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Frequently Asked Question's

12 Valve Questions

98-02 Ram Questions

03-06 Ram Questions

01-04 Duramax Questions

Important note on the PowerMaxCR for a 2006 or 2007 Dodge Ram:

- The rail pressure part of the PowerMaxCR does not currently work on Dodge trucks with a build date of June 2006 or later. TST is working on this problem and will update the program and/or harnesses at no additional cost when we get a fix. In the mean time, do not connect the TST rail pressure harness to the rail pressure sensor, leave the stock harness connected to the rail pressure sensor. - Also, the PowerMaxCR does not currently work on some Dodge trucks with a build date of June 2006 or later even with the TST rail pressure harness not hooked up. Some trucks run rough and some set a P0148 code. TST has stopped shipping PowerMaxCR units for Dodge trucks with a build date of June 2006 or later until the problems have been resolved.

 

I need to send my PowerMax in for service/updgrade. Do I need to call first and get an RMA#? What do I need to send and where do I send it?

- TST does not use RMA#s and you don't need to call first. If you are out of warranty (over 2 years from purchase date), there is $25 per item fee for checking it out (EXAMPLE- sending in a Powermax computer, a remote and one harness would be $75 + Shipping). There are no charge for repairs done under warranty period. There is no charge for reflashing for bug fixes. For more information on upgrades and prices, continue reading the FAQs below.

If sending a PowerMax to TST to be serviced, include a note with the following information:

- Name
- Phone number
- Address
- Make and year of truck
- Date of purchase. Need copy of invoice. If no proof of purchase, then TST will use the date it was shipped from TST.
- A detailed note stating what needs to be done. If it was causing any fault codes, include the exact fault code numbers (not "that crank code I heard about", etc).

- Send the PowerMax and the remote if you are getting an upgrade. Both the PowerMax and the remote will need to be reflashed when upgrading to new features. You do not need to send the harnesses for upgrades.
- Send the harnesses if you feel they could be causing problems so we can check them out.

- Send it to the address below, and don't forget the note:

TST Products
268 N Country Club Rd
Columbus IN 47201

 

 

 

Regarding any Diesel engine:

I don't have PowerMax or remote controller instructions, where can I get them?

- The instructions are available at this link Installation Instructions

 

Do I need my PowerMax Serial Number before calling TST technical support?

- Yes! You need to have the serial number and any fault codes that your truck is setting. Have this information ready before calling TST.

 

Where is the PowerMax serial number?

  

- The serial number is on a silver tag that is either on the side or on the end of the PowerMax.

 

How do I find out what Trouble Codes I have?

 

 

- On a Dodge, with the engine off, cycle the key from off to on 3 times.  The third time the key is turned on, the Trouble Codes will be displayed in the odometer readout. On an 06 Dodge, it works better if you start with the key on.   You can look up what the numbers mean at various places on the web, one example is http://www.actron.com/code_lookup.php .  There is no way to clear them without a Diagnostic Scan Tool.  For Chevy and Ford, you will need a Diagnostic Scan Tool to read and clear the codes.  Some auto parts stores will do this for free or a small charge.  A Diagnostic Scan Tool that will read only is about $40, and one that will read and clear codes is about $80.

Getting MAP sensor codes

-Try removing MAP sensor and cleaning the inside of it with electrical contact cleaner or brake parts cleaner.

-Try a new MAP sensor.

-Try a new MAP sensor harness.

-On '98-'02 Dodge check the 12V keyed connection on the firewall. If 12V is lost to the TST box it will not send MAP signal to Dodge computer.

Has smoke and low power even at low Power settings.

-Air leak would cause smoke at lower power settings. Charge air cooler could be leaking, 2005 Dodge has plastic sides and is not uncommon for them to pull apart.

-Check exhaust manifold bolts for tightness, see if there is any soot leaking out.

-Check that the exhaust system is not blocked or pinched off.

-Check that the air cleaner is clean and has no debris.

Runs good at first, then cuts out, misses, etc …

 

-Fuel pump is not keeping up.  Need an aftermarket fuel pump.  TST sells Fass.

 

 Regarding the Dodge Cummins 12 valve engines:

Low Power & MPG Loss

-Timing may have slipped

Low Power and/or Low Boost and High Exhaust temps

-Low Fuel Pressure, Should be 20PSI at Idle and 30 PSI @2000 RPM

-Thottle not going full forward on injection pump.

