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Banks PowerPack® TLC™

SystemINCLUDING • STINGER® TLC™

1998-2002 Class-A Motorhomes withCummins ISC 315, 330 or 350 horsepowerengine models

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Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334-1743

Product Information & Sales: (800) 438-7693Customer Support: (888) 839-5600 Installation Support: (888) 839-2700

bankspower.com

© 2 0 0 2 G A L E B A N K S E N G I N E E R I N G

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Preparation and Precautions

Dear Customer,

If you have anyquestions concerningthe installation of yourBanks Power system,please call ourTechnical ServiceHotline at (888) 839-2700between 7:00 am and5:00 pm (PT). If youhave any questionsrelating to shipping orbilling, please contactour Customer ServiceDepartment at (888) 839-5600.

Thank you.

1. For ease of installation of yourBanks system, familiarize yourselfwith the procedure by reading theentire manual before starting work.This instruction manual contains 12pages of text, illustrations and parts listing.

2. Disconnect the ground cablefrom the battery before beginningwork. If there are two batteries,disconnect both.

3. Route and tie wires and hoses aminimum of 6 inches away fromexhaust heat, moving parts and sharpedges. Clearance of 8 inches or moreis recommended where possible.

4. During installation, keep yourwork area and components clean toavoid possible dirt entry into theengine.

TYPICAL TOOLS REQUIRED:• Pocket knife or X-Acto knife• Metric wrench or socket and

ratchet set including 10mm, 13mmand 15mm

• 5⁄16", 7⁄16" deep 1⁄4" drive sockets• 1⁄2" standard 1⁄4" drive socket• Long 1⁄4" drive extension• 1⁄4" ratchet• (2) 1⁄2" open end wrenches• Inch-pound and foot-pound torque

wrenches (suggested)• Standard and Phillips-head

screwdrivers• Dead blow hammer• Needle-nose pliers• Standard pliers• Rust penetrant (optional)• Test light or multimeter• Clean rags or shop towels• Standard set of open-end wrenches• Pry-bar or large water pump pliers• 9⁄16" socket and ratchet or wrench• Wire crimper/ stripper• Drill motor• 3⁄16" and 7⁄16" drill bits• 1⁄4" NPT tap and tap handle• Heat gun or cigarette lighter

(suggested)

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TURBOCHARGER REMOVAL1. Loosen the clamps that attach theair inlet tube to the inlet for theturbocharger, and remove the hoseelbow from the inlet to gain access tothe turbocharger.

2. Loosen the hose clamps on theturbocharger oil drain-tube hose,located between the two sections ofthe oil drain tube. Slide hose updrain tube towards turbocharger.Depending on the turbo orientation,the oil drain tube may need to becompletely removed prior toremoving the turbocharger.

3. Disconnect the oil supply hose atthe turbocharger.

4. Remove compressor outlet boosttube hose from compressor outletelbow. Leave the elbow attached tothe compressor housing. Stuff a smallshop towel or rag into the end of theboost tube to keep foreign objectsfrom entering.

5. Remove exhaust V-band clampand loosen any remaining clamps toallow the turbine outlet pipe to bepulled away from the turbocharger.

6. Note the orientation of thecompressor housing and stock boostreference nipple in the vehicle. TheBanks BigHead actuator must beinstalled in the same orientation.When the new assembly is installedthe orientation of the compressoroutlet should remain the same.Remove the turbocharger mountingnuts and the turbocharger from theexhaust manifold.

CAUTION: Anytime theturbocharger is removed fromthe engine, take care that noforeign objects enter any of theturbocharger connections on theengine or the turbocharger.Foreign objects entering air,exhaust, or oil connections maycause major damage to theengine and/or turbocharger andis not covered under any

warranty. Cover the open end ofthe intercooler pipe with a rag,as this pipe is very susceptible toforeign object entry.

THERMOCOUPLE INSTALLATION7. Clean and inspect the exhaustflange mounting surfaces on theexhaust manifold. Make sure thesurface is clean and dry.

8. Stuff a small shop towel or rag 4to 5 inches into the rear exhaustmanifold passage through theturbocharger mounting flange. This isto prevent chips from entering themanifold while drilling and tapping.The Cummins ISC engine uses adivided exhaust manifold andturbocharger. The thermocouplemust be installed to sample exhausttemperature in the rear exhaustpassage (toward the flywheel).

