured to
standards far exceeding factory OEM specifi catio ns. However due
to normal variations in production v e h ic le s , it may be
necessary to slightly modify some exhaust comp onents for proper
f i t .
NOTE: All parts are furnished in kit unless noted otherwise.
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INSTALLATION PROCEDURE
1. Disconnect ground cables from both batteries. Disconnect electrical
connections from to p of in je ct io n pump .
2 . Disconnect plastic air inlet duc t from air cleaner- ho us in g
and remove air cleaner housing and e l em e n t .
3- Disconnect wire from oil pressure sender u n i t , loca ted on
top-rear of eng ine . ( O n some m o d e l s , the oil pressure sender
is mounted on the fi r e w a l l . )
4- Re mo ve oil pressure sender unit and it s conne ctio ns from rear of
engine block. (F it ti ng s, ho se , and brack et, e t c . , if firewall
m o u n t e d ) . Retain sender for later inst alla tion .
5- Install 1 / 8 " NPT brass pipe plug in hole at rear of block where
oil pressure sender unit and fitt ing were re m o v e d . Use
Teflon tape on thr ea ds .
6. Remove steel tube connected to transmission modulator va lve.
7. Remove oil fill-pipe from front of engine. (Note: 1 987
and later models use an inspection cover plate, remove
cover plate). See fig- U
ONPUMP ADJUSTMENT
To obtain the maximum available performance from your BANKS 6-
9/ 7- 3L diesel turbo system, and to comply with emissions
requirements, it is necessary to make an adjustment to the fuel
injection pump. The pump adjustment increases the fuel
delivery capacity of the pump. This adjustment is made by
turning an internal screw, found within the pump. The pumpadjustment will provide a 30 percent or greater increase in
rear wheel horsepower, suitable for general u s e , work trucks
and towing. (This is the ONLY emissions legal setting).
NOTE: Exhaust gas temperature ( E G T ) must NOT exceed 1150
degrees F, as shown on the EGT gauge (pyrometer)
furnished with the k i t . If the EGT approaches this
temperature under heavy, uphill lo ad, the fuel pump
capacity adjustment must be reduced. The recommended
pump setting should cause no problem, very rarely approaching
this temperature.
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8. Ad ju st injector pump delivery as follows:
NOTE: The engine must be COLD before starting this pro cedure.
Review warnings at the beginning of instruction booklet.
NOT E: Utmost cleanliness should be ex er ci se d. DO NOT allow any
foreign mat eri al , including lint from ra gs, to enter the
injector pump during the adjustment procedure - the lintfrom a rag can clog an injector. Lay any removed parts on a
clean newspaper during the adjustment procedure.
a. Place a drip pan under the rear of the engine, under the
flywheel inspection cover ar ea, to catch spilled fuel. Clean
the area of the pump in the vici nity of the small access
cover, located on the left side of the p ump, as viewed from
the .f:rp_n_t, of the vehicle, with diesel fuel or parts
so lv en t. DO NOT clean the pump while it is h o t ; doing so may
damage the pump.
b. Remove the cover p late, retained by two small screws . Use
care not to damage the rubber g asket; it will be reusedduring reassembly. IMPORTANT: Utmost care must be used to
prevent foreign obje cts and dirt from falling into the pump to
prevent dama ge.
c. Rotate engine slowly by hand, in a clockwise direc ti on , using
a breaker b a r , short extension and suitable socket on the
harmonic balancer retaining bo lt, to align the injector
drive p in, as viewed through the opening for the oil fill pipe
or inspection c o ver, in a straight up ( 1 2 o' clo ck )
position. Using a small mirror, check that the Alien head
adjustment screw is visible within the inspection hole on the
pump. It may be necessary to rotate the engine somewhat
more to gain access to the adjusting sc re w. See figs. 5 and6. DO NOT ATTEMPT TO ROTATE THE ENGINE WITH THE S T A R T E R ! ! .
d. Using a 5/32" Alien wrench (wit h sharp corners), rotate the
screw 1/4 turn, clockwise.
NOTE : The Alien screw turns fairly tightly and is self
locking. Turning the screw clockwise increases fuel delivery
capacity. Keep track of your adjustments!
e. Replace access cover on pump. Again exercise care to
prevent foreign material from entering pump.
f . Wipe up any spilled fuel remaining on valley cover.