White Smoke

-Slipped timing

-Grid heater not working

Black Smoke

-Blown charge air cooler hose

-AFC spring needs adjusted

-Defective Turbo

Low Boost with High EGT's

-Blown charge air cooler hose

-Leaking intake or exhaust manifold gaskets

-Plugged air filter or plugged CAT converter

Hard Starting after setting overnight

-Leak in rubber fuel line return hose

 

 Regarding the PowerMax for 1998 1/2 - 2002 Dodge Cummins 24 valve engines:

Where is the PowerMax serial number?

  

- The serial number is on a silver tag that is either on the side or on the end of the PowerMax.

 

How much power does the PowerMax, PowerMax2, PowerMax3, and PowerMax Competition add?

 

The non adjustable PowerMax has a power level of 65 horsepower and 160 lb-ft of torque above stock at the ground. The non adjustable PowerMax2 adds 90 horsepower and 240 lb-ft of torque at the ground.  The non adjustable PowerMax3 adds 120 hp and 360 torque at the ground.

 

The adjustable PowerMax3 is adjustable with a remote.  Level 0 = stock power, 1 =  20 hp and 40 lb-ft above stock at the ground with each step up equaling about another 15 horsepower (tapering down at the higher levels) and 40 torque at the ground.

 

Power Level     HP   Torque

          0             0          0

1             20        40

2             35        80

3             50       120

4             65       160      Max for stock automatic trans

5             80       200

6             90       240      Max for stock manual trans

7            100      280

8            110      320

9            120      360

 

A good rule of thumb is about 120/9 = about 13 HP increase per level.

 

The PMCE (Competition) adds 180 HP and 450 lb-ft Torque (on level 9) for the standard engine.  The HO (High Output) engine (2001-2002) already has 245 HP and the PMCE (Competition) does not make as much of a difference and adds 80HP and 310 lb-ft of Torque.

 

The PM3 starts cutting back at 3000 RPM.  The PMCE (Competition) starts cutting back at 4500 RPM.

 

 

Shortly after I installed a PowerMax my injection pump failed. I've heard power boxes are hard on injection pumps.

 

-The PowerMax does not directly cause injection pumps to fail.  If a VP44 is marginal it may fail sooner with an electronic power modification, but the VP44 was going to fail soon anyway.  If fuel pressure is marginal, this can also add to VP44 failures.

What does "Bnd" mean on the R45 (Remote with Boost & Pyrometer)?

-Band, which had to do with the bandwidth of the EGT. No longer used for anything and has been eliminated on the new remotes.

Sometimes is not fueling and sometimes the fuel light does not come on, or not fueling at all and the fuel light does not come on.

-Check the in-line fuse. When you check the fuse it may look good but still be blown, so either check it with an ohm meter or replace it with a new one. Replace it with a 5 amp fuse.

-Insure connections are good, including the connections on the in-line fuse (check for corrosion and/or loose fuse) and the injector pump connection for loose Scotchlock™ or grabber. Check all Scotchlock™ and grabbers very carefully. They often look like they're making contact, but are not. The best thing to do is disconnect all connections with Scotchlock™ or grabbers and use a Posi-Tap™ or solder the wires together. TST sells Posi-Tap™ connectors for $2 each and you can also get them at Walmart. You will need part number PTA1218-40.

Blown fuse in harness (pump wire) usually means:

-Loose connection to MAP sensor, usually the ground, or Loose connection to pump wire. Check all Scotchlock™ and grabbers very carefully. They often look like they're making contact, but are not. The best thing to do is disconnect all connections with Scotchlock™ or grabbers and use a Posi-Tap™ or solder the wires together. TST sells Posi-Tap™ connectors for $2 each and can also get them at Walmart. You will need part number PTA1218-40.

R45 flashes all 8s.

-Check the pump wire and fuse for loose connection. Check all Scotchlock™ and grabbers very carefully. They often look like they're making contact, but are not. The best thing to do is disconnect all connections with Scotchlock™ or grabbers and use a Posi-Tap™ or solder the wires together. TST sells Posi-Tap™ connectors for $2 each and can also get them at Walmart. You will need part number PTA1218-40.

Dots under Boost Gauge blink when key is turned on and the engine is not running.

 

- This is normal.  The dots will blink for a few seconds while the PowerMax initializes.

 

Dots under Boost Gauge blink when EGT cutback is in effect.

 

- This is normal.  The dots under the EGT gauge will blink while the PowerMax cuts power from the PowerMax to control the EGTs, and the dots under the Boost gauge will blink while the PowerMax cuts power from the ECM to control the EGTs.

 

The EGT cutback (over temperature cutback) is not working.

 

- When changing the maximum exhaust temperature for the over temperature cutback, you need to press and hold the gray button until it says "SAU" (for SAVE). Sometimes it flashes the SAVE real quick, which is normal.