9. Drill through the exhaustmanifold into the rear passage at thelocation shown in Figure 1. Use a7⁄16" drill, keeping the drill perpen-dicular to the manifold surface.

Installation Procedure

Figure 1

10. Tap the drilled hole with a 1⁄4"NPT pipe tap. Check the thread depthas you tap by periodically removingthe tap and screwing thethermocouple into the tapped hole.The thermocouple should thread in 3to 31⁄2 turns hand tight. Do not installthe probe in place at this time.

11. Remove as many loose chips aspossible from the exhaust manifold.A shop vacuum, small brush orfingers will help. Now remove the ragusing a coat hanger bent into a hook. Caution! Make sure rags areremoved from exhaust manifoldprior to reinstallingturbocharger!

12. Install the thermocouple in themanifold using anti-seize on thethreads.For PowerPack installation, proceedto Step 17.

BIG-HEAD ACTUATOR INSTALLATION13. Before removing the stockactuator, note the orientation of theboost reference nipple. The BanksBigHead actuator will need to beinstalled in the same orientation.Remove the e-clip holding theactuator rod end to the wastegatearm. Unbolt the three actuatorbracket bolts from the turbinehousing. Note the location of allspacers and retain the spacers andbolts for reinstallation. Remove thetwo nuts holding the actuator to thebracket and remove the actuator.

14. Install the Banks BigHeadactuator in place of the factory

actuator using the two 7⁄8" longhexagonal spacers provided. Thespacers are provided to clear theturbocharger compressor housing onsome installations.15. Turn the rod end link on thethreads of the actuator rod until thehole lines up with the pin on thewastegate arm. Turn the rod endclockwise an additional six full turnssuch that it will preload thewastegate.

16. Apply a regulated supply of airpressure to the nipple of the actuatoruntil the rod extends enough to slipover the wastegate arm. Reinstall thee-clip on the wastegate arm. An extrae-clip is supplied in the kit. Tighten allbolts and nuts that remain loose.

TURBOCHARGER DISASSEMBLY and RE-ASSEMBLY17. Clamp the turbine inlet flange ofthe turbocharger in a bench vise.Loosen the six bolts attaching theturbine housing to the center bearingsection of the turbocharger. SeeFigure 2.

18. Remove the bolts, lock plates,and/or clamp plates. Carefullyremove the center bearing andcompressor assembly from the castiron turbine housing. If theturbocharger has been in service forsome time, rust and carbon mayprevent the center bearing andcompressor assembly from easilyseparating from the turbine housing.If light hammer blows, penetrating oilor heat will not free the compressorassembly from the turbine housing,the clamp bolt adjacent to the turbo

oil inlet connection may be backedout so as to push against the bearingcasting and separate the twocomponents. Remove any loose rustor carbon from the bearing housingthat might prevent properengagement into the new turbinehousing.

19. Install the center bearing andcompressor assembly into the newBanks Quick-Turbo turbine housing.Apply a dab of anti-seize compoundto the bolts, and then install bolts,clamp plates, and lock plates finger-tight to allow for final positioning. Ifthe Banks BigHead actuator isinstalled on the bracket in the wrongorientation, remove the actuator androtate it 180 degrees. Do not changethe length of the actuator rod. Re-installby applying regulated shop air to theboost reference nipple until the rodend drops over the wastegate arm.Re-install e-clip.

TURBOCHARGER INSTALLATION20. Install the new turbine inletgasket provided and apply a dab ofanti-seize compound to the fourturbo mounting studs. Install theturbocharger on the exhaustmanifold. Tighten the turbochargermounting nuts to 24 ft-lbs.

21. Align the compressor outletelbow with the boost tube andtighten the clamp. Tighten the turbinehousing clamp plate bolts to 11.3N-m(100 in-lb.) torque.

Spin the turbocharger shaft to makesure it turns freely. If not, loosen theturbine clamp plate bolts and check

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for misalignment between theturbine housing and turbochargercenter section. Retighten bolts andcheck again.NOTE: If alignment cannot beachieved by loosening andretightening the bolts, it may benecessary to clean rust or depositsfrom the engaging portion of thecenter bearing housing. Refer backto Step 18.Reconnect and tighten the turbo oilsupply hose.

