1993-2001 Dynojet Research, Inc. All Rights Reserved.. 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 89031, USA. Printed in USA. Part Number: 98295109 (07/2001)
TABLE OF CONTENTS List of Figures............................................. iii Chapter 1 Optical RPM Sensor Installation Conventions Used In This Manual..................................1-1 Technical Support...............................................1-2 Parts List.......................................................1-2 Installation.....................................................1-3 Connecting the Optical RPM Sensor...............................1-3 Optical Sensor Set Up and Adjustment.............................1-4 Running WinPEP................................................1-6 Starting WinPEP..............................................1-6 Selecting a Name.............................................1-7 Editing the Notes and Parameters.................................1-9 Preparing for a Run...........................................1-13 Making a Test Run...........................................1-14 i
LIST OF FIGURES Figure 1-1: Optical RPM Sensor Assembly Parts.......................1-2 Figure 1-2: Attach Reflective Tape To Harmonic Balancer...............1-3 Figure 1-3: Hardware Stack Optical Sensor and Power Lead...........1-3 Figure 1-4: Optical Sensor Mount To Magnetic Base.................1-4 Figure 1-5: Optical Sensor Verify Position And Proper Function.........1-5 Figure 1-6: Error Message.........................................1-6 Figure 1-7: WinPEP Setup Window Dyno Parameters.................1-6 Figure 1-8: Make Run Window Select The Make.....................1-7 Figure 1-9: Make Run Window Select The Model....................1-7 Figure 1-10: Make Run Window Select Name.......................1-8 Figure 1-11: Make Run Window Example..........................1-8 Figure 1-12: Make Run Window Next Run Name and Run Title........1-9 Figure 1-13: Make Run Window Plug Fires, Tachometer Redline, and Tire Speed......................................1-10 Figure 1-14: Make Run Window Run Type and Run Notes............1-11 Figure 1-15: Make Run Window Optional Make Run Settings.........1-12 Figure 1-16: Make Run Window Gauges..........................1-13 Figure 1-17: Test Run Hand-Held Pendant.........................1-14 iii
C HAPTER 1 OPTICAL RPM SENSOR INSTALLATION This document provides instructions for installing the Optical RPM Sensor. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This manual will walk you through the installation procedures, running WinPEP and using the tachometer to verify proper function, and describe how to make any necessary adjustments. Document Part Number: 98295109 Last Updated: 07-25-01 CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to aid the user and protect both the user and the equipment. example of convention Bold description Highlights items you can select on in the software interface, including buttons and menus. Indicates a keyboard command. For example, press U means using the keyboard, press the letter U. 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. 1-1
CHAPTER 1 TECHNICAL SUPPORT For assistance, please contact Dynojet Technical Support at 1-800-992-4993, or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89031. Visit us on the World Wide Web at www.dynojet.com 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 Optical RPM Sensor Installation kit. 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 Sensor Assembly with Bracket is pre-assembled and includes: Sensor, Optical RPM (P/N 49822000) Sensitivity Adjustment Tool 35130221 Magnetic Base, Diesel PU 1 66954003 Cable, Optical RPM Lead 1 38910490 Tape, Reflective, 1/2 5 feet 1 sensor assembly with bracket optical sensor lead magnetic base reflective tape sensitivity adjustment tool Figure 1-1: Optical RPM Sensor Assembly Parts 1-2
OPTICAL RPM SENSOR INSTALLATION Installation INSTALLATION................................... This section describes the procedures for installing the optical RPM sensor. CONNECTING THE OPTICAL RPM SENSOR 1 Cut a one inch strip of reflective tape from the roll provided. 2 Clean a flat section of the harmonic balancer. Attach the strip of reflective tape. Note: High RPM engines will require a longer piece of reflective tape; use a 1.25-1.5-inch strip of tape. reflective tape Figure 1-2: Attach Reflective Tape To Harmonic Balancer 3 Attach the optical sensor lead to the hardware stack. You need to remove any inductive leads from the RPM module if installed. 4 Attach the small power lead from the optical sensor lead to the CPU module. optical sensor lead on RPM module optical sensor power lead on CPU module Figure 1-3: Hardware Stack Optical Sensor and Power Lead 1-3
