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with installation instructionsowners manual 2009 gale banks engineeringBanksDynaFact PYROMETER GAuGETHIS MANUAL IS FOR USE WITH SYSTEM 64001,64002 AND 64007Gale Banks Engineering546 Duggan Avenue Azusa, ca 91702(626) 969-9600 Fax (626) 334-1743Product Information & Sales: (888) 635-4565bankspower.com12/10/09PN 96325 v.5.0

General Installation PracticesDear Customer,If you haveany questionsconcerning theinstallation of theBanks DynaFactPyrometer Gaugeplease call ourTechnical ServiceHotline at (888)839-2700 between7:00 am and5:00 pm (PT). Ifyou have anyquestions relatingto shipping orbilling, pleasecontact ourCustomer ServiceDepartment at(888) 839-5600.Thank you.2 96325 v.5.01. This manual is aninstallation guide for all BanksDynaFact pyrometer gauges.For ease of installation andto determine what additionaltools or materials you willneed, read the entire 8–pagemanual before starting anywork. NOTE: there areportions of the installationprocedure and certainillustrations matched tospecific vehicle types. Forproper installation, selectthe text and illustrations thatmost closely correspond toyour vehicle. If you cannotcorrespond your vehicle to thetext provided, please contactCustomer Service at (626) 9699600 for assistance.IMPORTANT! Anytimethe vehicle is raised offits wheels, it shouldbe supported by safetystands or ramps ofadequate capacity for thevehicle’s weight. Neverperform any work undera vehicle supported onlyby its service jack or ahydraulic jack. Do not useconcrete blocks or othermasonry items that maycollapse under the vehicleweight.2. Position wires and hosesaway from exhaust heat,moving parts, and sharp edgesthat may cause cuts or otherdamage. Route or tie all wires aminimum of six (6) inches fromhot exhaust parts; eight (8) ormore inches is recommendedwhere possible.

Gauge PanelInstallationChoose a suitable location underthe lower edge of the dash panelfor mounting the instrumentpanel, or on top of the dash forthe molded instrument console.Be certain the instruments can beviewed conveniently by the driver.UNDER DASH: Using the panel asa template, drill two 3 16” diameterholes in the dash and mountthe panel with two No. 10 x 1 2”machine screws, nuts, and starwashers provided.ON TOP OF DASH: Wipe the dashtop with an alcohol pad or othersurface cleaner. Remove thebacking from the adhesive Velcrotape on the bottom of the consoleadapter, position the consoleadapter and press down firmly.Once the gauges are wired andsecured to the console accordingto the following instructions,attach the console assembly tothe console adapter using the twomachine screws provided.There are two methods of exhaustgas temperature measurementon turbocharged engines. Bothmethods are accurate if doneproperly, but will commonly differby as much as 300 F on the sameengine.TURBINE INLET TEMPERATURE:Measured in the exhaust streambefore the turbine wheel of theturbo (in the exhaust manifold).The tip of the pyrometer sensorshould not contact the metalsurface of the manifold.TURBINE OUTLET TEMPERATURE:Measured in the exhaust streamafter the turbine wheel (in theturbine outlet pipe). The pyrometersensor should be located asclose to the outlet of the turbo aspossible.Chevrolet/GMC 6.2L/6.5Ldiesel, naturally aspirated:Locate a portion of the thin-walledFigure 1exhaust tubing that is easilyaccessible with a drill and as closeto the engine as possible (not inthe actual manifold).Drill a 5 16” hole in the exhausttubing. Weld the 1 4” NPT bungprovided to the pipe centered overthe hole. Install the pyrometersensor into the bung.Chevrolet/GMC 6.2L/6.5L dieselwith Banks Sidewinder turbo:Install the threaded pyrometersensor into the 1 4” NPT threadedhole in the right exhaust manifold.Use anti-seize compound on thethreads. See Figure 1.Chevrolet/GMC 6.5L dieselwith factory turbo: TURBINEINLET TEMPERATURE: Disconnectboth the compressor inlet andoutlet hose joint connections.Loosen the V-band at the turbooutlet, the four bolts/nuts at theturbine inlet and the two bolts inthe oil drain flange. Remove theturbo from the engine.CHEVY/ GMC 6.2L/6.5LSelecting PyrometerSensor LocationMaximum allowable exhaust gastemperatures for diesel enginescan vary substantially, dependingon the engine and turbochargerconfiguration. Refer to the OwnersManual for your Banks system todetermine maximum temperaturespecifications for your specificapplication.3 96325 v.5.0