This completes the pump adjustment procedure.
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Reroute the in jec tor return ho se s. Refer to fig- 7 A . whic h
shows how the return lines should be ro ut ed . Re mo v e and install
necessary comp one nts as required to com ple te th e system as
sho wn. (A dd it ion al hose is provided for the r er ou ti ng .)
Note that there should be a m i n i m u m of four inches clearance
between the inje ct or return line ar:d t, he ; turbine hou sin g or
turbo moun ting br ac ke t. Be sure th at the new injec tor return
hose does not inte rfere w it h the transmission kickdown
linkage.
1989 and later models - if the injector return
fittings on the injector nozzles have the late style " o f f
center" nipples, see fig. 7, the injector return lines do not
need to be rerouted. Go to step 10 .
engine lifting lug from right front of the intake
Retain the bolts for later installation.
10. Remove the
manifold.
1 1 . Remove the engine lifting lug from right rear of the intake
manifold. Replace bolts with new 3/8"-l6 x 2-1/2" hex headbolts provided, and original washers. (Do not use original
bolts or reinstall lifting l u g . )
1 2 . Remove the engine lifting lug from left rear of the intake
manifold. Retain the bolts for later installation.
13- Remove the crankcase anti-depression valve (the round sheet
metal can attached to the rear of the intake manifold).
Remove standpipe and grommet from valley cover. (Standpipe
may come out attached to anti-depression v al v e. ) Retain anti-
depression valve and mounting bolts for later installation.
Note, 1987 and later models: Remove short length of hose and
clamp from anti-depression valve.
1-4- Carefully clean around the hole where the original grommet
was installed at the rear of the valley cover and where the
anti-depression valve was mounted on intake manifold. (Use
acetone, lacquer thinner or other non-oil based so lvent.)
15- Install grommet in valley cover as follows. Fill grommet
groove with RTV silicone sealer provided. Press grommet
through opening in valley cover and smooth RTV around
grommet. Remove excess RTV. See fig- 8.
1 6 . Install rubber
See fig. 8.
groove in manifold block-off plate
17. Install manifold block-off plate (and o-ring) on intake
manifold where anti-depression valve was removed, using two
5/16" - 18 x 1" hex head bolts and split lockwas hers. See Fig.
8.
o-r i n, i n
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1 8 . 1987 and later mo de ls , glow plug relay rel oca tio n:A. Un bo lt the glow plug relay fr om the rear of the intake
manifold (l ea ve wire loom attached to re la y. Remo ve cable
clamps holding wire loom to rear of e n g i ne . Disconn ect
relay ground wire from engine. If vehicle has the E 4 0 D
transmission (4 speed automat ic / o v e r d r i v e ) save one of the
cable clamps for step 49-B. Re mo ve the two intake man ifold bolts located betwee n the
third and fourth fuel in je ct or ( co unti ng from the front to
the rea r) on the right (p a ss e ng e r) side of the en gi ne .
See fig- 9-C. Mou nt the glow plug relay to the glow plug relay brac ket
( p r o v i d e d ) using two 1/4"-28 x 1" hex bol ts , two 1/ 2 "
O . D . x 1/ 4" I . D . washers, and two 1/4"-28 nylock nut s.
Clamp the relay ground wire under one of the nu t s . See fig.
9 -D. Install the bracket and relay on the intake manifold
using the intake bolts and washers rem ove d in section B.Route the wiring as shown in fig- 1 0 . Plastic clips may be
rem oved from wire loom ja ck et as required for rerouting
wiring.1 9 - Remove the screws holding the vacuum hose junct ion b lock,
located on upper right portion of fire wa ll , and lift block upward
as far as pos sib le. ( D o not disconnect any vacuum h o s e s . )
Temporarily retain the vacuum block u p , out of the wa y , by tying
with heavy string or other me ans.20 . Remove exhaust head pipes and exhaust sy s t e m , including
muffler and tailpipe. 2 1 . Remove the transmission dipstick from the dipstick t u b e .
