Installation Guide For Model 248 Four Post Lift Automotive Dynamometers.

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2 Dynojet Research, Inc. All Rights Reserved. Installation Guide For Model 248 Four Post Lift Automotive 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: Version 5 (12/2005)

3 Contents Chapter Initial Setup and Requirements Introduction Four Post Lift/Dyno Placement DynoWare EX+ Placement Requirements to Unload Truck Requirements to Install the Dynamometer Other Requirements Uncrating the Dyno Chapter Hardware Installation DynoWare EX Atmospheric Sensing Module RPM Module Dynamometer Input/Output Module CPU Module Connecting the DynoWare EX Chapter Installing the Dynamometer Install the Lift Install the Dynamometer Installing the Brakes Wiring the Dyno Part Catwalk Installation Wiring the Dyno Part Connect the Dyno Document # i

4 Contents Chapter Basic Dyno Operation Loading the Vehicle Connecting the RPM Pickup RPM Pickup Descriptions Connecting the Secondary Inductive Pickup Connecting the Primary Inductive Pickup Pre-run Inspection Before Starting the Engine Engine Warm Up After Engine Warm Up Making a Test Run Appendix A...A-1 Dyno to Lift Location...A-1 Interface Assembly...A-2 ii Document #

5 Chapter 1 Initial Setup and Requirements Thank you for purchasing the Dynojet Dynamometer. This document will give you the information you need to install the Dynojet Dynamometer (four post model). If you have any questions please call Dynojet at (800) Introduction Before installing your Dynojet Dynamometer, there are a few factors to consider. This chapter, Initial Setup and Requirements, is a brief overview of what you need to know to install your dynamometer and an overview of the installation steps. Comprehensive instructions are included in the remaining chapters. Initial Setup and Requirements should help you to decide where you want to place your dynamometer in your shop, where to place the Dynojet electronics, what you need to unload your dyno and what you will have to provide for the dynamometer. Document #

6 Four Post Lift/Dyno Placement Four Post Lift Placement Before you install the Four Post Lift, you need to think about the position of the lift relative to the garage and the dynamometer. For AMCO lifts you may place the dynamometer on either end of the lift but it is recommended that you place the dyno on the end of the lift with the hydraulics. For BENWIL lifts you place the dyno on the opposite end of the hydraulic controls. Keep in mind the placement of your computer, monitor and DynoWare EX+ hardware. 1-2 Document #

7 DynoWare EX+ Placement The DynoWare EX+ system is comprised of four modules: the CPU module, the Dynamometer Input/Output module, the RPM module and the Atmospheric module. The Dynamometer Input/Output module connects to the dynamometer. (A 20 foot (6.1 meter) long cable is provided.) The CPU module connects to a personal computer. (A 12 foot (3.7 meter) long cable is provided.) RPM Pickups and a Hand Held Pendant also connect to the modules. These modules need to be located where they will be visible during a dyno run. It is recommended that they be mounted on a shelf on the wall or on a cart along side the PC. An optional extended Hand Held Pendant cable is available if needed. Document #

8 Requirements to Unload Truck When your dyno arrives, you must provide equipment to unload the dynamometer from the truck, with skids or forks a minimum of 6 inchs wide by 6 feet long. It must be capable of lifting and moving at least 8000 pounds (3642 KG). The dyno has 2 C-Channels that run lengthwise along the bottom of the dyno. Unload the dynamometer using these channels. Requirements to Install the Dynamometer Installation of the dynamometer requires equipment capable of lifting and moving at least 8000 pounds (3642 KG). 1-4 Document #

