Dukane DK100 Radar Detector User Manual
Contents
1. ME OU HE EI EIE LE EE LE LEAL I Document 98210104 224 4WD TROUBLE SHOOTING GUIDE 1 Make sure the following is turned on Hardware stack EX Computer Dyno brake red button on pendent in on Press IN OUT button on movement pendent to see if dyno moves If not proceed to step two 2 Check to see if relay is working When the brake button on the dyno pendent red lighted button is turned off and on the relay should click If this does not happen go to step 2A if this is happening go to step 3 2A To verify ifthe relay is working use a multi meter to check the continuity of the following When the dyno brake is on red light on pendant is on Pin 30 and 87A of the relay are connected When the dyno brake is off red light on pendant is off Pin 30 and 87 of the relay are connected 2B the relay is not working check to see if it is getting the 12VDC supply from the break out board Check the voltage between the brake pins on the break out board When the dyno brake is off red light on dyno pendent brake button is off there should be 12VDC across the pins when the brake is on red light on dyno pendant button is on there should be OVDC across the pins 3 Check the continuity of the pressure switch2. Document 498210104 Dyno Placement Note The first step to installing your Dynojet Dynamometer depends on the location of your existing 248 dyno It can go in front of or behind the 248 dyno The Dynamometer drums can rotate in either direction Choose the Dyno placement that best matches your shop Method 1 Dynamometer Position lt Ground Hooks 224 4WD This image represents 224 4WD dyno near the garage door Method 2 Dynamometer Position Ground Hooks 224 4WD This image represents a 224 4WD dyno away from the garage door Document 98210104 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 Dynamometer Input Output module connects to the 224 4WD 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 Remote Pendant cable is available if needed Document 498210104 1 3 Computer Placement Note The driver of the vehicle must be able to vi
3. 1 Left Interface Plate 1 Center Interface Plate 1 Right Interface Plate 7 3 8 UNC x 1 Truss Head Bolts Document 98210104 Notes Document 9810104 1 15 Chapter 2 Hardware Installation DynoWare EX The standard dynamometer electronics package is comprised of 4 interconnected modules System Expansion Connector Atmospheric Sensing Module RPM Module 777 Dynamometer Input Output 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 Revision C 11 16 00 Document 498226100 Master 2 1 2 2 Master 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
4. Installation Guide For the Automotive Dynamometer 224 4WD Model Upgrade Dynojeta Research Inc Revision A 4 12 00 Document 98210104 1993 1994 1995 1996 1997 1998 and 1999 Dynojet Research Inc All Rights Reserved Dynojet Installation Guide for use with Dynojet s Automobile Dynamometer model 248 This manual is furnished under license and may only be used or copied in accordance with the terms of such license The information in this manual is furnished for informational use only is subject to change without notice and should not be construed as a commitment by Dynojet Research Inc Dynojet Research Inc assumes no responsibility or liability for any errors or inaccuracies that may appear in this book The Dynojet Logo is a trademark of Dynojet Research Inc Printed in the USA Document 498210104 Contents Initial Setup and Requirements Introduction otn 1 1 Dyno Placement u eine 1 2 DynoWare EX Placement 1 3 Computer Placement 1 4 Requirements to Unload 1 5 Pit Requiiremenis u ern 1 5 Requirements to Install the Dynamometer 1 6 Other Requirements 1 6 Optional Accessories 1 7
