Torque Module Installation and User Guide for model 250i Motorcycle Dynamometers.

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2 Dynojet Research, Inc. All Rights Reserved. Torque Module Installation and User Guide for model 250i Motorcycle Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, as well as the software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license. This manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Dynojet. Dynojet assumes no responsibility or liability for any error or inaccuracies that may appear in this manual. Except as permitted by such license, no part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Dynojet. The Dynojet logo is a trademark of Dynojet Research, Inc. Any trademarks, trade names, service marks, or service names owned or registered by any other company and used in this guide are the property of their respective companies. Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA. Printed in USA. Part Number: (03/05)

3 TABLE OF CONTENTS Chapter 1 Chapter 2 Torque Module Installation Introduction Conventions Used In This Manual Technical Support Parts List Connecting and Disconnecting Power to the Dyno Load Cell Installation Removing the Carriage and Dyno Top Cover Removing the Eddy Current Brake Top Cover Installing the Load Cell Torque Module Installation Accessing the Dyno Electronics Installing the Torque Module Routing the Load Cell Cable Replacing the Dyno Top Cover and Carriage Replacing the Eddy Current Brake Top Cover Using the Torque Module Torque Cell Calibration Appendix A The Torque Module and WinPEP 6 Torque Module Calibration A-2 Index Index-i i

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5 C HAPTER 1 TORQUE MODULE INSTALLATION This document provides instructions for installing and using the Torque Module with WinPEP 7. Appendix A includes instructions for using the Torque Module with WinPEP 6. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This chapter will walk you through installing the load cell and installing the Torque Module. Document Part Number: Version 2 Last Updated: This chapter is divided into the following categories: Introduction, page 1-2 Load Cell Installation, page 1-4 Torque Module Installation, page

6 CHAPTER 1 Introduction INTRODUCTION The Torque Module, when added to Dynojet's market leading inertia dynamometer, results in a complete vehicle performance test. CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. Example of Convention Bold Description The Caution icon indicates a potential hazard to the dynamometer equipment. Follow all procedures exactly as they are described and use care when performing all procedures. The Warning icon indicates potential harm to the person performing a procedure and/or the dynamometer equipment. Highlights items you can select on in the software interface, including buttons and menus. The arrow indicates a menu choice. For example, select File Open means select the File menu, then select the Open choice on the File menu. TECHNICAL SUPPORT For assistance, please contact Dynojet Technical Support at , or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV Visit us on the World Wide Web at where Dynojet provides state of the art technical support, on-line shopping, 3D visualizations, and press releases about our latest product line. PARTS LIST The following table lists all of the parts included in the Torque Module Installation kit (P/N ). Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support. part number description quantity Weight, 25 pounds Calibration Arm Assembly or Torque Module Sub-Assembly or Torque Module High Resolution Sub-Assembly Cable, Torque Cell

7 TORQUE MODULE INSTALLATION Introduction CONNECTING AND DISCONNECTING POWER TO THE DYNO Many instructions in this guide will require you to connect or disconnect the power to the dyno as part of the installation process. Use the following steps to connect and disconnect power to the dyno. 1 Use the main breaker to turn power on and off to the dyno. 2 The main breaker is located inside the power distribution assembly. 3 Disconnect the power plug to ensure all power has been removed from the dyno before performing certain installation procedures. power plug main breaker Figure 1-1: Main Breaker Location Version 2 1-3

8 CHAPTER 1 Load Cell Installation LOAD CELL INSTALLATION This section describes how to remove the top covers, install the load cell, and replace the top covers. REMOVING THE CARRIAGE AND DYNO TOP COVER screws You will need to remove the tire carriage and top cover in order to route the load cell cable to the dyno electronics. 1 Using a 5/32-inch allen wrench, remove the two button-head screws securing the carriage screw support bracket and set aside. 2 Remove the support bracket and set aside. support bracket carriage screw belleville washers Figure 1-2: Remove the Support Bracket 1-4