9 Other Requirements Shop Air The dyno air brake requires a 3/8-inch air hose with a minimum pressure of 60 psi. You must provide 3/8-inch air line that will reach from the dynamometer to the Air Pressure Regulator and another air hose to connect the regulator to your shop air supply. Computer Requirements You will need to provide a computer system to run the WinPEP software. WinPEP 7 includes complete documentation in online Help. From the WinPEP 7 menu bar, choose Help WinPEP 7 Help or visit (accessible with a valid user name and password). minimum system requirements recommended systems requirements Microsoft Windows 2000/XP Microsoft Windows 2000/XP Pentium 800 MHz Processor 2.4 GHz Processor or greater 256 MB of available RAM 256 MB of available RAM or greater one COM port, two COM ports for Tuning Link one COM port, two COM ports for Tuning Link 800x600, 256 color monitor (SVGA) 1280x color monitor (SVGA) or better 1.2 gigabyte hard drive 1.2 gigabyte hard drive 30 MB of available hard-disk space 100 MB of available hard-disk space CD ROM and floppy disk drive CD ROM and floppy disk drive printer, if hard copies are needed printer (preferably HP DeskJet ) Document #

10 Uncrating the Dyno Step 1 Use a crowbar or the like to remove the plywood shipping shell from the dynamometer. Remove catwalk pallet from the top of the crate (if purchased). Remove the top of the crate. Remove the sides of the crate. Remove the bottom skids and discard. Step 2 Remove the front and back dyno covers. Step 3 Carefully remove the cardboard boxes and brake weldments that are stored within the dynamometer s frame. 1-6 Document #

11 Step 4 Verify the hardware contents as follows: Brake Hardware: 2 brake weldments (The following are attached to the dyno frame) six 5/8" bolts six lock washers six flat washers six nuts Mounting Hardware: 4- Foot Stands 4-7/16 x 1 Bolts 4-7/16 Flat Washers 4-7/16 Lock Washers 4-3/8 x 1 Bolts 4-3/8 Flat Washers 4-3/8 Lock Washers 4- Anchors 1- Set Tool Document #

12 Electronic Hardware: Pictures and descriptions on page 3-6 : Lift Hooks: 6 Catwalk Hooks Straps: 2 axle straps 2 Long axle straps (not shown) 4 ratchet straps 2 ratchet straps with sleeves Chocks (4): 1-8 Document #

13 Chapter 2 Hardware Installation DynoWare EX+ System Expansion Connector The standard dynamometer electronics package is comprised of 4 interconnected modules: Atmospheric Sensing Module RPM Module Dynamometer Input/Output Module CPU Module Atmospheric Sensing Module: The atmospheric sensing module measures absolute pressure, air temperature and relative humidity. These measurements are used by WinPEP to correct power and torque measurements to standard atmospheric conditions according to a DIN, SAE or other formula. The green LED glows when the atmospheric sensing module is receiving power. The flashing amber LED indicates the module processor is operating properly. Document #

14 RPM Module: The RPM module receives and processes signals from up to 2 inductive pickups for measurement of engine RPM. Each input has an automatic gain circuit to compensate for a wide variance of ignition systems. The green LED glows when the RPM module is receiving power. The amber LED flashes when an RPM signal is detected. A steady flash rate, proportional to engine RPM, indicates a good RPM signal. These connectors are the inputs for both primary and secondary inductive pickup clips. Either input may be used with a primary inductive pickup or a secondary inductive pickup on a single ended coil. Both inputs can be used for a wasted spark ignition. 2-2 Document #

15 Dynamometer Input/Output Module: The dynamometer I/O module sends and receives data from the dynamometer and the hand held pendant. The module also contains a buzzer and light which are activated when either the vehicle or dynamometer speed limit is approached. The green LED glows when the dynamometer input/output module is receiving power. The amber LED flashes proportionally to dynamometer drum RPM. This 25-pin receptacle connects to the shielded cable from the dynamometer. This 9-pin receptacle connects to the hand held pendant which houses the button used to Start/Stop acquiring data. The pendant may also contain a brake switch. Document #

16 CPU Module: The CPU module contains a 32-bit processor which acquires data from the expansion modules and communicates to the main computer running the WinPEP software. The processor queries the expansion modules to determine their identity and capabilities. The green LED glows when the CPU module is receiving power. The blue LED is lighted when data from the modules is being acquired and saved. One of these connectors is used to communicate to the main computer. The 9-pin receptacle (left) connects to the PC s RS-232 serial communications port. The 8-pin modular connector (right) provides communications according to the RS-422/485 specification. 2-4 Document #