5. Setting Tool Used for expanding the anchors Document 98210104 3 17 3 8 Bolts T T Ring Setting Tool Ring Plate Anchors Drop In Anchor A drop in anchor is a heavy duty internally threaded anchor used to bolt the ground hooks onto a concrete floor Ground Hook Placements The placement of the ground hooks are provided with the Pit Dimensions drawing Your Sales Contact can provide these for you 18 Document 98210104 Installing Ground Hooks Note Step 1 Using an Impact Drill drill the two holes in the cement at each location on the drawing in Appendix A Use a ring plate as a template for the precise hole placement You will need a 1 2 drill bit to drill a hole to a minimum depth of 1 5 8 Clean the cuttings and debris from the hole 1 The use of a carbide drill bit is recommended for the installation of this anchor 2 Do not use core drills to drill hole for this anchor 3 Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors Step 2 Drive anchor into the hole flush with the surface of the concrete Document 98210104 3 19 Step 3 Expand the anchor with the setting tool The anchor is properly expanded when the shoulder of the setting tool is flush with the anchor Step 4 Bolt the ground hooks onto the anchors to complete the ground hook installation p ip Document 49821010
6. 248 dyno Document 98210104 3 7 Connect the Air Supply Note Note Note Step 1 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 Make sure the arrow on the regulator is the same as the direction of the air flow Connect a 3 9 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 Hose Hook Up The regulator should be set to 60 psi Step 2 Connect the air hose pg 3 22 letter F from the 224 4WD Dyno to full line pressure 100 125 psi Be sure that your air source supplies clean dry air Document 98210104 Prop Air Wiring This section is for the Prop Air Braking System Standard Brake customers should skip this section Step 1 Connect the Prop Air Cable pg 3 22 letter C to the EPR You will need to remove the clear plastic cover from the EPR Plug the Prop Air Cable into the terminal block on the EPR EPR Prop Air Cable Step 2 Connect the Modified Power Supply wire to the 224 AWD Power Cord pg 3 22 letter D with the two pin connector Step 3 Connect the Control Pendant into the C
7. from Power Supply Computer Serial Port Cable 2 6 Master Document 98226100 Chapter 3 Installing the 224 4WD Dynamometer Now that you have the Dyno unpacked you may begin the installation of the Dynamometer Track Placement The dyno is designed to roll back and forth on the track The track must be anchored to the floor using cement anchors Step 1 Lay out the track as shown in figure Appendix A Step2 Place the rail clamps over the rails before placing the two end rail supports Rail Rail Clamp Revision A 4 12 00 Document 98210104 3 1 Note The distance between the inside of the rails should be 72 5 0 06 Step 3 The track assembly should be 1 975 away from the pit wall closest to the 248 dyno 1 975 Step 4 Line up the centerline of the track assembly with the centerline of Model 248 Chassis Dyno Step 5 Check the square of the track assembly measure from corner to corner Be sure that the track is fully seated under the rail clamp See Figure 2 in Appendix A 72 5 Document 498210104 Note Note Note Step 6 Install the cement anchors and 115 bolts The bolts should secure the track and track tie When the bolts are tightened down check the square of the track again See Figure 3 in Appendix A See page 3 36 for anchor installation Step 7 Place two straps capable of supporting a minimum of 4000 Ibs or 1820