9 TORQUE MODULE INSTALLATION Load Cell Installation 3 Using the hand crank or power carriage, unscrew the carriage screw until it is free from the nut block. Slide the carriage off the dyno. hand crank Figure 1-3: Remove the Carriage 4 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. 5 Using a 1/2-inch wrench, remove the bolts and washers securing the nut block and carriage clamps and set aside. Remove the nut block, carriage clamps, and shims and set aside. Version 2 Figure 1-4: Remove the Nut Block, Carriage Clamps, and Shims 1-5

10 CHAPTER 1 Load Cell Installation 6 Remove the six 1/4-inch screws securing the top cover on the dyno and set aside. Note: Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap- On FA5E) to remove the 1/4-inch screws. A standard allen key may round off in the shallow screw head. 7 Remove the cover and set aside. top cover Figure 1-5: Remove the Top Cover 1-6

11 TORQUE MODULE INSTALLATION Load Cell Installation REMOVING THE EDDY CURRENT BRAKE TOP COVER 1 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. 2 Remove the six screws securing the eddy current brake top cover and set aside. 3 Disconnect the battery ground cable. brake cover Figure 1-6: Remove the Brake Top Cover Version 2 1-7

12 CHAPTER 1 Load Cell Installation INSTALLING THE LOAD CELL 1 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. 2 Remove the two bolts and nuts securing the existing bar on the eddy current brake and remove the bar. Set the bolts and nuts aside. bar Figure 1-7: Remove the Existing Bar 1-8

13 TORQUE MODULE INSTALLATION Load Cell Installation 3 Install the load cell. 3a Verify the eyelets on the load cell are spaced the same as the bar removed earlier. Adjust the load cell spacing by loosening the lock nut and turning the eyelet. bar eyelet lock nut distance must be the same Figure 1-8: Verify Load Cell Spacing 3b 3c Orient the load cell so the cable faces the dynamometer. Secure the load cell to the mounting bracket using the two bolts and nuts removed earlier. load cell cable load cell Figure 1-9: Install the Load Cell Version 2 1-9

14 CHAPTER 1 Torque Module Installation TORQUE MODULE INSTALLATION This section describes how to install the Torque Module, route the load cell cable, replace the carriage, and replace the brake cover. ACCESSING THE DYNO ELECTRONICS You will need to access your dyno electronics in order to add the torque module. Use the following steps to access the dyno electronics. 1 Turn off the main power to the dyno. To prevent possible injury, place the breaker inside the power distribution enclosure to the off position and unplug the dyno. Refer to page 1-3 for more information. 2 Remove the four screws securing the dyno electronics enclosure and set aside. 3 Slide the enclosure toward you and out of the dyno. Be sure not to pinch or pull any cables. dyno electronics enclosure Figure 1-10: Remove the Dyno Electronics Enclosure 1-10

15 TORQUE MODULE INSTALLATION Torque Module Installation 4 Remove the twelve screws securing the cover and lift the cover off. Figure 1-11: Remove Electronics Enclosure Cover 5 Add the torque module to the top of the dyno electronics. Refer to Installing the Torque Module on page Leave the dyno electronics enclosure out. You will need to route the load cell cable to the Torque Module later. dyno electronics Figure 1-12: Inside the Electronics Enclosure Version

16 CHAPTER 1 Torque Module Installation INSTALLING THE TORQUE MODULE 1 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. 2 Turn off the main power switch on the CPU Module on the dyno electronics and unplug the power cord. 3 Remove the dust cover from the existing top module. dust cover power cord input power switch Figure 1-13: Remove Dust Cover 4 Loosen the top right screw on the back of the existing top module. 5 Plug the Torque Module into the existing top module. Place the dust cover, removed in step 3, on the Torque Module. 6 Secure the grounding strap on the back of the Air Fuel Module to the existing top module. grounding strap Figure 1-14: Secure Grounding Strap 1-12

17 TORQUE MODULE INSTALLATION Torque Module Installation torque module 7 Secure the Torque Module to the dyno electronics with the plastic tie straps (one on each side). Note: Do not attach the load cell cable at this time. tie strap green LED light load cell cable and port do not attach at this time Figure 1-15: Attach Torque Module Version

