Technical > Tech
Byting Into New Diesel Electronics
Banks Engineering & Bully Dog Add Convenience to Power
story by Mike Magda
photography courtesy of manufacturers
Even as automakers design more complex computers to control diesel engine functions, aftermarket companies have found success not only in deciphering the codes but also switching a few ones and zeros to achieve specific goals. These enterprising companies find late-model diesel trucks especially strong candidates for finding unbridled horsepower. High-tech fuel injectors are responsive to intricate, multi-task instructions, and turbos are becoming larger and more efficient. There may be a trend to lower compression ratios to help with emissions and noise, but computers know the time-honored formula of more air and fuel equals torque and horsepower.
Traditional truck-owners may find these computer enhancements intimidating. Other gigabyte-savvy owners might be comfortable with computers but wish they had more control over the electronics and a deeper knowledge of what’s going on under the hood. Still others may just want to make sure the pricey upgrades are worth the effort and money before investing in the upgrades.
Plug-in technology has been obsessed with performance in the past. Now that computer programmers have a handle on controlling the engine, the focus will be on driver convenience and customer service. Recent product introductions from Gale Banks Engineering and Bully Dog Technologies reflect that trend and are designed so consumers can adjust, monitor and evaluate the performance upgrades offered by each company.
The PowerPDA from Banks is a standard PalmOne Tungsten E handheld computer or personal digital assistant (PDA) that can be integrated into a Banks Six-Gun Diesel Tuner. The PowerPDA allows drivers to adjust power levels at any time, monitor crucial engine functions and read diagnostic codes.
“A child could operate it,” promises Gale Banks. “With the PowerPDA we have changed the way you relate to your vehicle.”
While the PowerPDA is designed to enhance a current Banks product, the new Triple Dog Power Pup downloader from Bully Dog is a stand-alone programmer that not only offers shift-on-the-fly adjustment while driving; it allows owners to shift to an entirely different truck. The new Triple Dog downloader is compatible with all three major late-model diesel pickups. And in a new twist, the Triple Dog technology is available for a free 30-day trial. Bully Dog retailers like 4 Wheel Parts now have the ability to download a time-sensitive program that gives the vehicle owner a sample of the horsepower increase, and when the program has elapsed, the vehicle’s computer is automatically returned to stock condition.
“With this technology, there’s no sales pressure, no obligation and no money out of the pocket,” says Bart Miller, vice president of marketing at Bully Dog.
Perhaps the most convenient feature of the new Triple Dog downloader is the ability to download the latest upgrade programs using a home computer.
“Rather than having to send in your downloader for an upgrade, all you need is a USB cable and internet access,” says Miller.
The new pieces from Banks and Bully Dog showcase the emerging trends and engineering designed to add value to an existing product, especially in the performance arena. Diesel technology is advancing rapidly not only to serve the utility needs of owners, but also save money with lower fuel bills and increase the drivability of a notoriously unruly powerplant. In many cases, the aftermarket is pushing horsepower and torque to the mechanical limit of the engine and driveline. But not everyone needs the full power potential offered by the aftermarket. The option to choose a desired level of performance and ability to monitor the engine to ensure reliability is also important.
For those issues, the PowerPDA leverages the computing power of a PDA in conjunction with the Banks Six-Gun powertrain control module. The Six-Gun is available for ’03-05 Dodge Rams with the 5.9-liter Cummins engine, ’01-05 Chevy/GMC pickups with the 6.6-liter Duramax and ’03-05 Ford Super Duty trucks with the 6.0-liter Power Stroke. The Six-Gun offers six different power levels that can be adjusted in 20-percent increments from the cab with a rotary switch. The module also offers a number of reliability features such as EGT limitation, controlling fuel during shifting and keeping the turbo within a safe range of operation. For extra power, there’s a Speed-Loader plug-in upgrade. Banks says a Power Stroke engine can see up to 138 more horsepower and an additional 231 lb-ft of torque at the rear wheels with the Six-Gun and Speed-Loader. Other applications can see up to 155 more horsepower and 385 extra lb-ft at the rear wheels.