Then unb olt , the transmission dipstick tube at the bellho using
and rem ove the dipstick tube from the transm iss ion. Ret ain all
these components for later insta lla tio n. Cover the dipstick
tube opening with a clean r a g , paper towel or tape to prevent
contamination from entering the transmi ssi on. Reinstall
bellhousing bol t. 22 . Re mo ve 1 / 8 " NPT pipe plug for oil feed c on ne ct io n, located on
lower left side at rear of b l o c k , ab ove and to the rear ofthe oil filter. See fi g. 1 1 .
23- Install 1/ 8 " NPT x -4AN turbo oil feed elbow in b l o c k . A i m
elbow at approximately one o' cl oc k position. See fig- 1 1 - 2 ^ . Install oil feed hoses onto oil feed line t e e . Use Teflon
tape on th re ad s. See fig- 1 2 . 2 5 . I nsta ll oil pressure sender onto oil feed line te e . Use
Teflon tape on th re ad s. See fig- 1 2 .
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2 6 . Install oil feedline tee on intake ma nifold, using rear-most
intake manifold mounting bolt hole, on the left side. Use
original bolt and wa sher . Replace the other left rear manifold
bolt with one new 3/ 8"-l6 x 2- 1/ 2" hex head bolt and original
wa sh er . NO TE : Oil feed line to block must go under injector
tubing loop at rear-most injector.
27. Connect oil feed hose to elbow installed in step 23-
28. Lengthen the oil pressure gauge sender wire as follows:
Cut the plug from the wire loom leaving 2-3 inches of wire
attached to the plug. Lengthen the wire from the loom as
required using wire and connectors provided in the k i t . Route
the wire in front of the intake manifold air inlet opening to
the gauge sender. Keep wire clear of any mo vin g parts. Note:
Connectors squeeze together onto the wire with pliers. Re-
install plug on se nder.
29- Tie wrap glow plug wiring and throttle cable at rear of
intake manifold (snugly but not tight enough to cause binding or
kinking). See fig. 13-
30. If vehicle is equipped with a plastic acoustic shield on the
firewall, cut and remove a section as shown in fig- 1 4-
3 1 . Cut one 9" x 24." heat blanket into one piece 9" x 1 2 " and two
pieces 9" x 6 " . Wrap one 9" x 6" piece around the glow plug
wiring and throttle cable near turbine housing. Secure using
wire ties provided. Save the other pieces for later
installation. On 1989 and later models, wrap injector return
hose together with glow plug wiring and throttle cables near
turbine housing.
32. Bend firewall lip back as far as po ssible, on both s i d e s , forinstallation of exhaust pi ping . Use adjustable wrench to grip
lip as deeply as possible and bend entire seam back parallel with
bell housing. A 3 '-4 ' piece of pipe or metal bar may be used as
a lever against the seam to flatten the me tal. It may also be
necessary to slightly reshape the floorpan heat shields for
proper exhaust system clea ra nc e. See fig. 15-
33- Install the pyrometer adapter fitting and probe ( f r o m the
pyrometer kit) into the 1/4" NPT threaded hole in the turbo
mounting bracket.
34- Install four 3/8" x 1- 1 / 2 " studs in the rectangular pad on
the turbo mounting bracket. Note that the coarse threads on
the studs fit into the turbo mounting bracket.
35- Install two 3/ 8" x 2" studs in the circular pad on the turbo
mounting bracket. Again note that the coarse threads or. the
studs fit into the turbo mounting bracket.
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36 Mount turbo on turbo mounting br ac ke t, using four 3/8"-24
stainless steel collet lock nuts and four 5/ 8" O . D . x 3/8"
I . D . flat washers. No gasket is requ ired. (See general
notes on collet locknut installation, Fig. 3 ) -
37 IMPORTANT: Remove the plastic caps from the turbocharger oil
inlet and outlet connections.
38 Use gasket adhesive ( "Gasg acinch" or similar) to attach the oil
drain tube gasket to the oil drain tube. Place a small bead of
RTV silicone sealer around the oil drain pipe about 3/8" up
from the bottom, then insert the oil drain pipe into the
grommet in the valley co ver.
39 Position the turbo mounting bracket and turbocharger in place at
the rear of the right hand cylinder h ead. Start one 3/8" -l 6 x
1-1/4." hex head bolt, two or three turns, through the top
mounting hole in the turbo mounting b racket, into the cylinder
head.