17 CPU Module:... Continued This connector provides a synchronization signal to a 3rd-party data acquisition system. This connector provides 12 Volt DC power to a 3rd-party data acquisition system. This connector accepts 12 Volt DC power from a power supply or battery. The adjacent LED glows bright green when power is properly connected. When this switch is on, power is supplied to all connected modules. Connecting the DynoWare EX+ Use the cables that came in the DynoWare package to make the following connections: 9-pin shielded serial cable between the RS-232 connector of the CPU Module and a free COM (serial communications) port on the PC. A 9- pin to 25-pin adapter may be required at the PC. 25-pin shielded cable from the dynamometer to the Dynamometer Input/Output Module. 9-pin connector from the hand held pendant to the Dynamometer Input/Output Module. 3-pin plug from the power supply to the CPU Module with its flat side facing down. (Refer to the picture on the next page) Note: The DynoWare EX+ stack must be mounted in your shop so as to be easily seen while making dyno runs. Document #

18 Primary Inductive Pickup Cable (not shown) Remote Switch Breakout Board to DynoWare Cable Cord from Power Supply Computer Serial Port Cable 2-6 Document #

19 Chapter 3 Installing Dynamometer Now that you have the dynamometer and the Four Post Lift unpacked you may begin the installation.. Install Lift Four Post Lift Installation Refer to the installation guide of the Four Post Lift for installation. Install Dynamometer After complete assembly of the Four Post Lift, raise and lower the lift a few times to insure proper operation. Whichever side of the lift you choose to put the dynamometer on, the short ramps on the lift must be removed from that side. Step 1 With the lift all the way down, move the dyno into position. (Refer to the diagram in Appendix A for the location of the dyno relative to the lift) Document #

20 Step 2 Install the Feet on the four corners of the dyno. Use the 7/16 x 1 bolts with flat and lock washers to secure the feet to the dyno frame. The bolts should be installed through the slotted hole in the foot. Do Not Tighten the Bolts. The hardware should go through the slotted hole in the foot. Step 3 Once you have the four feet mounted to the dyno, use a marker to mark the floor mounting holes. When you have marked all the holes, remove the feet. Mark the holes with a felt tip marker. 3-2 Document #

21 Step 4 Using a carbide bit designed for concrete (see instructions included with anchors), drill four 1/2 holes in the floor where you made your marks. The holes should ideally be as deep as the length of the anchors (approx. 1 5/8 ). Note: Be sure to clean the debris out of the holes that you drilled. Step 5 Place the slotted end of the anchors in the holes that you drilled. They will most likely be very snug, so use a brass drift punch and hammer to drive them down. Step 6 Use the Set Tool to expand the base of the anchors. Place the small end of the Set Tool into the threaded end of the anchor (threaded end should be up). Drive the Set Tool with a large hammer until the anchor is fully seated. Step 7 Reinstall the feet. The hole that goes into the Document #

22 dyno gets the 7/16 bolt, lock washer, and flat washer. The 3/8 bolt, lock washer and flat washer go into the anchor in the floor. Step 8 Raise the lift and put the roller assembly portion of the interface kit on the cross beam of lift at its center line. Refer to the Interface Assembly Drawing in Appendix A. Position the roller wheel part of the interface on the lift so it passes through the tube part of the interface on the dynamometer. 3-4 Document #

23 Step 9 Tighten the roller part of the interface to the lift s cross beam. Make sure that it runs smoothly in the receiver part of the kit. Installing the Brakes Use the following steps to install the brakes on your Dynojet Dyno: Step 1 Locate the brake hardware. You should have six 5/8" bolts, six lock washers, six flat washers, six nuts (mounted on the dyno) and two brakes. Left Right Step 2 The brakes mount on the inside of the dyno frame with the air canister on the top. Identify the left and right brakes. As shown in the figure above, the brakes can only be mounted one way. Step 3 Document #

