Dynojet Research Motorcycle Accessories 250 User's Manual
Contents
1. Note 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 Torque Cell Calibration Calibration is complete Remove the calibration arm and mass You are now ready to use your dyno lt Previous Figure 2 6 Calibration Is Complete Window 2 6 Torque M odule Installation and User Guide for M odel 250 Dynamometers APPENDIX THE TORQUE MODULE AND WINPEP 6 This appendix provides instructions for using the Torgue Module with WinPEP 6 To ensure safety and accuracy in the procedures perform the procedures as they are described A 1 Torque Module Installation and User Guide for Model 250 Dynamometers ge APPENDIXA Torque Module Calibration We 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 r File Si Tools Window J Pop Open DynoTrac TE Az a DynoTrac icon HH 71 N FJERN E C MS DOS 6 z CA CARun Data CJ ducati inf 916 bip DYNORUN OO1 DYNORUN 002 Figure A 1 Launch WinPEP The DynoTrac window will appear 2 Select Option2. 2191 Mendenhall Drive North Las Vegas NV 89081 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 Torque Module Installation and User Guide for M odel 250 Dynamometers gr TORQUE MODULE INSTALLATION This section describes how to i PARTS LIST The following table lists all of t TORQUE MODULE INSTALLATION Torgue M odule Installation nstall the Torgue Module he parts included in the Torgue Module 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 guantity 36708100 Nut 1 2 13 Nylock Hex 2 36801640 Bolt 1 2 13 x 2 Hex 2 36933100 Washer 7 16 Flat 4 66114002 Torgue Module Sub Assembly 1 or or 66104001 Torgue Module High Resolution Sub Assembly 76950500 Cable Load Cell 1 DM150 034 5 8 Cable Clamp 3 73422230 3 8 Cable Clamp 1 DM150 020 005 1 4 20 Crush Nut 3 The following parts are included in the calibration arm assembly p n 63920002 35430899 Weight 25 LB 4 22105040 Weight Support Pin 1 32904480 Pin Cotter 1 8 x 1 1 2 1 36488100 Nut 3 8 16 Nylock 3 36584070 Bolt 3 8 16 x 2 5 Hex 3 63920001 Calibration Arm Main Bar Assembly 1 63920003 Calibration Arm Extension Assembly 1 DM150 002 007 5 16 Flat Washers 6 The followin
3. 8 Attach the power cord to the dyno electronics and turn the power switch on The green LED light on the Torgue Module should now be on torgue module tie strap green LED light load cell cable and port Figure 1 3 Attach Torgue Module and Load Cell Cable 1 5 Version 4 Torque M odule Installation and User Guide for Model 250 Dynamometers V CHAPTER 1 7 amp Load Cell Installation LOAD CELL INSTALLATION This section describes how to remove the hood install the load cell and replace the hood REMOVING THE HOOD 1 Disconnect all power to the dyno 2 Remove the four bolts securing the eddy current brake cover and set aside Note You may want to place the four bolts you just removed back into the hood to prevent misplacement 3 Remove the two bolts securing the hood clamps to the brake and set aside brake cover pt hood clamps MC0006 Figure 1 4 Remove the Brake Cover and Hood Clamps Remove the four bolts securing the hood to the dyno and prop up the hood Disconnect the wires to the key switch if present Disconnect all battery wires Remove the hood from the dyno and set aside NO Uf Mcooo7 key switch Figure 1 5 Remove the Hood 1 6 Torque Module Installation and User Guide for Model 250 Dynamometers TORQUE MODULE INSTALLATION Sx Load Cell Installation INSTALLING THE LOAD CELL 1 Remove the two bolts securing the existing
4. bar on the eddy current brake and remove the bar bar TM009 Figure 1 6 Remove the Bar 2 Install the mounting bracket Note If you already have the newer style bracket attached to your eddy current brake skip this step and continue with step 3 2a Remove the four bolts securing the existing mounting bracket and set aside 2b Install the new mounting bracket using the four bolts you just removed 2c Torque the bolts to 100 ft Ibs old bracket TM010 AE TT TM011 Figure 1 7 Install the Mounting Bracket _____ _ _ i 7 Version 4 Torque Module Installation and User Guide for Model 250 Dynamometers 4 CHAPTER 1 E Load Cell Installation 3 Install the load cell 3a Orient the load cell so the cable faces the dynamometer and the printing on the load cell is right side up 3b Secure the load cell to the mounting bracket and the bracket welded to the frame using two 1 2 13 x 2 inch bolts four 7 16 inch flat washers and two 1 2 13 inch nylock nuts mounting bracket load cell cable I load cell bracket welded TaZ Ss to frame A i TM012 Figure 1 8 Install the Load Cell Note Older versions of the eddy current brake frame will require you to install the sleeve into the load cell You must also use a 3 8 16 x 2 inch bolt and 3 8 16 inch nylock nut for the lower hole 3 8 inch bolt SFU _ pe i TM013 Figure 1 9 Install the Load Ce