40 Mount the oil drain tube in position on the turbo, using two
3/ 8" -l 6 x 1" hex head bolts and four 3/8" I . D . circle lock
washers. (Circle lock washers must be used in pairs as shown
in fig. 1 7 . ) Carefully smooth the RTV around the oil drain
pipe at the grommet with a r a g , to assure a good se al. An
additional bead of RTV sealant may be added if desired.
41 Install the other two bolts in the turbo mounting bracket
(one 3/8"-l6 x 1-1/4-" hex head and one 3/8"-l6 x 1" hex head;
short bolt goes through thin corner of br ac ke t. ) Leave bolts
loose enough to adjust turbo mounting bracket position to suit.
42 Install 1/ 4 " NPT x -4AN elbow in the oil inlet connection on topof the turbocharger. Aim the fitting as shown in fig-1 6 . Use
Teflon tape on the pipe threads.
43 Place air inlet gasket and intake casting in position on the
intake man ifold. Make sure the intake casting touches and sits
squarely on the gasket .
44 Line up turbo compressor discharge connection with the intake
casting hose j o i n t , lifting the turbo slightly if needed for
proper al ignmen t. Tighten the top bolt in the turbo mounting
bracket, then the other two.
NOTE_ If the turbocharger needs to be rotated to correct
misalignment, it can be easily aligned by lo os en in g, but not
remo vi ng, the six turbine housing bolts and the six compressor
housing bolts arid rotating these parts slightly into the proper
position. Be sure to bend the locking tabs over against the
heads of the bolts after re-tigh te nin g.
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45 Remove intake casting from intake manifold.
4 6 Modify the transmission dipstick tube as shown in fig- 1 9 -
47 Lower turbo down-tube in place, but do not mo un t.
48 ON C-6 AUTOMATIC TRANSMISSION VEHICLES ONLY, install
transmission dip stick tub e, using one 3/8 " - 1 6 x 1 / 2 " hex headbolt and 3/8" split lockwasher. It may be necessary to bend
the tube slightly to fit. Tube mounts to turbo mounting
bracket.
4 9 On E40D (4 SPEED OVE RDR IV E) AUTOMATIC MODELS ONLY, install
transmission dipstick tube using a cable clamp retained from
step 18 , a 90 bracket, a 5/16-18 x 1" hex bol t, two 1 1 / 1 6
O . D . x 5/16 I . D . washers, and a 5/16-18 Nylock nut. 90
bracket mounts under belIhousing-to-engine bolt. See figs. 1 9
and 21 .
50 Line up the turbine heat shield and gaskets on the
turbocharger. You may use 5 / 1 6 " studs, pins or bolts with
heads removed as guides to ease the installation.
5 1 Bolt the turbo down-tube to the turbocharger, using six
5/l6"-18 x 7/8" stainless steel hex head bolts and 9 / 1 6 " O . D . x
5 / 1 6 " I . D . flat washers. Make sure gaskets and heat shield are
properly in place, and that the heat shield does not touch the
firewall. Note: Heat shield may be crushed slightly to provide
clearance.
52 ON E40D (4 SPEED OVERDRIVE) AUTOMATIC MODELS ONLY, use
hacksaw to remove aproximately 1 / 2 " of the corners of the boss
indicated in fig- 27. This is necessary for the Y-pipeassembly to clear the transmission-bellhousing area.
53 Install exhaust "Y -pipe " assembly to engine exhaust manifolds
'under the vehicle. Bolt the extension tube flange to the turbo
mounting bracket using two 3/8-24 stainless collet lock nuts and
two 13/1 6 O . D . x 3/8 I. D. flat washers. Leave nuts loose
enough for alignment. Do not install U-clamp at this time .
N O T E : ON E40D (4 SPEED OV ER DR IV E) AUTOM ATIC MODELS ON L Y , unbolt the
shift linkage pivot bracket from the left side of the
transmission to allow the extensi on half of the Y- pipe to be
mounted in place between the linkage and the tra ns mi ss io n. It is
not necessary to completely rem ove the li nk ag e. When the Y-pipe assembly is in p l a c e , reinstall the l i n k a g e . See fig. 27.