24 Mount the brakes on the dyno frame. Use three bolts, three nuts, and three lock washers on each brake weldment. - Remove the nuts and lock washers from the dyno frame leaving the bolts in place. - Place the brake weldments over the bolts on the frame. - Finish the installation of the brake weldments with the nuts and lock washers. Step 4 Install the air hose between the brakes, using the ports on the sides of the air canisters. 3-6 Document #

25 Wiring the Dyno Part 1 The following hardware and wires are shipped in boxes with the dyno except the DynoWare EX+ (A) that is shipped separately with the WinPEP software. Refer to the following page for item descriptions. C B A I D G J1 K E F H J2 L Basic Kit O R N M S P Additional Items for Proportional Air Brake Systems Document #

26 Basic Kit: A: DynoWare EX+ Modules B: Air Brake Pressure Regulator C: Air Brake Control Valve (Replaced by N with Proportional Air brake systems) D: DynoWare EX+ Power Supply and Cord E: Wall Mount for DynoWare EX+ F: DynoWare Cable G: Dynamometer Control Pendant H: Serial Port Cable I: Primary Inductive Cable J1&2: Secondary Inductive Cables K: Mounting Hardware L: Pickup Card Optional Proportional Air Brake Systems: (M) Booster Valve Assembly (Replaces C) (N) Electronic Pressure Regulator (EPR) (O) DIN Rail (for mounting the EPR) (P) Temperature Sensor (Q) Temperature Sensor Bracket (R) Four 1 / 4 " Button Head Allen Bolts In addition to the parts listed above there is an EPR cable. Note: This section is laid out to aid the operator with the installation of Standard Air or Proportional Air braking systems. Steps with Standard Air in front of them are to be followed solely by operators that are installing the Standard Air Brake system. Steps with Proportional Air in front of them are to be followed solely by operators that are installing the Proportional Air Brake system. Steps without any designation are to be followed by both. 3-8 Document #

27 Step 1 Install the pickup card. - Remove the pickup card and the 2 screws from the bubble bag. - Attach to the pickup bracket on the dyno so the optical pickup is facing the axle and the 3 pronged plug is facing away. - Turn the drum carefully and check to see that both pickup tabs on the dyno axle go through the center of the optical pickup on the pickup card. This tape secures the Pick Up Card to the dyno during shipping. Step 2 Prepare the Breakout Board - Remove the Bubble Bag from the Breakout Board and bracket. Break Out Board Document #

28 - The Data Acquisition Cable is coiled around the Breakout Board. Uncoil the cable and Plug the cable into the Pickup Card on the dyno. Note: The rest of the instructions for wiring the dyno follows the catwalk installation Document #

29 Catwalk Installation The following steps will explain how to put the catwalks on the dyno. The three pictures above identify the components referred to in these steps. Step 1 Place the catwalk (A) on the dynamometer above the brakes, so the lip of the catwalk lays on the dynamometer frame and butts up against the deck plate on the dynamometer. Using the 3/8" x 1" slotted truss head machine screws, secure it to the top of the dynamometer frame. Document #

30 Step 2 Using the 3/8" x 1" bolts, loosely secure each of the four support braces to the dynamometer and the bottom of the back catwalk. When the support tubes have been attached, tighten the bolts on the bottom of the support tubes. Tighten the bolts at the top of the support tubes where they attach to the catwalk. Step 3 Place the side-catwalks on the dynamometer so the Dynojet stickers are upright and visible when looking from the brake side of the dynamometer. Secure them to the dynamometer with the 3/8" x 1" bolts and to the back plate with the 3/8" x 1" bolts and nylon insert nuts. Step 4 Screw the supports (with rotating head) onto the threaded rods on the side-catwalks. Place the support tubes over the pegs on the side of the dynamometer Document #

31 Step 5 To adjust the side catwalks so they are level, the support arms can be turned while on the pegs and the screw will raise or lower the side catwalks. Step 6 Place the railing posts in the pockets and secure them with the 1/4 bolts and nuts. Step 7 String the chain through the holes (using the end with the bolt) in the top of the railing post. The chain should start on one end of the side catwalks, pass through all the posts and terminate on the opposite side catwalk. Place the end-cap over the bolt on the end of the chain and tighten it until the bolt comes to the end of the end-cap. Document #