22. Slide oil drain hose intoposition and tighten clamps. Replacegasket with new one provided, ifdrain line was removed.

23. Install the air inlet tube (fromthe air cleaner housing) and theturbo exhaust pipe onto theturbocharger. Reattach the wastegateactuator boost line using a crimp lockclamp provided. A length of bluesilicone hose is provided for boostline if needed.

OTTOMIND INSTALLATION24. Locate a gray, rectangular, 4-wire connector on the fuel injectionpump. See Figure 3. IMPORTANT: Do not confuse thisconnector with an identical onelocated slightly above theinjection pump near the valvecover of the engine. Theconnector may be painted tomatch engine color.Unplug the connector and plug thecorresponding connectors on theOttoMind wire loom into the factoryconnectors.

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Figure 2

INJECTION PUMP

DO NOT USE THIS CONNECTOR

(LOCATED ON THE PASSENGER SIDEOF THE VEHICLE)

GRAY CONNECTOR

Figure 3

25. Plug the Manifold AbsolutePressure (MAP) sensor into theOttoMind main wiring loom. Locatethe MAP sensor on the intakemanifold. It will be located towardthe back of the engine (toward theflywheel). Unplug the factoryconnector and plug thecorresponding connectors on theOttoMind wiring loom into the sensorand the factory wire loom.

26. Locate the 2-pin power sourceconnector in the main loom of theengine. This will be a 2-pin blackconnector with a cap located nearthe engine identification tag. It willmost likely be fastened to the loomwith nylon ties. Cut the nylon tiesand remove the cap, exposing theconnector. Plug the correspondingconnector on the OttoMind wireloom into the power sourceconnector. This connector may not beavailable on some installations. If not,use extension harness provided totap into a key-on 12v power sourcewithin the engine compartment.Install 5 amp fuse in fuse holder.

27. Locate the bulkhead connectorfor the transmission wiring. This willbe on the driver’s side of the coachnear the output end of thetransmission (away from the engine).See Figure 4. Expose the wires onthe bulkhead side of the connectorand locate wire number “107-T3.”This wire is normally green (but maybe another color) and should have itsname printed on it. This wire goes tocavity “E” in the bulkhead connector.Install a T-Tap on this wire.

28. Connect the blue wire with themale spade connector to the T-Tap.

29. Determine a good mountinglocation for the OttoMind. Makesure that it is in a location that isclear of water or debris from theroad. Using the two holes in themounting bracket, and the sheetmetal screws provided, mount theOttoMind to a suitable location suchas underneath the bed over theengine compartment.

30. Plug the main connector fromthe wire loom into the OttoMindconnector.

31. Connect the correspondingleads of the thermocouple leadwireto the thermocouple. Route theleadwire across the engine baytoward the OttoMind. Plug theremaining end of the leadwire intothe proper port on the OttoMind.Secure the leadwire with theprovided cable ties away from heatand moving components.

GAUGE INSTALLATION32. Choose a suitable locationunder the lower edge of the dashpanel for mounting the instrumentpanel provided where it can beconveniently viewed by the driver.Note: Molded instrument consolesfor top-of-dash mounting andadditional gauges are availablethrough Gale Banks Engineering.

33. Using the panel as a template,drill two 3⁄16" diameter holes in thedash and mount the panel with two

no. 10 x 1⁄2" machine screws, nutsand star washers provided.

34. Locate the gauge wire loomwith the four wire connector in theBanks system. Plug the connectorinto the corresponding location onthe OttoMind box. Route the wireloom from the OttoMind box towardthe gauge location.

35. Install the Dynafact boost andpyrometer gauges in the mountingpanel using the clamps andthumbnuts provided. Plug one blackwire lead into the (-) terminal oneach gauge. Plug the white wire intothe boost gauge and the red wireinto the pyrometer. Green wireremains unused.