54 Tighten Y-pipe co ll et lock nu ts .
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55 Install exhaust U -clamp on slip connection jo i n i n g Y- pipe-
halve s. NOTE: Both 2 1 / 1. and 2 1/2 inch U- clamp:; are
i n c l u d e d , use the proper size clamp for the tube size
su ppl ied . See f i g . 1.
5 6 Connect oil feed hose to turbocharger oil inlet e l b o w .
57 If installing optional boost g a ug e , install boost gauge
fitting (su ppl ied in boost gauge ki t ) in the 1/8 N . P . T . boss on
the intake cast in g. NO TE : Nut on fitting may be rem oved to
allow instal lation . Fitting should be aimed toward left side
of v ehicl e. Refer to f ig . 20. If boost gauge will not be
inst alled, substitute 1 / 8 " NPT pipe pl ug , from k i t . Use Teflon
tape on pipe t hr ea ds .
5 8 Install 2" diamete r x 2" long silicone hose and two #36 hos e
clamps on the intake casting compressor con ne ct io n. Tighten
the clamp nearest the intake cas ti ng , leave the other clamp
loose. Position the clamps as shown in F i g . 2 to provide
access for tightening and prevent clamp from touching ki ck-down
rod .
5 9 Install turbocharger compressor air inlet elbow and cla mps on
turbocharger. N^OT_E: Large end uses #56 clamp, small end
uses #52 clamp. Do not tighten clamps at this t i m e .
6 0 Install intake casting ( an d gas ket) on intake ma ni fo ld , using
one 3 /8 " -l 6 x L, 1/ 2" hex head bolt, and 1 3 / 1 6 " O . D . x 3/8"
I . D . flat wa sh er . Guide the intake casting and turboc harger
hose jo int s together as the casting is set in p l a c e . Make sure
all loose clamps are in position on the hos es. Torque the
mounting bolt to aproximately 1 2 - 1 5 f t . Ib s. NJDT E : On some
m o d e l s , fuel return line tube may have to be bent slightly so
fuel hose will not be kinked by the undersid e of the intakecas tin g. Check for cle ar anc e.
6 1 Tighten remaining turbocharger compressor discharge hoseclamp .
6 2 WARNING_!_ Make sure transmission kick-down rod has clearance thru
its entire trave l. Improperly located cl am ps , bent throttle
l e v er s , ho se s, e t c . may rub or push against the kick -down rod
and interfere with transmission shifting and/or throttle
opera tion. Check this before starting en gi ne .
6 3 Tighten air inlet elbow hose cl am ps , at turbocharge r and ai r
filter body .
6 4 Install air filter element in the intake ca st in g. Check that
element is properly seated in groo ve.
NOTE Be sure you have the 3 1 / 2 " hi gh ai r fi lt er e l e m e n t . The
older 3 " high e l e m e n t , if In st al le d, wil l not fi lt er in t h i s
c a s ting.
R e v . 8 Pa g e 10 of 1 5
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6 5 Install air filter co ve r, including gask et, , usi ng eight5/1 6"-18 x 2" hex head bolts a nd 9 /1 6" O . D . x 5/1 6" l . D . f J .-i
was her s. Make sure that a i r filter element is pro per ly engaged
in groove on und ersi de of cover before ti gh te n in g bolt s. Use a
light coat of grease on body ga sk et , su rf ac
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75 Install accessory instruments, if used. Refer to
manufacturer's instructions included with instruments.
76 Install muffler and exhaust system (not included with the
turbo system) as shown in fig- 2 6 . Because of various
vehicle/chassis combinations, the illustration provided is
general, but typical of the exhaust system routing.
NOT E: The factory muffler and exhaust system are NOT suitable
for turbocharged engines. The entire exhaust system, from the
turbo down-pipe through to the tail pipe, should be three inch_diam
eter_, including the muffler. Use of a smaller muffler or exhaust
piping will result in significantly inferior performance. A separate
3" high-flow exhaust system is available from GALE BANKS
ENGINEERING. This exhaust system includes a special low
restriction 3" core muffler, pre-formed tubing sections and all
components necessary to install the complete exhaust system.
The BANKS 3" exhaust system is REQUIRED for emissions legal
applications. Use of any other exhaust with the turbo system is
not emissions legal.