5. 00 160 1004 DYNORUN OOZ Max Power 186 39 Max Torgue DYNORUN 010 Max Power 201 62 Max Torque DYNORUN 016 Max Power 217 71 Max Torque ra x t r 50 50 60 70 0 99 100 110 120 130 140 TORQUE MODULE NSTALLATION AND USER GUIDE For Model 250 Motorcycle Dynamometers P N 98295104 04 2001 2005 Dynojet Research Inc All Rights Reserved Torque Module Installation and User Guide for Model 250 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 res
6. all Drive Kromstraat 82 E North Las Vegas NV 89081 5345 AD Oss Tel 800 992 3525 The Netherlands 702 399 1423 Tel 31 0 412 403770 Fax 702 399 1431 Fax 31 0 412 403636 bikedynosalesedynojet com international dynojet com autosales dynojet com www dynojet com
7. g parts are also used in the eddy current brake retrofit kit p n 73920002 DM150 002 007 5 16 Flat Washers 2 61329301 Load Cell Bracket 1 36583270 Bolt 3 8 16 x 2 Hex 1 36488100 Nut 3 8 16 Nylock 1 22461002 Sleeve 3 8 ID x 1 2 OD 1 21227106 Spacer Calibration Bar Retro 1 Version 4 Torgue M odule Installation and User Guide for M odel 250 Dynamometers ca 1 3 V CHAPTER 1 ZE Torque Module Installation INSTALLING THE TORQUE MODULE 1 Turn off the main power switch on the CPU Module on the dyno electronics and unplug the power cord 2 Remove the dust cover from the existing top module Eg dust cover power cord input power switch Figure 1 1 Remove Dust Cover 3 Loosen the top right screw on the back of the existing top module 4 Plug the Torgue Module into the existing top module Place the dust cover removed in step 2 on the Torque Module 5 Secure the grounding strap on the back of the Torque Module to the existing top module grounding strap Figure 1 2 Secure Grounding Strap 1 4 EE Torque M odule Installation and User Guide for M odel 250 Dynamometers TORQUE MODULE INSTALLATION yp Torque Module Installation N 6 Secure the Torgue Module to the dyno electronics with the plastic tie straps one on each side 7 Attach the 9 pin connector on the load cell cable to the front of the Torque Module and tighten down the screws
8. le Installation and User Guide for Model 250 Dynamometers TORQUE MODULE INSTALLATION Ss z Calibration Arm Assembly CALIBRATION ARM ASSEMBLY Dynojet recommends you use the calibration arm with the extension unless space constraints in your dyno room do not allow you to 1 Place the extension on the main arm and secure using a 3 8 16 x 2 5 inch bolt 5 16 inch flat washer and a 3 8 16 nylock nut Be sure to insert the bolt from the bottom 2 Inserttwo 3 8 16 x 2 5 inch cross bolts with four 5 16 inch flat washers and secure with two 3 8 16 nylock nuts cross bolts extension Je insert bolt from bottom TM003 TM004 Figure 1 14 Assemble the Calibration Arm 1 11 Version 4 Torque Module Installation and User Guide for Model 250 Dynamometers CHAPTER 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 Torque Module Installation and User Guide for Model 250 Dynamometers ZV CHAPTER 2 pr 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 a
9. ll on Older Brake Models 1 8 Torque Module Installation and User Guide for Model 250 Dynamometers Version 4 TORQUE MODULE INSTALLATION Ke Load Cell Installation N 4 Route the load cell cable 4a Make sure the load cell cable is clear of any power cables or hot or rotating objects 4b Secure the load cell cable to the three existing bolts underneath the aluminum top using three 5 8 inch cable clamps and 1 4 inch lock nuts load cell cable secure under aluminum top load cell cable Figure 1 10 Secure the Load Cell Cable to the Dyno 4c Remove the bolt on the brake and place a 3 8 inch cable clamp on the bolt 4d Run the load cell cable through the clamp and tighten the bolt load cell cable cable clamp Figure 1 11 Secure the Load Cell Cable to the Brake 1 9 Torque Module Installation and User Guide for Model 250 Dynamometers Pr CHAPTER 1 vad Load Cell Installation REPLACING THE HOOD 1 Replace the hood on the dyno leaving it propped up Secure the key switch if present and connect the battery 2 Lower and secure the hood using the four bolts you removed earlier y key switch y VA JH Wa Figure 1 12 Replace the Hood 3 Secure the hood clamps to the brake using the two bolts you removed earlier 4 Replace the brake cover and secure using the four bolts you removed earlier 1 hood clamps Figure 1 13 Replace the Brake Cover and Hood Clamps 1 10 Torque Modu