36. Snap the lamp bulbs into thesockets in the back of each gauge.Using the wiring kit provided stripand connect one end of each of thesix-foot wires to one of the wires oneach of the lamp assemblies with thebutt connectors, using an appropriatecrimp tool. (See Figure 5). If morethan two gauges are being used, thewires from other bulbs may bedoubled up in the connectors. Nomore than two wires should be ineither end of the butt connector.Route the red wire to the fuse panel.Identify the circuit for the dashboardlights and remove the fuse. Install theappropriate fuse tap under the non-powered leg of the fuse. This is theside of the socket that has no powerwhen the dash light switch is on, astested with a test light or multimeter.Cut and strip the red wire to anappropriate length and install the

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female push-on connector. Connectthe wire to the fuse tap. Route theblack wire to a location where agood ground can be found. Cut andstrip the wire to an appropriatelength and crimp the ring terminal tothe wire. Install the ring terminalunder an existing grounded bolt orwasher, or use the self-tapping screwprovided to connect to ground.

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BULKHEAD CONNECTOR

TO TRANSMISSIONCONNECTOR

BULKHEAD CONNECTOR

VIEW LOOKING UPT-TAP ON WIRE 107-T3

TO TRANS CONNECTOR

Figure 4

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Figure 5

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Checking Engine PerformanceGo over the entire installation as aprecautionary check to ensure thatall clamps are tight, wiring and hosesare properly routed, and connectionsare tight. Start the engine and allowit to warm up. Drive the vehicleunder light load (normal around-town driving) for 20 to 30 minutes,and listen for any exhaust leaks orrattles, or intake boost leaks. Shut offthe engine and re-tighten allintercooler and turbocharger boostclamps. These connections may haveloosened with time, and if leaking,will cause a drop in boost pressurewith a loss in performance. Checkthat clamps are properly positionedon hoses, and periodically checktightness of hose clamps at regularmaintenance intervals, such as whenthe oil is changed.

Observe the operation of the boostand pyrometer gauges while drivingunder varying conditions.Turbocharger boost pressure willincrease as a function of load andengine RPM, thus the engine willproduce little boost while cruising atlight throttle, with maximum boostwhile climbing hills heavily loadedand during acceleration. Note theboost level seen during hardacceleration with a given load. Ifperformance seems to havedeteriorated sometime in the future,the maximum boost figures may becompared to see if boost hasdropped off. Lower boost may be

caused by turbo ducting leaks, amalfunctioning wastegate or fuelinjection pump, or dirty air filter.Typical maximum boost pressuresettings may vary considerably withmodel year of vehicle, engine CPLand altitude.

Use your pyrometer gauge tomonitor exhaust gas temperature(EGT) in the engine. At idle, exhaustgas temperature will be very low,perhaps only 300° F. As the engine isaccelerated for higher speeds withgreater loads, the EGT will rise. Thehighest EGT will be seen undermaximum load at full throttle, suchas climbing a steep grade with aheavily laden vehicle.

A bypass plug is included in the kit. Ifthe OttoMind module must beremoved for any reason, installbypass connector on end of mainwire harness.

Your OttoMind is calibrated tomaintain a maximum EGT of 1300°F.The EGT may exceed 1300° for shortperiods of time during high-loadconditions. This is normal and EGTshould return to at or below 1300°within a few seconds. If you find thatEGT remains high for any length oftime, check for boost leaks of a dirtyair filter. If the condition persists,contact our technical servicedepartment at (888) 839-2700.

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Parts List:1998-2002 Class-A Motorhomes with Cummins ISC 315, 330 or 350 horsepower engine models

ASSEMBLY, Quick-Turbo w/ Big Head Actuator (PowerPack only)ACTUATOR, Big Head (Stinger only)OTTOMIND TLCHARNESS, Main WiringTHERMOCOUPLEGAUGE, PyrometerGAUGE, BoostLEADWIRE, PyrometerHARNESS, Gauge WiringPANEL, Two-Gauge Mounting Kit(2) CLAMP, Spring BandKIT, Light WiringCONNECTOR, T-Tap(2) SCREW, Sheet MetalANTI-SEIZEGASKET, Turbine InletFUSE, 5AHARNESS, Power ExtensionE-ClipGASKET, Oil DrainSILICONE HOSEBYPASS PLUG(6) CABLE TIE, 8"(3) UROCALOWNERS MANUALCARD, Product RegistrationWARRANTY STATEMENT, 2 year

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Gale Banks Engineering 546 Duggan Avenue • Azusa, CA 91702 (626) 969-9600 • Fax (626) 334-1743

Product Information & Sales: (800) 438-7693Customer Support: (888) 839-5600 Installation Support: (888) 839-2700

bankspower.com