CHAPTER 1 Installation 5 Mount the optical sensor to the magnetic base. The base is adjustable to allow the sensor to be oriented in many directions. 6 Attach the other end of the optical sensor lead into the optical sensor. optical sensor magnetic base optical sensor lead Figure 1-4: Optical Sensor Mount To Magnetic Base OPTICAL SENSOR SET UP AND ADJUSTMENT 1 Disconnect the negative battery cable. This will prevent the vehicle from starting. 2 Mount the optical sensor (attached to the magnetic base) in a location where the red lens has an unobstructed view of the reflective tape. Use the magnetic base on/off switch to secure the assembly to a stationary metal object. 3 Connect the negative battery cable. 4 Verify the optical sensor is working. Note: At this point you will need to skip to Running WinPEP on page 1-6 and follow those instructions for making a run. These instructions will allow you to use the tachometer gauge to verify whether the optical sensor is functioning properly. Return to this section to adjust the optical RPM sensor as needed. 5 Verify the hardware stack is on. 6 Verify the optical sensor cable is plugged in to the RPM module and the power lead from the cable is connected to the CPU module. Refer to Figure 1-3. Note: Dynojet recommends you ground the vehicle to the dyno for the electronics to function properly. 1-4
OPTICAL RPM SENSOR INSTALLATION Installation 7 Verify both the green and red lights on the optical sensor are on. Both lights will be on if the optical sensor in the correct position. The red lens on the sensor must be pointed at the reflective tape. If the red light is not on, the sensor will need to be relocated or adjusted. This condition indicates that the sensor can not see the reflective tape. Disconnect the negative battery cable any time you work under the front of the vehicle. This will prevent the vehicle from starting and ensure your safety. 7a Try to relocate the magnetic base and sensor assembly closer to the reflective tape. If this is not possible, you will need to adjust the sensitivity on the sensor. Be sure the placement of the magnetic base and sensor assembly do not interfere with the operation of the vehicle. The vehicle s fan may turn on at any time; always use caution when working around the fan. 7b Use the adjustment tool to turn the sensitivity knob until both the green and red lights are on at the same time. Note: The red light will flash every time it sees the reflective tape. While running the vehicle the red light will be flashing very fast and may be difficult to see. red lens red light green light sensitivity adjustment tool Figure 1-5: Optical Sensor Verify Position And Proper Function 1-5
CHAPTER 1 Running WinPEP RUNNING WINPEP................................... Use the following steps to run WinPEP, use the tachometer to verify the optical sensor is functioning properly, and make a test run Note: Depending on your version of WinPEP, the appearance of the windows and messages may be slightly different than the ones used in this example. STARTING WINPEP 1 Double-click the WinPEP icon on the desktop. 2 Click the Make Run icon in the work space toolbar to display the Make Run window. Note: If the following error message is displayed, you will need to select a different Com port (for DynoWare EX+) or a different address (for a PC Card). 2a Click OK to continue. Figure 1-6: Error Message 2b The WinPEP Setup window will be displayed with the Dyno Parameters tab automatically selected. Make any necessary corrections and click OK to continue. Figure 1-7: WinPEP Setup Window Dyno Parameters 2c Once you have made your corrections, click the Make Run icon to display the Make Run window. 1-6
OPTICAL RPM SENSOR INSTALLATION Running WinPEP SELECTING A NAME Use the following procedures to set up your Make Run window and make a test run. In this example we will use a Chevy Corvette owned by Larry Hall. 1 Select the Make. 1a Select Chevy from the file structure. file structure Figure 1-8: Make Run Window Select The Make 2 Select the Model. If your model is not present in the file structure, you will need to add your model to the list. 2a Press Insert to insert a new model. 2b 2c Type the name of your model. You can use small or capital letters. Example: CORVETTE Click OK to continue. Figure 1-9: Make Run Window Select The Model 1-7
CHAPTER 1 Running WinPEP 3 Type the name of the owner. The name can be one to eight characters long with no spaces and use small or capital letters. Example: LARRY 4 Click OK to continue. Figure 1-10: Make Run Window Select Name Using the Corvette as an example, the Make Run window should look like Figure 1-11 below. Figure 1-11: Make Run Window Example 1-8
OPTICAL RPM SENSOR INSTALLATION Running WinPEP EDITING THE NOTES AND PARAMETERS You will need to fill in the Make Run data necessary for making a dyno run. We will continue using the Corvette as an example. Note: Absolute Pressure, Room Air Temperature, and Relative Humidity are automatically determined by DynoWare s Atmospheric module and cannot be changed. NEXT RUN NAME Type in the name of the run. Refer to Figure 1-12. The name entered will appear on the printed graph. Example: LARRY. RUN TITLE Enter the description of the run in the Run Title. Example: 94 CORVETTE ZR-1, 4TH GEAR TEST next run name run title Figure 1-12: Make Run Window Next Run Name and Run Title 1-9
CHAPTER 1 Running WinPEP PLUG FIRES Enter 360 for the number of plug fires when using the optical RPM sensor. Refer to Figure 1-13. TACHOMETER REDLINE Enter the Tachometer Redline from your vehicle s tachometer or your owner s manual. Refer to Figure 1-13. Example: 7,250 RPM = 7.25 This places a redline on the tachometer that appears on the computer screen during a run. If you exceed this redline during your run, the tachometer needle on the computer screen will change colors. TIRE SPEED RATING From the following list, enter the Tire Speed Rating of the drive tires in mph for the vehicle. Note: If you exceed this speed, the computer will stop the run. tire rating Non-Rated S H V Z mph 93 mph 112 mph 130 mph 150 mph 150 mph and higher plug fires tachometer redline tire speed rating Figure 1-13: Make Run Window Plug Fires, Tachometer Redline, and Tire Speed 1-10