10. nish Enter the number stamped on the calibration arm extension NOTE If you don t have enough room to install the extension use the number stamped on the main bar If the number shown below matches the calibration arm then press next to continue Finish Figure 2 2 Calibration Mass Window Enter the calibration number stamped on the calibration arm extension If you do not have enough room to install the extension use the number stamped on the main bar Note Dynojet recommends you use the calibration arm with the extension unless space constraints in your dyno room do not allow you to calibration arm with A calibration arm extension main bar N AL pr TM001 dla TM002 Figure 2 3 Calibration Arm 2 3 Version 3 Torque Module Installation and User Guide for Model 250 Dynamometers Pr CHAPTER 2 ZE Torque Cell Calibration 6 Click Nextto 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 Torque Cell Calibration Span Calibration Please install the calibration arm and place the mass on the peg Press next to finish the calibration procedure lt Previous Finish Figure 2 4 Span Calibration Window 2 4 Torque Module Installation and User Guide for Model 250 Dynamometers USING THE TORQUE MODULE Torque Cell Calibration A 8 Install the calibration arm and weights 8a Insert the stud on the end of the calibrati
11. nstalling the load cell and assembling the calibration arm Document Part Number 98295104 Version 4 Last Updated 03 09 05 This chapter is divided into the following categories Introduction page 1 2 Torque Module Installation page 1 3 e Load Cell Installation page 1 6 e Calibration Arm Assembly page 1 11 1 1 Torque Module Installation and User Guide for M odel 250 Dynamometers r 1 2 P gre v CHAPTER 1 Introduction INTRODUCTION The Torgue 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 eguipment example of convention description The Caution icon indicates a potential hazard to the ATLETE dynamometer eguipment Follow all procedures exactly as they are described and use care when performingall procedures The Warning icon indicates potential harm to the SWE person performing a procedure and or the dynamometer equipment Bold Highlights items you can select on in the software interface including buttons and menus gt 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 1 800 992 3525 or write to Dynojet at
12. on arm into the bracket on the mounting plate on the front of the eddy current brake 8b Insert the cotter pin in the small hole on the stud This will secure the calibration arm during the calibration process Note If the calibration arm is not level you will need to use the spacer included 8c Place the weight support pin in the end of the calibration arm 8d Gently place the weights on the calibration arm AGU The calibration weights are very heavy The weights must be set on the arm gently or you will damage the load cell 7 bracket D A weight support pin weights me 9 PY stud ate cotter pin AM mounting connecting arm ZE with extension insert spacer if arm is not level TM007 Figure 2 5 Install Calibration Arm and Weights 2 5 Version 3 Torque Module Installation and User Guide for Model 250 Dynamometers 4 CHAPTER 2 amp Torque Cell Calibration We 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 Note Let the torque gauge needle stabilize before clicking Next 9 From the Span Calibration window Figure 2 4 click Next to continue
13. pective companies Dynojet Research Inc 2191 Mendenhall Drive North Las Vegas Nevada 89031 USA Printed in USA Part Number 98295104 03 05 Chapter 1 Chapter 2 TABLE OF CONTENTS Torque Module Installation INERQQUCHION TE Conventions Used In This Manual Technical Support 4404 sa satses a ane EE oli Torque Module Installation P SE NG Installing the Torque Module Load Cell Installation oo NE A ER klekket we ces Removing the Hood Installing the Load Cell Replacing the Hood Calibration Arm Assembly Using the Torgue M odule Torque Cell Calibration Appendix A The Torgue M odule and WinPEP 6 Torque Module Calibration Torque Module Installation and User Guide for M odel 250 Dynamometers CHAPTER TORQUE MODULE INSTALLATION This document provides instructions for installing and using the Torque Module on the model 250 dynamometer dyno 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 Torque Module i
14. re 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 www dynojet com manuals shtml 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 Nextto 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 Torque Cell Calibration Zero Calibration Remove the calibration arm and mass if installed The brake must be off The drum should be stopped but free to rotate Cancel Figure 2 1 Zero Calibration Window 2 2 Torque Module Installation and User Guide for Model 250 Dynamometers USING THE TORQUE MODULE Z Torque Celi Calibration 4 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 Torque Cell Calibration Calibration Mass This step is optional It is only required periodically If you do not wish to perform this step press Fi