32 Wiring the Dyno Part 2 Standard Air Step 1 (Go on to step 2) Proportional Air Step 1 Install the electronic regulator. Measure down and mark 16" and 19 3 / 4 " from the top of the right center deck support. Drill a 7 / 32 " hole in each spot marked above Document #

33 Fasten the DIN rail to the support using two 1/4" self tapping screws (provided). The electronic pressure regulator snaps onto the DIN rail, hook one side on the DIN rail then rotate electronic pressure regulator toward the DIN rail until it snaps into place. Standard Air Step 2 Screw the Air Brake Control Switch into the top of the right hand air canister. Document #

34 Proportional Air Step 2 Install the Booster Valve Assembly. Screw the booster valve assembly into the right side brake canister. Tighten it so the air gauge is facing out as shown below. There are two air lines coming from the electronic pressure regulator labeled "IN" and "OUT". The line labeled "OUT" is connected to the 3-way valve. Push the hose in then hand tighten the fitting. Pull on the hose to ensure it is seated properly. If it moves, tighten the fitting more Document #

35 The line labeled "IN" is connected to the brass cross. Push the hose in then hand tighten the fitting. Pull on the hose to ensure it is seated properly. If it moves, tighten the fitting more. Standard Air Step 3 (Go on to step 4) Proportional Air Step 3 Install the Temperature Sensor on the left rear panel. Loosely install the left side back cover over the brake so the Dynojet stickers face out and upright. (Use the self tapping screws provided.) Measure down 24" from the top of the dyno and mark the left dyno support tube. Document #

36 Measure from the left side of the dyno to the right edge of the knurled drum surface as shown below. Using the above distance and beginning 24" from the top of the dyno, measure over and mark the left rear panel as shown below. Measure down 24" from the top of the dyno and mark the mark the left rear panel where it intersects the previous mark as shown below Document #

37 Center punch and drill a 7 / 32 " pilot hole and then expand it to a 3 / 4 " hole for the temperature sensor. Mount the temperature sensor in the 3 / 4 " hole and adjust it so that it s tip is approximately 3" from the surface of the drum. Document #

38 Standard Air Step 4 Connect the remaining wires to the Breakout Board. Fasten the two black wires into the connecting block in the connectors marked with the word BRAKE. (The 2 wires can go in either order.) Connect the yellow and black wires from the Brake Control to the two connectors marked with the letters -SIG-. (The 2 wires can go in either order.) 3-20 Document #

39 Proportional Air Step 4 Complete the breakout board wiring as in the following descriptions: A B C D E (A) Data acquisition cable coming from the optical pickup on the dyno shown on the left. These four wires go to the section of the card Labeled DRUM : The red wire connects to R1. The white wire connects to W1. The black wire connects to B1. The silver wire connects to S1. (B) One yellow and one black wire go to the two connections Labeled PRESS. They connect to the air sensor (shown on the left) located on the Booster Valve Assembly. They can connect in either order. Document #

40 (C) There are five wires in the cable that connects the EPR (shown left) to the breakout board in the spot labeled Load Control : The black wire connects to V-. The red wire connects to V+. The clear wire connects to 0+. The green wire connects to 0-. The silver or ground wire connects to SH. (D) The brake wires (shown left) come from the air switch on the Booster Valve Assembly. They connect to the two connectors on the breakout board labeled BRAKE. They can connect in either order. Connect the Dyno (E) The five wires in the cable coming from the Temperature Sensor (shown left) connect to the connectors labeled TEMP : The green wire connects to G1. The white wire connects to W1. The black wire connects to B1. The red wire connects to R1. The silver or ground wire connects to S1. Step 1 Plug the 25 pin DynoWare Cable into the bottom of the Breakout Board and hand tighten the thumb screws Document #

41 Step 2 Thread the DynoWare Cable under the dyno frame. Proportional Air Step 3 Attach the center panel and tie up the cables as shown below. Standard Air Step 3 Attach all the side panels so that the Dynojet Stickers face outward and the brake wires go through a slot in the center panel as shown below. Document #