For those wishing to do their own exhaust system fabrication,
the following recommendations should be followed:
a. Be sure to use a high quality, low restriction 3" core
muffler, designed for turbocharged diesel applications.
( M o s t 3" mufflers available from muffler shops are low
quality, high restriction "economy" replacement mufflers,
usually based on a 2-1/2" or smaller c o r e . )
b. Make all bends as gradual as possible. Align all weld
joints as carefully as possible so the exhaust flow will
not experience "steps" in the tubing. See fig. 26A.
c. Do not " c h e a t " bends or make miter-weld joints. These
types of bends are too abrupt for proper exhaust flow.
d. Maintain adequate clearance to chassis, floorboards,
dr iv el ine , moving suspension parts, etc. Suspend exhaust
tubing in rubber hangers to allow for engine movement. The
original hangers may be reused if in good condition.
7 7 . Install a 9" x 24 heat blanket on turbo down-pipe. Slide
blanket up from bottom as far as possible. Wrap top of pipe
with the remaining part of the other 9" x 24." heat blanket.
Secure using wire ties provided.
78. Install a 7" x 24" heat blanket on Y-pipe extension, (that
portion of exhaust piping connected to the turbo mounting
bracket) sliding it up from the bott om , all the way up to the
pyrometer fitting on the' turbo mounting bracket. Secure,
again using wire ti es.
5/18/89 73TA01 R e v . 8 Page 12 of 15
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CHECKING ENGINE PERFORMANCE
Use your pyrometer (exhaust temperature gauge) to monitor your
en gi ne 's operation. At id le , EGT (exhaust gas temperature) will
be very l o w , perhaps only 150 degrees F. As the throttle is opened
for higher speeds and greater load s, the EGT will ri se. The highest
EGT will be seen under maximum load at full throttle, such as
climbing a steep grade with a heavily laden vehicle. Use caution ifyour EGT approaches 1100 degrees F, with 1150 degrees F being the A BSD
LUT E_M A X I_ MUM !
If the vehicle approaches those EGT level under these conditions,
downshift the vehicle to reduce the load, or back off the
thr ot tle . If frequent high EGT levels are en countere d, the fuel
delivery of the injection pump will have to be reduced by backing
out the Alien-head screw in the injection pump as indicated in the
Pump Ad ju st me nt section. A high EGT can also be caused by a
restrictive exhaust system.
We recommend engine oil temperature be below 24.0 degrees F, as
measured in the oil pan. ( A n optional oil temperature gauge isavailable from GALE BANKS ENGINEERING). Optimum oil temperature is
230 degrees F. Continuously high oil temperature is indicative of
the need for an additional oil cooler. If you do not have an oil
temperature gaug e, watch your oil pressure. Falling oil pressure
under a heavy load is caused by rising oil temperature. Use caution.
We recommend that coolant temperature, al so, should not exceed
220 degrees F.
5/18/89 73TA01 Rev.8 Page U of 15
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OPERATING CHARACTERISTICS
s h o u l d e x h i b i t t heYour BANKS turbocharged diesel engine
following operating characteristics:
Cruise Conditions (Constant 60 mph on Level R o a d ) : EGTshould be approximately 4 0 0 degrees F; boost gage, if so
equi pped, should read 1 to 2 pounds.
High Load Conditions (Up hill with Heavy Lo a d ) : EGT should
typically be 900 to 1000 degrees F, with 1100 as a m a x i m u m ;
boost levels may approach 9 pounds.
It is important to realize that diesels, unlike gasoline engines,
run cooler with additional air. It is impossible to run a diesel
too " l e a n " . Exhaust gas temperature rises as more fuel is added.
Turbocharging a diesel typically lowers the EGT. Normal cruise
condition EGT for a normally aspirated (non-turbocharged) dieselengine is typically 600 to 650 degrees F. As noted above, cruise
condition EGT for a turbocharged diesel is typically /i.OO degrees
F. This lower EGT translates directly to lower piston and valve
temperatures, and significantly increased engine life.