OPTICAL RPM SENSOR INSTALLATION Running WinPEP RUN TYPE Select the type of run you will be performing. Refer to Figure 1-14. A description of each Run Type is listed below. Example: RO run type RO AG FA NG description Roll-On All Gear Run Fast Acceleration Negative Horsepower RUN NOTES Enter up to five lines of information about your run. Example: 4TH GEAR ROLL ON TEST, LARRY HALL S 1994 CORVETTE, ZR-1 BEFORE FULL SERVICE, TUNE-UP. run type run notes Figure 1-14: Make Run Window Run Type and Run Notes 1-11
CHAPTER 1 Running WinPEP OPTIONAL MAKE RUN SETTINGS Auto Download automatically saves a delimited text file in a numbers data format after each run. The name of the file will be the same as the run with a DAT extension and will be stored in the same directory as the run. Hold BaseLine when this option is checked the first run in the selection list or the first run made is held in the number one slot on the graph for comparison. To change the base run, change the run in the number one slot in the selection list on the work group form. Graph Data Following Run this option allows you to toggle the graph on and off after making a run. Display Neg Values allows you to view negative values on the graph after making a run. Once all of the notes and parameters have been entered, click Make Run or press Enter to start the run. optional make run settings Figure 1-15: Make Run Window Optional Make Run Settings 1-12
OPTICAL RPM SENSOR INSTALLATION Running WinPEP The following gauges window will appear. The tachometer gauge will be used to verify the optical RPM sensor is functioning properly. Refer to Make a Test Run, step 2 on page 1-14 for instructions on testing the tachometer. Figure 1-16: Make Run Window Gauges PREPARING FOR A RUN Use the following procedures and safety checks to prepare for a run. BEFORE STARTING THE ENGINE 1 Connect an exhaust hose or hoses (if dual exhaust) on the car, 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. 2 Perform the following safety checks: Check the radiator coolant and oil levels. 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. 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 drums. Visually inspect the vehicle. Make sure it is in safe, running order. Make sure to wear safety glasses and ear protection when operating the dyno. 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 car on the dyno. 1-13
CHAPTER 1 Running WinPEP ENGINE WARM UP 3 Warm the vehicle s engine and drivetrain before beginning testing. Consistent engine temperatures will assure your runs are repeatable. FOLLOWING ENGINE WARM UP 4 When you exit a vehicle while still on the dyno, always leave the vehicle in Park (automatic transmission) or in first gear (manual transmission); turn the engine off; and make sure both the vehicle emergency brake and the dyno brake are on. 5 Repair any fuel, oil, or coolant leaks that may have appeared after engine warm up. Check the carburetor for leaks. 6 Inspect any loud or unusual engine noises or excessive exhaust smoke. These issues must be resolved before continuing. MAKING A TEST RUN Make sure that the vehicle is secured properly. 1 Accelerate the vehicle. 1a Place the vehicle in a low gear and release the dyno brake using the hand-held pendant. 1b Slowly accelerate the vehicle to about 20 mph. Figure 1-17: Test Run Hand-Held Pendant 2 Test the tachometer. If the tachometer does not move, you will need to adjust the optical RPM sensor. Refer to Optical Sensor Set Up and Adjustment on page 1-4 for instructions on adjusting the sensor. If the tachometer is moving but not registering the correct RPM values, the number entered for Plug Fires may be incorrect. Stop the vehicle, press Escape to return to the Make Run window and enter the correct value for the plug fires. Refer to page 1-10 for more information about plug fires. Note: You should now be able to use the optical RPM sensor. Continue with step 3 to stop the vehicle and step 4 if you are planning to perform a high speed run on the dyno. 1-14
OPTICAL RPM SENSOR INSTALLATION Running WinPEP 3 Stop the vehicle. 3a Remove your foot from the accelerator pedal. 3b Take the vehicle out of gear (manual transmission only). 3c Press brake button on the hand-held pendant to stop the dyno drums. Do NOT use the vehicle s own brakes to slow the dyno drums! Using only the vehicle s brake to stop the drums will severely over stress the vehicle s brake parts. The vehicle s brakes should be used in emergency stop situations only. 3d 3e 3f Shut the engine off. Put the vehicle in gear (manual transmission) or park (automatic transmission). Set the vehicle s emergency brake. Leave the dyno brake on. 4 Check the straps. 4a Make any adjustments to the straps that may be needed. 4b Verify the drive tire s alignment on the dyno drums. 4c Perform any other safety checks that you deem appropriate to your particular situation. You are now ready to perform a high speed run on the dyno. 1-15