42 Step 4 Connect your shop air to the dyno. Mount the Air Pressure Regulator on the wall in the shop with the bracket provided. Connect a supply air hose to the inlet of the regulator from your shop air supply. Note: Make sure the arrow on the regulator is the same as the direction of the air flow! Connect a 3 / 8 " air hose to the outlet side of the regulator. Connect the other end of the air hose to the barbed inlet fitting on the Air Control Switch (Standard Air) or the Booster Valve Assembly (Proportional Air) on top of the right air canister on the dyno. Proportional Air Standard Air Note: The regulator should be set to 60 psi. Standard Air Step 5 (Go on to step 6) Proportional Air Step 5 Install the rest of the side panels so the Dynojet stickers face out and upright. (Use the self tapping screws provided.) 3-24 Document #

43 Step 6 Check the brakes. The DynoWare Stack must be on to release the brakes. Slowly rotate the drums (this can be done manually) then press the brake button (the red button on the Hand Held Pendant). The button should light up and engage the brakes stopping the drums. Press the button again and the light will go off, disengaging the brake. If the brakes do not engage, make sure the pressure gauge Air Brake Regulator is set to 60 PSI (276 kpa), and check all connections. If you have any installation questions, call Dynojet at (800) Document #

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45 Chapter 4 Basic Dyno Operation The Dynojet Dynamometer gives state of the art technology, durability, and accuracy that you need. Dynojet s advanced engineering delivers the precise horsepower measurements a technician needs to make quick and accurate evaluations of engine performance and drive train problems. This chapter includes instructions for basic dyno operation. For more detailed instructions, refer to the WinPEP 7 User Guide. This manual can also be found on your WinPEP CD or at This chapter is divided into the following categories: Loading the Vehicle, page 4-2 Connecting the RPM Pickup, page 4-5 Pre-Run Inspection, page 4-9 Making a Test Run, page 4-11 Document #

46 Loading the Vehicle Use the following steps to load a vehicle on the dyno. 1. Verify your computer is running. Set the dyno brake on by pressing the red button on the hand held pendant. 2. For four or all-wheel drive vehicles, measure the wheel base on the vehicle and adjust the 224-4WD dyno to that dimension before driving the vehicle on the dyno. CAUTION: Do not make any adjustments with the vehicle on the dyno. 3. Drive the vehicle onto the dyno and align the vehicle straight with the dyno. 4. Stop the vehicle when the drive axle is centered on the drum. center drive axle on dyno drum center drive axle on dyno drum adjust wheel base of 224-4WD dyno 4-2 Document #

47 5. When the vehicle is positioned properly on the dyno, shut the engine off. If the vehicle has an automatic transmission, place it in park. If the vehicle has a manual transmission, place it in gear. 6. Set the vehicle s emergency brake. 7. Secure the non-drive wheels using the provided tire chocks. Do not use tire chocks for four wheel drive vehicles. 8. Attach the tie-down straps. Rear Wheel Drive Attach two tie-down straps from secure anchor points to the rear of the vehicle. Attach additional tie-down straps from the rear of the vehicle as shown in Figure 5-2. Attach two tie-down straps from secure anchor points to the front of the vehicle. Front Wheel Drive Attach two tie-down straps from secure anchor points to the rear of the vehicle. Attach two tie-down straps from secure anchor points to the front of the vehicle. Attach additional tie-down straps across the front of the vehicle to form a crisscross. Four Wheel (All-Wheel) Drive Attach two tie-down straps from secure anchor points to the rear of the vehicle. Attach additional tie-down straps across the rear of the vehicle to form a crisscross. Attach two tie-down straps from secure anchor points to the front of the vehicle. Attach additional tie-down straps across the front of the vehicle to form a crisscross. rear wheel drive front wheel drive four wheel drive Document #