 

Dots flash all the time (flashes all decimals) and no power.

 

- Check if EGT limit is set to 1700, which will cause the EGT cutback to stay on all the time. This is a bug in the program, can't set EGT limit to 1700.

 

How to take the PM/PM2/PM3 for the 1998-2002 Dodge out of the system to get back to stock for testing.

- To put it back to stock, disconnect the TST MAP sensor connector from the boost sensor and reconnect the factory connector, and disconnect pump wire.

- Also disconnect the PowerMax from the harness by unscrewing the round connector that connects them together.

The remote says "Open" on the EGT display.

- You have an older unit without EGT display capability.  To check, disconnect the PowerMax from the harness and count the pins in the round PowerMax connector.  If there are only 6 pins, your unit does not have EGT display capability.

-There is a bad connection to the thermocouple or it is defective. Note: The thermocouple is the temperature sensor in the exhaust manifold and the pyrometer is the temperature gauge in the remote.

- If you have the 9-pin connector and the thermocouple and lead wire are OK, then send your PowerMax to TST with a note explaining the problem.  Sometimes it just needs to be reprogrammed.  The cost for reprogramming/repairing is $55.

Misses under hard load and green light on box is staying on.

-Check fuel pressure at idle, should be 10-16 psi.

-Check fuel pressure at wide open throttle, should be at least 6 psi.

Sometimes has a miss.  Sometimes green light flickers, engine surges.  Have checked all connections.  MAP sensor is good.  Problem goes away when PowerMax is removed.  Tried another PowerMax, got ECM reflashed, checked injector pump and injectors, has good fuel pressure, nothing helps.

 

-Check all Scotchlock™ and grabbers very carefully.  They often look like they're making contact, but are not.  The best thing to do is disconnect all connections with Scotchlock™ or grabbers and use a Posi-Tap™ or solder the wires together. TST sells Posi-Tap™ connectors for $2 each and can also get them at Walmart. You will need part number PTA1218-40.

 

 

-It's not uncommon for a blown diode in the alternator to cause a pulsating signal in the power circuit.  Check if the alternator has a blown diode.

 

PowerMax Pin Out

Engine Harness Connector Pin Out

 

 

  1. 12 Volt Keyed Run and Start
  2. MAP Boost Sensor to Cummins ECM
  3. MAP Boost Sensor Signal from engine
  4. Currently Not Used
  5. Engine Ground
  6. Thermocouple positive (yellow)
  7. MAP Boost Sensor Ground
  8. Thermocouple negative (red)
  9. Fused Injection Pump Signal (5 Amp Max)

The female side of the pin connector has terminals 1-9 engraved on the connector. Do not start truck while the POWERMAX is not connected. With the key tuned to the run position, engine NOT running, check the following, with the POWERMAX wiring harness unplugged in cab of truck, with a digital volt/ohm meter.

Using Pin# 5 as ground, Pin# 1 should measure battery voltage 11 to 14 volts DC. If no voltage, check the 12 volt Scotchlock™ connection between the POWERMAX wiring harness and the vehicle harness underhood. Check all Scotchlock™ and grabbers very carefully. They often look like they're making contact, but are not. The best thing to do is disconnect all connections with Scotchlock™ or grabbers and use a Posi-Tap™ or solder the wires together. TST sells Posi-Tap™ connectors for $2 each and can also get them at Walmart. You will need part number PTA1218-40.

Using Pin# 5 as ground, Pin# 9 should measure battery voltage 11 to 14 volts DC. If no voltage, check the Scotchlock™ connection at the injection pump, and the fuse in the POWERMAX main wiring harness. Check all Scotchlock™ and grabbers very carefully. They often look like they're making contact, but are not. The best thing to do is disconnect all connections with Scotchlock™ or grabbers and use a Posi-Tap™ or solder the wires together. TST sells Posi-Tap™ connectors for $2 each and can also get them at Walmart. You will need part number PTA1218-40.

Using Pin# 8 as ground, Pin# 6 should measure less than .0085 volts or 8.5 milli volts if temperature is below 400 F.

Using Pin# 7 as the ground, Pin# 3 should measure 1.05 volts DC on 2001 vehicles and 0.5 volts DC on 1998-2000 vehicles.

Can I add a R35, R45, or R46 adjustable remote to my PowerMax?

- If the PowerMax has a phone jack on the back, then a remote can be added. It might need a reflash. Get the serial number of the PowerMax and call TST to find out if it has the right program. For an R45/R46, disconnect the PowerMax from the harness and see how many pins are in the connector. If it has 9 pins, then the R45/R46 will work. If it only has 6 pins, then only the R35 will work.