It is also important to understand that turbocharged boost
pressures are load related, that is the turbocharger makes boost
only when called upon to do so ( b y load requirements). The turbo
will not "make boost" with the transmission in neutral, but makes
boost proportional to the load. Long uphill grades, with a heavy
load, will result in maximum boost. In other words , the turbo
makes boost only when it is needed. This characteristic makesturbochargers so attractive that the vast majority of long haul
trucks and off-road earth moving equipment are equipped with
turbochargers. Turbocharging typically results in more power and
torque, better fuel economy and increased engine life.
- G B E -
GBE/1000
5/18/89 73TA01 Rev. 8 Page 15 of 15
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GALE BANKS ENGINEERING
Bill of Materials For
AUTOMATIC TRANSMISSION
ITEM # QTY / KIT DESCRIPTION1 1 Banks Turbocharger
2 1 Turbo Mounting Bracket
3 1 Intake Casting
5 1 Air Filter Cover
7 1 Air Filter Element, 3-1/2" tall
8 1 Air Filter Support Bracket
10 1 Intake Manifold Block-off Plate
11 1 Turbo Oil Drain Tube12 1 Y-pipe, left half
13 1 Y-pipe, right half
U 1 Turbo Down Pipe-- 1 Bracket, dipstick tube-- 1 2-1/4" Exhaust U-clamp17 1 2-1/2" Exhaust U-clamp
18 1 Pyrometer Adapter and Probe
20 1 Turbine Heat Shield
21 1 7" x 24" Heat Blanket
22 2 9" x 24" Heat Blanket
23 1 Air Inlet Gasket
24 1 Air Filter Cover Gasket25 1 Turbo Oil Drain Gasket
26 2 Turbine Outlet Gasket
27 1 0-ring
28 1 Grommet29 1 2" I . D . x 2" Silicone Hose
30 1 Compressor Air Inlet Elbow
31 1 Crankcase Vent Hose32 1 Crankcase Vent Hose Adaptor
33 1 Turbo Oil Feed Hose, 13- 1/2 " Long34 1 Turbo Oil Feed Hose , 2 1 " Long
35 1 Glow Plug Relay Bracket
36 2 N o. 16 Hose Clamp37 2 No. 36 Hose Clamp38 1 No . 52 Hose Clamp39 1 N o . 56 Hose Clamp
40 1 N o . 10 Hose Clamp
REV. 5/19/89 Sheet 1 of 21001/KN
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ITEM QTY/KIT DESCRIPTION
41 2 1/8" NPT Brass Hex Head Pipe Plug
42 1 1/8" NPT x -4AN 90-degree Elbow
43 1 1/ 4" NPT x -4AN 90-degree Elbow
44 1 1/4" NPT Tee with Tab
47 4 5/16" Split Lock Washer
48 8 13/16" O.D.x3/8" I. D . Flat Washer
49 4 3/8" Circle Lock Washer50 1 3/8" Split Lock Washer
51 14 9/16" O.D.X5/16" I.D . Flat Washer52 4 5/8" O.D.x3/8" I.D. Flat Washer
53 3 5/l6"-18 x1" Hex Head Bolts54 8 5/l6"-18x1-3/4" Hex Head Bolts55 1 3/8"-l6x1/2" Hex Head Bolt56 5 3/ 8" -l6x 1" Hex Head Bolt57 2 3/8"-1 6x1-1 /4" Hex Head Bolt
58 3 3/8"-l6x2-1/2" Hex Head Bolt59 1 3/8"--l6x4 1/2" Hex Head Bolt
61 6 3/8"-24 Collet Locknut
62 6 5/l6"-18x1" Stainless Hex Head Bolt63 4 3/8"x1-1/2" Stud
-- 2 11 / 16 " 0. D. x 5/16 flat washer65 2 3/8"x2" Stud-- 1 5/16" - 18 Nylock Nut
68 2 5/l6"-18x2" Hex Head Bolt
-- 1 K&N Air Filter Cleaner - 1 K&N Air Filter Oil69 2 1/4"-28x1" Hex Head Bolt
70 2 1/4"-28 Nylock Nuts71 2 1/2" O.D.x l/4" I-D. Flat Washers
-- 2 "Banks Turbo" Emblems
NOTE: SOME ITEMS IN KIT ARE NOT SHOWN IN ILLUSTRATIONS.
R E V . 5/1 9/8 9 Sheet 2 of
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