48 9. Tighten the tie-down straps evenly making sure that the drive wheels remain centered on the drum. CAUTION: The tie-down straps should always be connected to the vehicle s solid axle or the suspension control arms. Factory tie-down hooks connected to the vehicle s frame may be used on the end opposite the drive wheels (for example: the front end of a rear driven vehicle). 10. Release the brake on the vehicle and the dyno. 11. Start the vehicle and put the transmission into first gear or drive. 12. Press the accelerator pedal so the drums begin turning slowly. While the drums are slowly turning, get a feel for the stability of the vehicle. 13. Check all the straps and ensure the vehicle is tracking straight on the dyno. 4-4 Document #

49 Connecting The RPM Pickup Your Dynojet dynamometer includes a primary wire inductive pickup and two secondary wire inductive pickups. These small clothespin like inductive pickups are used to sense RPM. An RPM pickup is required if you want to view torque graphs. Generally you will use one secondary wire inductive pickup on a spark plug wire. Vehicles with wasted spark ignition systems may require two secondary inductive pickups. On a wasted spark ignition, typically one coil will be connected to two spark plug wires. Attach one secondary pickup to each of these wires. If the pickups are connected to two plug wires that do not fire at the same time, an erratic RPM readout may occur. The primary wire inductive pickup senses RPM pulses from the coil. Although this pickup location generally works better, it is harder to find the correct location to connect the RPM pickup. Note: If a pickup is not being used, disconnect it from the dyno electronics to prevent any stray pick up of signals. The optional Optical Sensor is useful on diesel powered vehicles, MSD ignitions, and other high RFI ignition systems. For more detailed information on the Optical Sensor, refer to the Optical RPM Sensor Installation Guide (P/N ). CAUTION: Inductive pickups are very fragile. The ferrite core can easily be damaged and is not covered under warranty. Dropping, snapping, vibration, and heat can all damage the ferrite core. The dyno electronics RPM module contains the electronics that sense the RPM pulses. An auto-gain circuit looks at only the peak voltage of the vehicle s spark, ignoring the lower voltages to help reduce electronic noise problems. Wasted spark ignition systems will produce a lower voltage level on the exhaust stroke than the compression stroke. By definition of the auto-gain circuit, lower voltage spark levels will be ignored, missing every other spark the vehicle would produce. Document #

50 RPM Pickup Descriptions RPM pickup Secondaries (Non- wasted spark system) Secondaries (Wasted spark ignition system) Primary pickup Optional Optical RPM Sensor description Use one secondary pickup. Unplug the other pickup from the RPM module and set the degrees between plug fires to 720 in WinPEP 7. Use two secondary pickups. Attach one pickup on each spark plug wire on the same coil and set the degrees between plug fires to 360 in WinPEP 7. Attach the primary wire pickup to the primary side of the coil. Set the degrees between plug fires by taking 720 (four cycle engines) or 360 (two cycle engines) divided by the number of cylinders multiplied by the number of coils. For example, the number of degrees between plug fires on a four cylinder four cycle engine with dual coils (where each coil fires two cylinders) is 720/4 x 2=360 degrees. Attach the sensor wire to the RPM module, also be sure to plug in the small power lead into the CPU module. The other end of the wire attaches to the Optical Sensor. Set the degrees between plug fires to 360 in WinPEP. Refer to the Optical RPM Sensor Installation Guide (P/N ). 4-6 Document #

51 Connecting the Secondary Inductive Pickup The secondary inductive pickup cannot be in contact with, or it s connecting wire be crossing, other engine electrical wires or stray RF interference may result. 1. Clip the secondary inductive pickup around one spark plug wire. 2. Route the inductive pickup cable clear of devices that produce electronic noise (spark plug wires, coil wire, coil etc.) to the dyno electronics RPM module. Note: Inductive pickup placement is important. Position the inductive pickup so that it is not making contact with any other spark plug wires. Separate the spark plug wire from the spark plug wire bundle for proper operation. Note: You must ground the vehicle to the dyno for the electronics to function properly. connect secondary inductive pickup on a single spark plug wire automobile distributor Document #