 

Boost light is on when the key is turned on and the engine is not running.

- This is normal.

 

DRB Tool reads 14 psi MAP when the key is turned on and the engine is not running.

 

- This is normal, MAP is the Absolute Pressure (Ambient).

 

DRB Tool reads 0 psi MAP when the key is turned on and the engine is not running.

 

- On a 2000-2002 Dodge, the MAP voltage with the key is turned on and the engine is not running is 1V. 

 

 - On a 1998-2000 Dodge, the MAP voltage with the key is turned on and the engine is not running is .5V, some DRB Tools will read this as 0 psi.

 

Does the PowerMax3 or PowerMax Competition do timing advance?

 

- The PowerMax3 and PowerMax Competition do not directly do timing advance.  Under steady state conditions, such and cruising on the highway, when the PowerMax adds power the ECM will compensate and cut power to keep the power constant for a constant load.  When the ECM cuts power, it will advance timing (to reduce emissions).

After installing a Pac-Brake (or other brand), the PowerMax quits working right, the remote blanks out when the power is turned on.

- You need to install a 1N4004 diode between the power wire that activates the brake solenoid and ground. Connect the end that does not have a silver stripe to ground.Some Radio Shack stores will have this diode, Catalog #276-1103. Or try www.jameco.com or www.mouser.com.

 

 Regarding the PowerMaxCR for 2003 - 2005 5.9L Dodge Cummins Common Rail:

 

 

Where is the PowerMax serial number?

- The serial number is on a silver tag that is on the end of the PowerMax.

 

My PMCR Serial 4000+ for my 04.5 or newer truck didn't come with a boost control, where is it?

 

- You no longer need it if your serial number is past 4000.  We have programed these units with the Boost Limit feature.  This allows you to control boost electronically, so you do not need the wastegate modification and can skip steps 23-27 on page 4 of the instructions.

- The newer R47 remotes have Boost Limit control that allows you to set the boost limit to OFF or from 35-40 psi, the same as the R49.

 

- A third mode has been added to the R37 to turn Boost Limit on or off.  Press the center (gray) button until the top LED displays a "b".  The bottom LED will display a "0" or a "1".  A "0" means Boost Limit is off and a "1" means Boost Limit is on.  When Boost Limit is on, the POWERMAXCR™ computer will limit power to keep the boost from exceeding the safe limit for the stock turbo (35 psi).

Is it OK to pressure wash the PowerMax?

- NO! The PowerMax is water resistant, but not waterproof.

 

When the rail pressure harness is connected, the truck runs bad, misses, and surges.

 

The rail pressure connector might be hooked up backwards where the stock harness connects to the TST harness.  The stock harness connector will have a clip on it with a thumb tab to press when removing the connector.  This clip is designed to keep the connectors from coming apart by snapping over a stub and it needs to connect to the correct side of the TST rail pressure harness connector.  The stub on the correct side will be tapered so it is triangle shaped if you look at it from the side.  The stub on the wrong side is not tapered and is oval shaped if you look straight down on it and rectangle shaped if you look at it from the side.  If you still have problems after making sure the connector is on right, then check the TST rail pressure harness to make sure it didn't get wired backwards.  To do this, disconnect both ends of the TST rail pressure harness from the truck and connect the TST connectors together (make sure you have the clip on the correct stub).  Check that the black wires are lined up straight across and the blue wires are lined up straight across.  Check that the white wire goes into the connector with the clip and the purple wire goes into the connector with the stub.

The PowerMaxCR on my late 06 or early 07 Dodge sets a P0148 code and it runs rough.

- The rail pressure part of the PowerMaxCR does not currently work on Dodge trucks with a build date of June 2006 or later. TST is working on this problem and will update the program and/or harnesses at no additional cost when we get a fix. In the mean time, do not connect the TST rail pressure harness to the rail pressure sensor, leave the stock harness connected to the rail pressure sensor. - Also, the PowerMaxCR does not currently work on some Dodge trucks with a build date of June 2006 or later even with the TST rail pressure harness not hooked up. Some trucks run rough and some set a P0148 code. TST has stopped shipping PowerMaxCR units for Dodge trucks with a build date of June 2006 or later until the problems have been resolved.

 

The instructions on the web site don't match my PowerMaxCR. I have only 1 orange wire. My remote does not have the screens shown in the instructions.

 

If you only have 1 orange wire, connect it to fuse 28. Connect the red wire to fuse 27. To get a copy of the correct instructions, call TST and press 1 and ask for the instructions to be mailed, emailed, or FAXed to you.