Mark a position on the exhaustmanifold to locate the pyrometersensor. Stuff a small shop towelor rag four to five inches into theexhaust manifold through theturbo mounting flange to preventchips from entering the manifoldwhile drilling and tapping.Drill through the manifold atthe location previously marked.Use a 7 16” drill, keeping the drillperpendicular to the manifoldsurface.Tap the drilled hole with a 1 4” NPTpipe tap. Check the thread depthas you tap by periodically removingthe tap and screwing the sensorfitting into the tapped hole. Thesensor should thread in three tothree-and-a-half turns hand-tight.Remove as many loose chips aspossible from the exhaust manifoldusing a shop vacuum, small brush,or fingers. Remove the rag usinga welding rod or coat hanger bentinto a hook.CAUTION: Make sure exhaustmanifold is free of foreignmatter prior to reinstallationof the turbo!exhaust passages. Typically theexhaust temperature will not differappreciably between the twopassages.Install the sensor in the manifold.Anti-seize on the threads isrecommended. Inspect the gasketsfor the oil drain and the turbineinlet and replace if necessary.Select the location that will simplifythe routing of the sensor wiring.Disconnect both the compressorinlet and outlet hose jointconnections. Loosen the V-bandat the turbo outlet, the four boltsand nuts at the turbine inlet andthe two bolts in the oil drain flange.Remove the turbo from the engine.Reinstall the turbo following factoryservice recommendations.TURBINE OUTLET TEMPERATURE:Locate a position in the turbineoutlet pipe that is accessible witha drill. Drill a 5 16” hole in the pipe.Weld the 1 4” NPT bung provided tothe pipe centered over the hole.Install the pyrometer sensor intothe bung.Cummins B5.9L/C8.3L dieselwith factory turbo: TURBINEINLET TEMPERATURE: TheCummins engines use a dividedexhaust manifold and turbo.The pyrometer sensor mustbe installed to sample exhausttemperature in one of the twoLOCATE PORT 3/4 INCH BEHIND FLANGE CENTEREDOVER REAR EXHAUST MANIFOLD PASSAGE/4"34 96325 v.5.0Drill through the manifold atthe location previously marked.Use a 7 16” drill, keeping the drillperpendicular to the manifoldsurface.CUMMINS B5.9L/C8.3LFigure 2DRILL AND TAP 1/4" NPT PORT REARPASSAGE OF EXHAUST MANIFOLD OUTLETMark a position on the exhaustmanifold to locate the pyrometersensor. (See Figure 2). Stuff asmall shop towel or rag four to fiveinches into the selected exhaustmanifold passage through theturbo mounting flange, to preventchips from entering the manifoldwhile drilling and tapping.

Tap the drilled hole with a 1 4” NPTpipe tap. Check the thread depthas you tap by periodically removingthe tap and screwing the sensorfitting into the tapped hole. Thesensor should thread in three tothree-and-a-half turns hand-tight.Ford/Navistar 6.9L/7.3L IDIdiesel, naturally aspiratedwith Banks Stinger: Install thepyrometer sensor into the 1 4” NPTbung provided on the headpipe.Anti-seize on the threads isrecommended.Remove as many loose chips aspossible from the exhaust manifoldusing a shop vacuum, small brush,or fingers. Remove the rag usinga welding rod or coat hanger bentinto a hook. CAUTION: Makesure exhaust manifold is freeof foreign matter prior toreinstallation of the turbo!Ford/Navistar 6.9L/7.3L IDIdiesel with Banks Sidewinderturbo: Install the pyrometer sensorinto the 1 4” NPT bung provided inthe turbine inlet casting. Anti-seizeon the threads is recommended.Install the sensor in the manifold.Anti-seize on the threads isrecommended. Inspect the gasketsfor the oil drain and the turbineinlet and replace if necessary.Reinstall the turbo following factoryservice recommendations.Ford/Navistar 7.3L IDI diesel,with factory turbo: Locate aportion of exhaust pipe behind theturbo that is easily accessible witha drill and as close to the engineas possible. Drill a 5 16” hole in theexhaust tubing. Weld the 1 4” NPTbung provided to the pipe centeredover the hole. Install the pyrometersensor into the bung.TURBINE OUTLET TEMPERATURE:Locate a position in the turbine outletpipe that is accessible with a drill.Drill a 5 16” hole in the pipe. Weld the1 4” NPT bung provided to the pipecentered over the hole. Install thepyrometer sensor into the bung.Ford/Navistar 7.3L IDI diesel,with factory turbo and BanksPowerPack: Install the pyrometersensor into the 1 4” NPT bungprovided in the turbine outletpipe. Anti-seize on the threads isrecommended.Ford/Navistar 6.9L/7.3L IDIdiesel, naturally aspirated:Locate a portion of the thin-walledexhaust tubing that is easilyaccessible with a drill and as closeto the engine as possible (not inthe actual manifold). Drill a 5 16”hole in the exhaust tubing. Weldthe 1 4” NPT bung provided to thepipe centered over the hole. Installthe pyrometer sensor into thebung.Ford/Navistar 7.3L PowerStroke diesel with factory turbo:TURBINE OUTLET TEMPERATURE:Locate a portion of the exhaustpipe that is easily accessiblewith a drill and as close to theengine as possible. NOTE: it maybe necessary to move as fardownstream as the inlet to thecatalytic converter to locate aportion of tubing that will allowthe sensor to clamp properly.Drill a 5 16” hole in the exhausttubing. Weld the 1 4” NPT bungprovided to the pipe centered overthe hole. Install the pyrometersensor into the bung.Ford/Navistar 7.3L DI PowerStroke, with factory turbo andBanks Stinger, Stinger Plus, orPowerPack: Install the pyrometersensor into the 1 4” NPT bungprovided in the turbine outletpipe. Anti-seize on the threads isrecommended.Pyrometer Kit64002 (TOP clamp)Installation:Select a location on the TurbineOutlet Pipe (TOP) with enoughclearance from the vehicle frame,engine, etc. to safely mount theEGT probe and clamp assembly.Center-punch the probe locationand drill a 1 4” hole into the TOP.Separate the ends of the clampand install the probe into the TOPhole. Reassemble and tighten theclamp around the TOP.Wiring InstallationAll gauge wiring should be routedaway from heat sources such asexhaust manifolds or piping, andaway from sharp edges. Avoidsharp bends or kinks. Secure thewiring to other wiring inside theengine compartment with cableties.5 96325 v.5.0