18 CHAPTER 1 Torque Module Installation ROUTING THE LOAD CELL CABLE 1 Route the load cell cable from the eddy current brake through the air hole in the drum bulkhead, under the carriage assembly bulkhead, and over to the dyno electronics. Make sure the load cell cable is clear of any power cables or hot or rotating objects. 2 Secure the load cell cable with a zip tie to the underside of the carriage assembly bulkhead. Make sure there is enough slack in the cable to allow the dyno electronics enclosure to slide out of the dyno. load cell cable air hole in drum bulkhead torque module route cable under carriage assembly bulkhead Figure 1-16: Routing the Load Cell Cable 1-14

19 TORQUE MODULE INSTALLATION Torque Module Installation 3 Route the load cell cable through the cable clamp on the back of the dyno electronics enclosure. 3a Loosen the two screws and lift the clamp up to slide the load cell cable through. 3b Secure the clamp with the two screws. 4 Attach the 9-pin connector on the load cell cable to the front of the Torque Module and tighten down the screws. 5 Attach the power cord to the dyno electronics and turn the power switch on. cable clamp torque module load cell cable Figure 1-17: Route the Cable to the Torque Module Version

20 CHAPTER 1 Torque Module Installation torque module 6 Plug the main power cord for the dyno in and place the breaker inside the power distribution enclosure to the on position. Refer to page 1-3 for more information. 7 The green LED light on the Torque Module should now be on. tie strap green LED light load cell cable and port do not attach at this time Figure 1-18: Attach Torque Module and Load Cell Cable 8 Replace the dyno electronics cover. Refer to Figure 1-11 on page Slide the dyno electronics enclosure back in the dyno. Refer to Figure 1-10 on page

21 TORQUE MODULE INSTALLATION Torque Module Installation REPLACING THE DYNO TOP COVER AND CARRIAGE 1 Secure the top cover to the dyno using the six 1/4-inch screws removed earlier. Note: Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap-On FA5E) to remove the 1/4-inch screws. A standard allen key may round off in the shallow screw head. Figure 1-19: Replace the Top Cover Version

22 CHAPTER 1 Torque Module Installation 2 Using a 1/2-inch wrench, install the shims, carriage clamps, and nut block using the bolts and washers removed earlier. Figure 1-20: Install the Shims, Carriage Clamps, and Nut Block 3 Using the hand crank or power carriage, screw the carriage through the nut bolck. Figure 1-21: Replace the Carriage 1-18

23 TORQUE MODULE INSTALLATION Torque Module Installation 4 Install the screw support bracket. 4a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure b Place the screw support bracket in front of the carriage screw. The two threaded holes in the bracket should face the two matching holes in the carriage. Loosely install the two 1/4 x 1/2-inch button-head screws. 4c Before tightening the screws, apply some pressure to the bracket to compress the belleville washers. The handle should still turn freely, but the turning force should now be around five to six pounds. To adjust the force needed to turn the crank handle, adjust the compression of the belleville washers. 4d Using a 5/32-inch allen wrench, tighten the two button-head screws. 5 Tighten the clamp and nut block bolts with a 1/2-inch wrench. screws support bracket carriage screw belleville washers Figure 1-22: Install the Support Bracket Version

24 CHAPTER 1 Torque Module Installation REPLACING THE EDDY CURRENT BRAKE TOP COVER Before replacing the top cover, be sure to calibrate your load cell. Refer to Chapter 2 "Using the Torque Module". 1 Connect the battery ground cable. 2 Secure the eddy current brake top cover using the six bolts removed earlier. Note: Before replacing the top cover, be sure to calibrate your load cell. Refer to Chapter 2 "Using the Torque Module". brake cover Figure 1-23: Replace the Brake Top Cover 1-20

25 C HAPTER 2 USING THE TORQUE MODULE This chapter provides instructions for using the Torque Module with WinPEP 7. Appendix A includes instructions for using the Torque Module with WinPEP 6. To ensure safety and accuracy in the procedures, perform the procedures as they are described. 2-1