 

The instructions show which fuses to connect the orange wires of the Cool Down Timing Harness to, but don't say which orange wire goes where.

 

Both orange wires are the same, they are connected together, so it doesn't matter which orange wire, connect one to each of the 2 fuses shown in the instructions.

 

How much power does the PowerMaxCR add?

 

The PowerMaxCR has 10 power levels @ 2900 rpm and 10 torque levels @ 1600 rpm that are adjustable under power on the fly.  Setting the power level on zero turns truck power back to stock.  Power level #1 advances timing only for better fuel mileage, reduced exhaust temperature, and adds about 35 wheel horsepower but does not add extra fuel.  Power levels 2 thru 9 add increasing amounts of fuel and about 20 horsepower per step at 2900 rpm.  Each torque setting step adds about 60 additional foot pounds of torque at 1600 rpm and Torque Level has no effect until the Power level = 2 or above.

 

Power Level     HP increase at 2900 rpm

          0                      0

1                      35

2                      55

3                      75

4                      95

5                      115      need pusher fuel pump

6                      135      need pusher fuel pump

7                      155      need pusher fuel pump

8                      175      need pusher fuel pump

9                      190      need pusher fuel pump

 

Note: The Torque Level has no effect until the Power level = 2 or above

Torque Level    Torque increase at 1600 rpm

1                      60

2                      120

3                      180

4                      240

5                      300

6                      360      need pusher fuel pump

7                      420      need pusher fuel pump

8                      480      need pusher fuel pump

9                      540      need pusher fuel pump

 

Boost elbow will turn boost up to about 40 psi to help reduce exhaust gas temperature.

Runs good at first, then cuts out, misses, etc …

 

- Fuel pump is not keeping up.  Need an aftermarket fuel pump.  TST sells Fass.  A pusher fuel pump needs to be added in series with the stock lift pump when at Power level 5 or above.

 

The PowerMax is not adding power.

-If you are not using a thermocouple (temperature sensor) the red and yellow wires of the PMCR need to be connected together. If they are not, then it could cause a false temperature reading, which will cause the EGT cutback to go into effect.

 

What is the best way to connect the power to my FASS pump on a 04-1/2 to 05 Dodge?

 

- Remove the Fuel Pump Relay. There should be 5 pins. Not all relays are labeled on the bottom, so use the drawing on the side of the relay to identify the pins. Pins 85 and 86 are the coil to the trip relay. Pin 30 is where the 12V source is coming from. Pin 87 puts power to the transfer pump. Bend pin 87 out to the side so you can connect a mini female spade terminal and connect it to the FASS Pump power wire. Connect the FASS Pump ground to the battery ground.

 

Getting Crank/Cam codes, such as P0016 and/or P0341.

 

- Check if there is an after market auto start system on the truck, such as a Python Alarm with Auto Start from Directed Electronics.  If so, need to disconnect the wire that is connected to the Cam/Crank sensor, ECM pin 24, K44 18DB/GY = CMP SIGNAL.  This will disable the auto start, but the Crank/Cam codes should no longer come up.  In some cases, adding a 10k ohm (about a 1/4 watt) resistor in series with the auto start wire going to ECM pin 24 will allow the auto start to work and still not set codes.

What does "bt" mean on the R47?

-Box Temperature, which is the temperature of the PMCR module. No longer used for anything and has been eliminated on the new remotes.

 

The EGT cutback (over temperature cutback) is not working.

 

- On some of the older remotes, when changing the maximum exhaust temperature for the over temperature cutback, you need to press and hold the gray button until it says "SAUE" (for SAVE). Sometimes it flashes the SAVE real quick, which is normal.

The Power digit on my R37 (remote without gauges) sometimes flashes.

-If you are not using a thermocouple (temperature sensor) the red and yellow wires of the PMCR need to be connected together. If they are not, then it could cause a false temperature reading, which will cause the EGT cutback to go into effect. On the R37 (remote without gauges) the Power digit will blink when the EGT cutback is in effect.

 

 

R47 or R49 EGT displays 1769 and dots blink, no power added.

 

-Yellow wire from thermocouple is not connected.

 

R47 or R49 EGT displays 31.

 

-Red wire from thermocouple is not connected.

How much dielectric grease should I use?

-Don't use dielectric grease. It will not help and can actually make it worse. The connectors have seals that will keep moisture out.

Getting Crankshaft Position Sensor code P0336.