While the Six-Gun is adjustable with a rotary switch, going through the PowerPDA offers the driver flexibility in monitoring engine performance. The full color touch screen shows four parameters, including EGT and boost all the time. The other two displays can be chosen from a menu of 15 functions, including coolant temperature, oil temperature, transmission temperature, corrected miles-per-hour (w/ larger tires), transmission slippage, throttle position and torque-converter clutch status. The PowerPDA allows the user to select from different screen display designs, and future upgrades will be more graphically appealing. The PowerPDA also times 0-60 and quarter-mile runs and logs important data such as boost and EGT for later review. In addition, the Power PDA reads and clears vehicle diagnostic codes. If the “check engine” light comes on, just ask the PowerPDA to find the problem.
The PowerPDA can be located on a dash-mounted recharging station for easy reach and reading. The PalmOne unit retains all of its traditional capabilities as a personal assistant, can be upgraded with more than 20,000 available software programs and plays MP3 music. Banks’ engineers saw the potential of the hardware and chose to develop programs around it rather than design a Banks-specific stand-alone unit.
“Our intention for the PowerPDA is to provide an interface that is far more powerful than any that have come before it,” says Banks. “A piece of hardware that will quickly be obsolete with a small LCD screen readout is the last thing we wanted. The Power PDA allows us to be able to constantly update everything.”
For absolute power-control truck owners, the PowerPDA gives the user the ability to modify the top level of calibration to particular requirements. Banks says these modifications are strictly for off-road and racing use but allow the user to change limits for EGT, low-boost fueling and other critical engine parameters.
The obvious concern for PowerPDA users is security. A PDA left unattended can be an invitation to a smashed window but officials at Banks say the unit is small enough to fit in a shirt pocket. When the PowerPDA is removed, the Six-Gun tuner stays at the last-chosen power level so it’s not necessary to always have it in the cab. Just pop it in when you need to change settings often such as on a long trip with an RV in tow.
Despite the strong reputations many of the aftermarket diesel programmers have developed over the years, many skeptics remain. They just aren’t willing to part of hundreds of dollars to try one, even though many companies offer a 30-day full refund. Bully Dog has taken the worry out of a trial period with its new Triple Dog Power Pup downloader technology. Participating dealers who purchase the Master Downloader can upload a trial program into any late-model diesel pickup so customers can test drive the performance upgrade.
“It’s about a 50-85 horsepower level,” says Miller. “It’s different enough to show the potential but safe enough that it won’t hurt anything, even if it is double-stacked on another module.”
The test program won’t work if the engine management computer has been recalibrated with another aftermarket program but will work in conjunction with a plug-in module. Also, the test program can only be used once in each vehicle, so potential customers need not try visiting numerous Bully Dog dealers for repeat downloads.
“This will be the best sales tool anybody’s ever seen in this industry,” says Chris Russman of Cyclone Diesel Performance in Dallas. “Diesel performance is like handing candy to a kid. Once you hand them some chocolate, they’ll never be able to live without it.”
Russman says the ideal scenario is for the program to expire and return the engine computer to the stock settings when the customer is pulling a load in the Rockies. “He’ll be miserable on the way home and will buy one right away,” says Russman.
Miller says the idea for the trial program developed after seeing the success of trial software programs offered on the Internet. “Our team really got behind the idea and figured out how to get it down,” he says.
Bully Dog has offered a Power Pup downloader for each of the Big 3 diesels but there are three significant differences with the Triple Dog technology. In previous Power Pups, only the Ford offered adjustments on the fly. Now the Duramax and Cummins have that capability. Also, programs for all vehicles are included in each Triple Dog. So if an owner buys a different vehicle, he can take his downloader with him. Finally, the programs can be updated using a home computer.
The Triple Dog program is installed by hooking the controller up to the vehicle’s OBDII port. The download takes about 10 to 15 minutes. The program offers four settings: stock, tow (about 50-70 horsepower increase), performance (75-90 horsepower) and extreme (95-230 horsepower), according to Bully Dog.
The Triple Dog downloader doesn’t display engine information but it works with the Bully Dog Outlook that not only monitors critical engine functions but also can read and clear diagnostic codes and check 0-60 or quarter-mile times. The Outlook, which can be mounted in a convenient location on the A-pillar, can be used to change the Triple Dog’s power settings.
The future for additional high-tech enhancements is limited only by the engineers’ vision and budget restraints of the customer base. Manufacturers will be working to enhance the display graphics, provide more vital real-time engine information, and allow more adjustments to control braking or transmission operation. The technology is there but the challenge will be making it more accessible to truck owners. These new products from Bully Dog and Banks are clearly appealing to that audience.
Bully Dog products at 4wheelparts.com.
Banks products at 4wheelparts.com.