26 CHAPTER 2 Torque Cell Calibration TORQUE CELL CALIBRATION The Torque Module must be calibrated prior to use. Follow the directions on the screen exactly. Failure to perform the directions accurately will result in improper torque values. 1 Verify you are in the MakeRun screen. 2 Verify you are connected to the dyno electronics. Note: For more information on connecting to the dyno electronics, refer to the WinPEP 7 User Guide (on your WinPEP CD or at or the WinPEP 7 Online Help. 3 Select Tools MakeRun Options Torque Cell Calibration. Note: Before proceeding, be sure the eddy current brake is free and clear of any obstructions. There should not be anything resting on the eddy current brake or the dynamometer drum during this procedure. 4 Click Next to perform the Zero Calibration. The Calibration window will appear. The hardware is now zeroing out the torque cell. If the unit does not calibrate, recheck the setup and retry. Figure 2-1: Zero Calibration Window 2-2

27 USING THE TORQUE MODULE Torque Cell Calibration Once the Zero Calibration is complete, the Calibration Mass window will appear. 5 Enter the Torque Module calibration value. Refer to Figure 2-3. Note: You must perform this step the first time you calibrate the load cell. Or If you are only performing a Zero Calibration, click Finish. Figure 2-2: Calibration Mass Window Enter the calibration number stamped near the bolt pattern at the end of the calibration arm. If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the number stamped near the bolt pattern in the center of the arm. Note: Dynojet recommends you secure the calibration arm using the bolt pattern closest to the end of the arm unless space constraints in your dyno room do not allow you to. bolt pattern near the center of the calibration arm bolt pattern closest to the end of the calibration arm Figure 2-3: Calibration Arm Number Version 2 2-3

28 CHAPTER 2 Torque Cell Calibration 6 Click Next to continue. The Span Calibration window will appear. 7 Install the calibration arm and weights. Refer to step 8 and Figure 2-5 on page 2-5. Figure 2-4: Span Calibration Window 2-4

29 USING THE TORQUE MODULE Torque Cell Calibration 8 Install the calibration arm and weights using the bolt pattern at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm. Refer to Figure 2-6 on page a 8b Secure the calibration arm to the eddy current brake using the handle to tighten the bolt. Gently place the weights on the calibration arm. The calibration weights are very heavy. The weights must be set on the arm gently or you will damage the load cell. weight support pin weights secure arm to brake by tightening the handle Figure 2-5: Install Calibration Arm and Weights Using the Bolt Pattern Closest to the End Version 2 2-5

30 CHAPTER 2 Torque Cell Calibration If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in Figure 2-6. weight support pin weights secure arm to brake by tightening the handle Figure 2-6: Install Calibration Arm and Weights Using the Bolt Pattern in the Center 2-6

31 USING THE TORQUE MODULE Torque Cell Calibration While installing the calibration weights, you should notice the Torque Gauge on the DynoTrac Window moving from 0 to about 500 foot-pounds. Note: The Torque Gauge may or may not be in this range. If the torque cell has been previously calibrated incorrectly or has not been calibrated for a while, the gauge may show values out of this range until calibration is complete. If you use the bolt pattern in the center of the calibration arm, the gauge will show values around foot-pounds. Note: Let the torque gauge needle stabilize before clicking Next. 9 From the Span Calibration window (Figure 2-4), click Next to continue. At this point, the value on the gauge should match the value on the calibration arm. 10 Remove the calibration arm and weights and click Finish. Figure 2-7: Calibration Is Complete Window Version 2 2-7

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33 A PPENDIX A THE TORQUE MODULE AND WINPEP 6 This appendix provides instructions for using the Torque Module with WinPEP 6. To ensure safety and accuracy in the procedures, perform the procedures as they are described. A-1

34 APPENDIXA Torque Module Calibration TORQUE MODULE CALIBRATION After initial calibration, the Torque Module should be Zero Calibrated approximately every thirty hours of use. Before proceeding, be sure the eddy current brake (retarder) is free and clear of any obstructions. There should not be anything resting on the eddy current brake or the dynamometer drum during this procedure. 1 Launch WinPEP and click the DynoTrac icon. DynoTrac icon Figure A-1: Launch WinPEP The DynoTrac window will appear. 2 Select Options Display Eng Torque from the main menu. The gauge needs to display Eng Torque and not Braking. main menu gauge displays engine torque Figure A-2: DynoTrac Window A-2