-Some trucks will get this code if you have a PMCR with serial number 2879 or under. It tends to occur most around 1100 RPM under load.  It does not mean there is actually a problem and it can be ignored, but sometimes the engine will "stumble" or "hiccup" at low RPM under load.  This problem can usually be fixed by reprogramming the PMCR module.  There is no charge for the reprogramming to fix this code. If your PMCR serial number is 2880 or higher it has the latest fix for the P0336 code, so if you are still getting this code then there is currently nothing more we can do. It often helps to remove the timing harness and reconnect it to make sure the connectors are seated well. Don't use dielectric grease. It will not help and can actually make it worse. The connectors have seals that will keep moisture out. Make sure the Cam and Crank Sensor connectors are correct. It is possible to get them backwards. The connector farthest from the PMCR should go to the Crank Sensor, which is near the bottom of the engine, and the connector closest to the PMCR should go to the Cam Sensor, which is near the center of the engine. TST is continuing to try to resolve this issue. Check these FAQs for updates.

Getting P0606 trouble code.

 

- It is not unusual to get this code. It does not mean there is actually a problem and it can be ignored. This code occurring can be eliminated by replacing the Injector Harness with a new type.  There is no charge if still within warranty.  The warranty is 1 year of purchased before May 2006.  The warranty was extended to 2 years starting May 1st 2006.

 

Getting P0628 trouble code.

 

This code means "Fuel Pump Control Circuit Low".  It can occur if you don't have a pusher pump wired correctly.  See "Connecting the Power Wire of a Pusher Pump" below.

   

06 Dodge starts hard after running on Cool Down.

 

The lift pump may not be running during Cool Down.  You will need to use an automotive relay to power the pump during Cool Down.  DO NOT CONNECT THE PUMP POWER WIRE TO EITHER FUSE 28 OR 32.  Doing so will destroy the circuit board in the POWERMAXCR™ timing harness when the truck is running during Cool Down.   Connect an automotive relay as follows:    Connect pin 85 of the relay to ground and connect either fuse 28 or 32 (either orange wire from the POWERMAXCR™ ) to pin 86 of the relay.  Connect pin 30 of the relay to 12V battery and connect pin 87 of the relay to the pump power wire.

  

Connecting the Power Wire of a Pusher Pump.

 

On a 03 and early 04 Dodge:

DO NOT CONNECT A PUSHER PUMP POWER WIRE TO EITHER FUSE 36 OR 50.  Doing so will destroy the circuit board in the POWERMAXCR™ timing harness when the truck is running during Cool Down.  If your pump has been moved to the tank, follow the instructions below for a 04 1/2 to 05 Dodge.  Otherwise, make sure your pump kit has a relay to power the pump.

 

On a 04-1/2 and 05 Dodge:

DO NOT CONNECT A PUSHER PUMP POWER WIRE TO EITHER FUSE 36 OR 50.  Doing so will destroy the circuit board in the POWERMAXCR™ timing harness when the truck is running during Cool Down.  Remove the Fuel Pump Relay. There should be 5 pins. Not all relays are labeled on the bottom, so use the drawing on the side of the relay to identify the pins.  Pin 87 puts power to the transfer pump. Bend pin 87 out to the side so you can connect a mini female spade terminal and connect it to the pusher pump power wire. Connect the pusher pump ground to the battery ground.

 

On a 06 Dodge:

DO NOT CONNECT A PUSHER PUMP POWER WIRE TO EITHER FUSE 28 OR 32.  Doing so will destroy the circuit board in the POWERMAXCR™ timing harness when the truck is running during Cool Down.   You will need to use an automotive relay to power the pump.  Connect pin 85 of the relay to ground and connect either fuse 28 or 32 (either orange wire from the POWERMAXCR™ ) to pin 86 of the relay.  Connect pin 30 of the relay to 12V battery and connect pin 87 of the relay to the pump power wire.

 

 

If a constant miss and getting P21xx codes:

-Check for a broken diode or broken wire in the harness going to the injectors.

When the PowerMax is turned on, the AC (Air Conditioning) shuts off/quits working.

-This sometimes occurs when a pusher fuel pump has been added (such as a FASS or a Air Dog fuel pump).  Move the PMCR module ground from the battery terminal to inside the cab under the dash where there is a good ground. Don't leave it connected to the battery also, disconnect it from the battery and connect it only under the dash.

How to take the PMCR out of the system to get back to stock for testing.

- If you have a bypass connector, disconnect the PowerMax and connect the bypass connector in place of it. Otherwise, you will need to remove both TST harnesses to put it back to stock. To do this, first follow the TST harness with the gray connector to the cam and crank sensors and disconnect the TST harness and reconnect the factory connectors. Then follow the TST harness with the black connector to the injector connectors and MAP sensor and disconnect the TST harness and reconnect the factory connectors.