52 Connecting The Primary Inductive Pickup The primary inductive pickup cannot be in contact with, or it s connecting wire be crossing, other engine electrical wires or stray RF interference may result. 1. Clip the primary inductive pickup around the wire to the primary side of the coil. 2. Route the primary wire cable clear of devices that produce electronic noise to the dyno electronics RPM module. Note: You must ground the vehicle to the dyno for the electronics to function properly. coil connect primary inductive pickup on the negative side of the coil 4-8 Document #

53 Pre-run Inspection Perform a vehicle inspection before making a run. Check the radiator coolant (if applicable) and oil levels. Check the fuel source. Rotate the drum and check for rocks caught in the tire tread that could fly out. Check the tire pressure and tire speed rating. Improperly inflated tires or exceeding the maximum speed rating can result in premature wear or severe tire damage. Make sure the tire has no major deficiencies (cracks in sidewalls, tread life, etc.). Visually inspect the vehicle. Make sure it is in safe running order. Make sure ear protection and safety glasses are used when the dyno is being operated. Check the tie-down straps to make sure that they are tight and secured. Check the drive tires to be sure that they are aligned correctly on the dynamometer s drums. Keep all rotating components clear at all times. Only the operator should be near the dyno or the vehicle during the test. Never allow any person(s) to stand behind the dyno or vehicle when it is being operated. Perform any other safety inspections appropriate to running your vehicle on the dyno. WARNING: Never allow any person(s) to stand behind the dyno or vehicle when it is being operated. Only the operator should be near the dyno or the vehicle during the test. Before Starting the Engine Connect an exhaust hose or hoses (if dual exhaust) on the vehicle, make sure the hose fits over the tail pipe, is not plugged or kinked and the hose is vented correctly out of the dyno room. WARNING: Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death. Operate machine in well ventilated area. Document #

54 Engine Warm Up Warm the vehicle s engine and drivetrain before beginning testing. Consistent engine temperatures will assure your runs are repeatable. After Engine Warm Up Always leave the vehicle in neutral (automatic transmission) or in first gear (manual transmission), with the engine off, and make sure the park brake and the dyno brake are on when you get off the vehicle on the dyno. Fix any fuel, oil, or coolant leaks that may have shown up after engine warm up and check the carburetor for leaks. Any loud or unusual engine noises or excessive exhaust smoke should be resolved before continuing Document #

55 Making a Test Run Dyno runs provide safe, reliable road testing right in the shop. The dyno allows you to measure, record, and diagnose performance problems quickly. The dyno combined with WinPEP 7 produces consistent, easily interpretable power graphs. Use the following instructions to ensure repeatable and accurate measurements. 1. Verify the vehicle is secured properly. 2. Place the vehicle in a low gear and release the dyno brake using the hand held pendant. 3. Slowly accelerate the vehicle to 20 m.p.h. 4. Test the tachometer operation. Rev the engine. The gauges on the computer screen should be moving. If the tachometer is moving but not registering the correct RPM values, the number of degrees of revolution of the crank shaft (the plug fires number) is incorrect. Stop the vehicle, return to the MakeRun Configuration dialog box, and enter the correct value for plug firing order. 5. Press the red brake button to apply 100% braking and slow down the vehicle. CAUTION: Using the vehicle s rear brake to stop the drum at speeds over 30 m.p.h. can severely over heat the rear brake parts. Dynojet dynamometers with the air brake or eddy current brake accessory can be used to slow the vehicle and drum to a full stop at any speed. The vehicle s brake should be used in an emergency stop situation only. 6. Shut the engine off and put the vehicle in gear (manual transmission) or neutral (automatic transmission). 7. Set the vehicle s parking brake and leave the dyno brake on. 8. Perform a final inspection. Verify the drive tire s alignment on the dyno drums. Make any adjustments to the tie-down straps as needed. Perform any other safety checks that you deem appropriate to your particular situation. You are now ready to make a high speed run on the dyno. Refer to your WinPEP 7 User Guide for more detailed instructions. Document #

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57 Appendix A -Square the face of the dyno up to the face of the four post lift. The distance between the two is 4. Center Line of Dyno and Four Post Lift Lift Tube with Roller Portion of the Interface Kit Relative Dyno and Four Post Lift Location Document # A - 1

58 Appendix A A - 2 Document #