35 THE TORQUE MODULE AND WINPEP 6 Torque Module Calibration 3 Select Options Calibrate. Note: Before proceeding, be sure the eddy current brake is free and clear of any obstructions. There should not be anything resting on the eddy current brake or the dynamometer drum during this procedure. 4 Enter the Torque Module calibration value. Enter the calibration number stamped near the bolt pattern at the end of the calibration arm. If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the number stamped near the bolt pattern in the center of the arm. Note: Dynojet recommends you secure the calibration arm using the bolt pattern closest to the end of the arm unless space constraints in your dyno room do not allow you to. bolt pattern near the center of the calibration arm bolt pattern closest to the end of the calibration arm Figure A-3: Calibration Arm Number Note: Follow the directions on the screen exactly. Failure to perform the directions accurately will result in improper torque values. Version 2 A-3

36 APPENDIXA Torque Module Calibration 5 Click Next to continue. Figure A-4: Calibration Mass Window The Zero Calibration is now being performed. Figure A-5: Zero Calibration Window The Span Calibration window will appear. A-4

37 THE TORQUE MODULE AND WINPEP 6 Torque Module Calibration 6 Install the calibration arm and weights. Refer to step 7 and Figure 7 on page 6. Note: You must perform this step the first time you calibrate the load cell. Or If you are only performing a Zero Calibration, click Cancel. Figure A-6: Span Calibration Window Version 2 A-5

38 APPENDIXA Torque Module Calibration 7 Install the calibration arm and weights using the bolt pattern at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm. Refer to Figure A-8 on page A-7. 7a 7b Secure the calibration arm to the eddy current brake using the handle to tighten the bolt. Gently place the weights on the calibration arm. The calibration weights are very heavy. The weights must be set on the arm gently or you will damage the load cell. weight support pin weights secure arm to brake by tightening the handle Figure A-7: Install Calibration Arm and Weights Using the Bolt Pattern Closest to the End A-6

39 THE TORQUE MODULE AND WINPEP 6 Torque Module Calibration If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in Figure A-8. weight support pin weights secure arm to brake by tightening the handle Figure A-8: Install Calibration Arm and Weights Using the Bolt Pattern in the Center Version 2 A-7

40 APPENDIXA Torque Module Calibration While installing the calibration weights, you should notice the Torque Gauge on the DynoTrac Window moving from 0 to about 500 foot-pounds. The gauge is for display purposes only and may not read correctly. The gauge remains uncalibrated until the calibration process is complete. If the torque cell has been previously calibrated incorrectly or has not been calibrated for a while, the gauge may show values out of this range until calibration is complete. If you use the bolt pattern in the center of the calibration arm, the gauge will show values around foot-pounds. Note: Let the torque gauge needle stabilize before clicking Next. Figure A-9: Torque Gauge 8 From the Span Calibration window (Figure A-6), click Next to continue. 9 Remove the calibration arm and weights and click Finish. Figure A-10: Calibration Is Complete Window A-8

41 INDEX A accessing dyno electronics 1-10 B battery ground cable 1-7, 1-20 belleville washers 1-4, 1-19 brake cover removing 1-7 replacing 1-20 C cable clamp 1-15 calibration arm 2-3, A-3 number 2-3, A-3 weights 2-5, A-6 carriage assembly bulkhead 1-14 carriage clamps 1-5, 1-18 conventions 1-2 D document part number 1-1 drum bulkhead 1-14 dyno electronics accessing 1-10 cable clamp 1-15 dyno top cover removing 1-6 replacing 1-17 E eddy current brake cover removing 1-7 replacing 1-20 L load cell installation routing the cable 1-14 M main breaker location 1-3 N nut block 1-5, 1-18 P parts list 1-2 power connecting and disconnecting 1-3 main breaker location 1-3 R routing the load cell cable 1-14 S screw support bracket 1-4, 1-19 T technical support 1-2 tire carriage belleville washers 1-4, 1-19 carriage clamps 1-5, 1-18 nut block 1-5, 1-18 removing 1-4 replacing 1-18 screw support bracket 1-4, 1-19 torque cell calibration calibration arm 2-3, A-3 calibration number 2-3, A-3 calibration weights 2-5, A-6 torque gauge 2-7, A-8 torque module installation W WinPEP 6 A-1 WinPEP Z zero calibration 2-2, A-4 Index-i

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