- Reconnect original turbo wastegate fittings or you may get P0234 Engine Over Boost code because the PMCR module is no longer clamping the boost signal going back to the OEM (factory) ECM.

Misses under hard load.

-Check fuel pressure at idle, should be 8-12 psi.

-Check fuel pressure at wide open throttle, should not be 0 psi.

Getting P0111 = Intake Air Temperature Sensor Range/Performance

 

-Air Intake Sensor connector is not connected.

 

Moving a PMCR system from an 03-05 Dodge to a 06 Dodge and using the timing harness with only 1 orange wire:

 

-Connect the orange wire fuse tap to fuse 28.  Connect the red wire fuse tap to fuse 38.

 

What is the highest setting I can use?

- Power Level 0-3 TE Level 0-3: Good for everyday driving, and when towing heavier loads. Use this as the highest setting for stock 47RE and 48RE automatic.

 

- Power Level 4, TE Level 4: Good for everyday driving , and when towing lighter loads. Use this as the highest setting for stock 5 spd manual clutch.

 

- Power Level 5, TE Level 5: Good for driving when you really want a big increase in power. Not recommended for for towing applications due to stress on the drivetrain. Use this as the highest setting for stock 6 speed manual clutch.

 

- Power Level 6-9, TE Level 6-9: For competition only. Exhaust temperatures will be extreme. Aftermarket clutches required for manuals and valve body and torque converter upgrades for automatics. Fuel pressure monitoring suggested and auxiliary pusher pump likely required.

 

- A good rule of thumb to go by is to keep the sum of the power level and the torque enhancement level, under a total of 6 when towing. For example; if the power level setting is on 4 the TE level should be set no higher than level 2, which equals a total of 6. These are only suggested setting. Driver ability, road conditions, and amount of weight should all be a factor when choosing a power level.

 

What is the best setting to improve fuel mileage?

- Every truck and driver is different, so TST can not specify exactly what is best. Just timing only (P=1) will help, but also adding some power will help keep the engine in it peak efficiency rpm range and provide even better fuel mileage. Try Power/TE = 2/0 to start with and then do some tank to tank mileage testing at that setting. Then try slightly higher and/or lower and do some more mileage testing.  Please do not call TST and ask which settings give the best fuel mileage, we don’t know since all trucks and drivers are different.

 Using a Smarty with a PMCR:

- The Smarty can be combined with a PMCR and will improve the low end performance and extend the high end rpm range.  You will have to experiment to find the best Smarty and PMCR settings for you.  Start with the lower settings on each and work your way up to see which combination gives you the best performance.  Please do not call TST and ask which settings give the best performance and/or fuel mileage, we don't know since all trucks and drivers are different.

  

Can my existing PMCR be upgraded to the R49 Cool Down Turbo Timer?

- Yes. See "Upgrading older PMCRs and remotes to Adjustable Program" below.

 

What is the difference between the standard program and the twin turbos (twins) program?

  

- The twin turbos (twins) program fuels more at lower boost in order to help spool the turbo up faster.  It is not just for twin turbos, but is for any bigger turbo.  The regular program goes to full fueling at 32 psi boost.  There are 2 versions of the twins program.  The twins program for the 04-1/2 to 06 Dodge goes to full fueling at 24 psi boost, and the twins program for the 03 to 04 Dodge goes to full fueling at 12 psi boost.  The 03 to 04 Dodge program will work on a 04-1/2 to 06 Dodge, but there may be excessive smoke.  Any PowerMax-CR computer can be reprogrammed to either program, you just need to send us the computer to be reprogrammed.  The cost for the upgrade is $55.  You can get both twins programs, the standard program, and the economy program all in one if you upgrade to the Adjustable Program.  See below for details and prices.

 

What is the Adjustable Timing Advance program and how does it work?

 

- The R49AP with Adjustable Timing Advance gives the user the ability to control timing advance. The default is Auto mode with a limit of 12 degrees. This mode is the same as a standard PowerMaxCR where the timing advance varies from 0 to the limit based on rpm and boost. In Auto mode, the user can adjust the timing advance limit in increments of 3 degrees up to 18 degrees or turn it to OFF (0 degrees). In Set mode, the timing advance is not based on rpm or boost, but will stay at the Set value selected by the user. In Set mode, the user can adjust the timing advance limit in increments of 3 degrees up to 18 degrees or turn it to OFF (0 degrees). AdjustableTiming Advance is only available on the R49AP (Adjustable Program Cool Down) remote.