15. rocedure lt Previous ne Cancel Figure A 6 Span Calibration Window A 4 oe Torque Module Installation and User Guide for Model 250 Dynamometers THE TORQUE MODULE AND WINPEP 6 Ss Torque Module Calibration gt 7 Install the calibration arm and weights 7a Insert the stud on the end of the calibration arm into the bracket on the mounting plate on the front of the eddy current brake 7b Insert the cotter pin in the small hole on the stud This will secure the calibration arm during the calibration process Note If the calibration arm is not level you will need to use the spacer included 7c Place the weight support pin in the end of the calibration arm 7d Gently place the weights on the calibration arm ATU The calibration weights are very heavy The weights must be set on the arm gently or you will damage the load cell bracket ne Bi N k stud Far cotter pin AT mounting plate weight support pin weights connecting arm with extension insert spacer if arm is not level Figure A 7 Install Calibration Arm and Weights A 5 Version 4 Torque Module Installation and User Guide for Model 250 Dynamometers prog APPENDIXA ar v Torgue M odule Calibration While installing the calibration weights you should notice the Torgue Gauge on the DynoTrac Window moving from 0 to about 500 ft lbs The gauge is for display purposes only and may not read correc
16. s Display Eng Torque from the main menu The gauge needs to display Eng Torgue and not Braking main menu gt gauge displays engine torque Figure A 2 DynoTrac Window A 2 Torque M odule Installation and User Guide for M odel 250 Dynamometers THE TORQUE MODULE AND WINPEP 6 Ss Torque Module Calibration S 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 4a Enter the calibration number stamped on the calibration arm extension If you do not have enough room to install the extension use the number stamped on the main bar Note Dynojet recommends you use the calibration arm with the extension unless space constraints in your dyno room do not allow you to calibration arm with s calibration arm extension main bar o RA _ o GE TMO01 qlo ODE Figure A 3 Calibration Arm Note Follow the directions on the screen exactly Failure to perform the directions accurately will result in improper torque values 5 Click Nextto continue Torque Cell Calibration x Calibration Mass Enter the number stamped on the calibration arm extention NOTE If you don t have enough room to install the extension use the number stamped on the main bar If the number
17. shown below matches the calibration arm then press next to continue 500 lt Previous New gt Ene Figure A 4 Calibration Mass Window __eFFEFEFEFCFCFOCOFCOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOFOEFOFOFOEFOHOHOEHOEHOEHOHOEHOEHOEHOEHOHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOEHOHOHEHOEH OEHOEHOHOEHOEHOHOEH HEH OEHOHOHOHOEHOHOEH HOHOHOEH OEOEHOEOHOHOE HOEOERORHEROHOHEOROHR_AOEOCOROEROHOHOHEHRHRHRHRHmHmDmv _ A Version 4 Torque Module Installation and User Guide for Model 250 Dynamometers Pr APPENDIXA za Torque Module Calibration The Zero Calibration is now being performed Torque Cell Calibration l x Zero Calibration Remove the calibration arm and mass if installed The brake must be off The drum should be stopped but free to rotate lt Previous 1 Cancel Figure A 5 Zero Calibration Window The Span Calibration window will appear 6 Install the calibration arm and weights Refer to step 7 and Figure A 7 on page A 5 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 Torque Cell Calibration xi Span Calibration This step is optional It is only required periodically If you do not wish to perform this step press cancel Please install the calibration arm and place the mass on the peg Press next to finish the calibration p
18. tly The gauge remains uncalibrated until the calibration process is complete Note Let the torque gauge needle stabilize before clicking Next Figure A 8 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 Torque Cell Calibration i x Calibration is complete Remove the calibration arm and mass You are now ready to use pour dyno lt Previous Next Figure A 9 Calibration Is Complete Window A 6 Torque Module Installation and User Guide for Model 250 Dynamometers C calibration arm 1 11 A 3 installation 2 5 A 5 number 2 3 2 5 A 3 weights 2 5 A 5 conventions 1 2 D document part number 1 1 H hood removing 1 6 replacing 1 10 L load cell installation 1 6 1 10 mounting bracket 1 7 routing the cable 1 9 sleeve 1 8 M mounting bracket 1 7 P parts list 1 3 IN DEX R removing the hood 1 6 replacing the hood 1 10 routing the load cell cable 1 9 S sleeve 1 8 span calibration 2 4 A 4 T technical support 1 2 torgue cell calibration 2 2 2 6 calibration number 2 3 torgue gauge 2 6 A 6 torgue module installation 1 3 1 5 W WinPEP 6 A 1 WinPEP 7 2 1 Z zero calibration 2 2 A 4 Index i Torque Module Installation and User Guide for Model 250 Dynamometers RENSE AR CH DOMESTIC INTERNATIONAL Dynojet Research Inc Dynojet Research E M E A 2191 Mendenh
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