  

Upgrading older PMCRs and remotes to Adjustable Program:

  

- The R37AP and R49AP PowerMaxCR units have the standard program, both twins programs, and the economy program all in one.  Which program you want to run can be selected via the remote (on the fly).  The R49AP also has Adjustable Timing Advance and Cool Down (turbo timer), plus Adjustable Rail Pressure and Rail Pressure Gauge can be added to PMCRs with Serial Number 5000 or greater.  If you have an R49, it can be upgraded to an R49AP with Adjustable Program without Adjustable Rail Pressure for $110.00, or the Adjustable Program with Adjustable Rail Pressure and Rail Pressure Gauge for $135.  If you have an R47, the cost is $165.00 (+ $25.00 for 2006 Dodges, + $60.00 if you need a Cool Down timing harness - if your timing harness has only 1 fuse tap on the orange wire, you will need the Cool Down timing harness).  You will need to send both the PowerMax and the remote for the Adjustable Program upgrade.  If you have a R37, it can be upgraded to a R37 with with Adjustable Program for $110.00.  The R37AP does not have Adjustable Timing Advance or any Rail Pressure capability.  If you have a R37, it can be traded in for a R49 with Adjustable Program for $300. (+ $25.00 for 2006 Dodges, + $60.00 if you need a Cool Down timing harness - if your timing harness has only 1 fuse tap on the orange wire, you will need the Cool Down timing harness).

 

What is the new PowerMaxCR product line?

  

The PowerMaxCR has new programming and comes in 5 variations now:

 

  PMCR ECON, $575: This is the PowerMaxCR set on the Economy program with the Power Level set to 2 and the Torque Enhancement set to 1.  It is designed to improve fuel mileage.  It does not have a remote, does not use a thermocouple, does not adjust rail pressure, and does not have any gauges.  It uses aggressive timing advance to improve fuel mileage, as much as 4 MPG with trucks that do a lot of towing.  Empty trucks will see less mileage improvement, such as about 1 MPG.  It also adds an additional 55 HP at the rear wheels.  It has easy plug in installation that should be less than 1 hour.  It is upgradeable to either the R37AP (for $200) or the R49AP (for $400) by just buying the remote, no reprogramming is necessary.  The R49AP upgrade includes the thermocouple and rail pressure harness.

 

  PMCR 75, $575: This is the PowerMaxCR set on the Standard program with the Power Level set to 3 and the Torque Enhancement set to 2.  It does not have a remote, does not use a thermocouple, does not adjust rail pressure, and does not have any gauges.  It adds an additional 75 HP at the rear wheels, which is the maximum recommended for a stock automatic transmission.  It will also provide some fuel mileage improvement.  It has easy plug in installation that should be less than 1 hour.  It is upgradeable to either the R37AP (for $200) or the R49AP (for $400) by just buying the remote, no reprogramming is necessary.  The R49AP upgrade includes the thermocouple and rail pressure harness.

 

  PMCR 95, $575: This is the PowerMaxCR set on the Standard program with the Power Level set to 4 and the Torque Enhancement set to 3.  It does not have a remote, does not use a thermocouple, does not adjust rail pressure, and does not have any gauges.  It adds an additional 95 HP at the rear wheels, which is the maximum recommended for a stock manual transmission.  It will also provide some fuel mileage improvement.  It has easy plug in installation that should be less than 1 hour.  It is upgradeable to either the R37AP (for $200) or the R49AP (for $400, + $25.00 for 2006 Dodges) by just buying the remote, no reprogramming is necessary.  The R49AP upgrade includes the thermocouple and rail pressure harness.

 

  PMCR R37AP, $725: This is the PowerMaxCR with remote, without gauges.  It has the standard program, both twins programs, and the economy program all in one.  Which program you want to run can be selected via the remote (on the fly).  It does not adjust rail pressure, does not have Adjustable Timing Advance, does not use a thermocouple, and does not have any gauges.  It has easy plug in installation that should be less than 1 hour.  It is upgradeable to the R49AP (for $300, + $25.00 for 2006 Dodges) by just buying the remote, no reprogramming is necessary.  The R49AP upgrade includes the thermocouple and rail pressure harness.

 

  PMCR R49AP, $899: This is the PowerMaxCR with remote, plus boost gauge, pyrometer, and rail pressure gauge.  It has the standard program, both twins programs, and the economy program all in one.  Which program you want to run can be selected via the remote (on the fly).  It has Adjustable Timing Advance, Cool Down (turbo timer), Adjustable Rail Pressure, and Rail Pressure Gauge.

 

  

 

Regarding the POWERMAX for 01-04 Duramax

 

 

R47 EGT displays 1776 and dots blink, no power added.

 

-Yellow wire from thermocouple is not connected.

 

R47 EGT displays 32.

 

-Red wire from thermocouple is not connected.