8. the long lip is towards the drum Secure the grates to the dyno with 2 3 8 x 3 truss head bolts but do not tighten yet Motor Step 2 Place the Center Plate on the Grates and secure it with 8 truss head bolts the Center Plate is secured to the dyno with 1 3 8 x 3 truss head bolt When you have the front Grate Assembly fitted tighten down all the truss head bolts Document 98210104 3 15 Step 3 Set up the non motor side Grates in the same fashion as did for the motor side grates Also attach the Center Plate and then tighten everything down when complete Step 4 Set up the side grates Lay the side grates on the side of the dyno with the bolt holes towards the outside The side grates should be oriented with a 1 gap between the grates mounted to the dyno Use concrete anchors to secure the side grates to the concrete surrounding the dyno Note Be sure that the side grates do not touch the dyno or to the grates mounted to the dyno Side Grate 16 Document 498210104 Ground Hooks Ground hooks are points at which you can connect the straps that hold down the car that is being tested This keeps the vehicle from sliding side to side or off the drum of the dyno during a run Side To Side Forward and Back Shifting Ground Hook Installation Hardware Ground Hook 10 Rings 10 Ring Plates Anchors 20 Drop In Anchors Bolts 20 1 x 3 8 UNC Grade 5
9. 0104 1 9 m Lm 2 Rail Clamps 4 3 8 16 Shoulder Bolts O 4 220 Thick 1 2 Washers 2 Idler Sprockets r Oy T 12 UNC Bolts 2 250 Thick 1 2 Washers 0 Document 98210104 Grating Components 2 Center Covers 4 Front Rear Grates 2 Side Grates Document 98210104 1 1 Boxes Containing 4 Ratchet Straps w Sleeve 4 Axle Straps Bolt Pack 1 20 3 8 16 x 1 Truss Head Bolts 6 3 8 16 x 3 Truss Head Bolts 46 Concrete Anchors 34 3 8 16 x 1 UNC Bolts 10 3 8 16 x 1 1 2 UNC Bolts 10 3 8 16 x 2 UNC Bolts 54 3 8 Flat Washers 54 3 8 Lock Washers 9 9 Ground Hooks 4 Ground Hook Baseplate and Hook 8 Concrete Anchors 8 3 8 16 UNC x 1 Bolts 1 Anchor Instructions 1 Anchor Set Tool 9 Document 98210104 Electronic and Miscellaneous Hardware 1 Hardware Stack 1 Hardware Stack Mounting Kit 1 Sample Brake Pendant 2 Power Cables 1 Power Supply 1 Power Supply modified 1 Primary Inductive 2 Secondary Inductives 1 Computer Cable 9 1 Computer Cable 25 Pin installed 277 Airline Hose 2 Barbed Fittings 1 Air Solenoid Assembly or Prop Air Assembly 1 Air Regulator Mounting Bracket Barbed Fitting 9 lt 9 9 Document 98210104 1 13 Pit Covers 248 Dyno and Hardware E o9
10. 4 Notes Document 98210104 Appendix A Figure 1 Revision A 4 12 00 Document 98210104 Appendix A 1 Figure 2 Appendix A 2 Document 98210104 YOHONY ININJO All Wd Figure 3 415354 dO 14 8M 415 NMOA 1108 NOVEL Appendix A 3 Document 98210104 Rail Brake Clamp 224 Dyno Rail Brake Clamp a ee Ss 248 Dyno Document 98210104 Appendix A 4 Figure 5 APIS 10 905 1607 Appendix A 5 Document 98210104 Figure 6 Side View P3 5 F gt e ES LL D 0 Appendix 6 Document 98210104 Figure 7 Pit Cover Layout Top View Document 98210104 Appendix A 7 Appendix A 8 Figure 8 224 4WD Grate Layout Top View TAE fr 1 i mmm Ii 1111 INT II x z I a a
11. Ground Hooks 3 17 Installing the Ground HOOKS 3 19 Appendix A neenon Figure ae 1 Figure a ee A 2 3 m 4 Figure et 5 A 6 Figure 7 Pit Cover Layout A 7 Figure 8 224 4WD Grate Layout A 8 224 AWD Trouble Shooting Guide A 9 lii Document 498210104 Chapter 1 Initial Setup and Requirements Introduction Revision A 4 12 00 Thank you for purchasing the Dynojet Automotive Dynamometer This document will give you the information you need to install the 224 4WD Dynojet Dynamometer pit model If you have any questions please call Dynojet at 800 992 4993 Before installing your Dynojet Dynamometer there are a few factors to consider This chapter nitial 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 decide where to place your Dynamometer where to place the Dynojet electronics what you need to unload your Dyno how to prepare your Dynamometer pit and what must be provided for the Dynamometer
12. KG around the drums Position the straps so that they are on the knurled surface of the drum away from the brake surface Step 8 Lower the dyno onto the tracks Be sure that the wheel flanges are on the inside of the track The Rail Clamps should be positioned as shown in Figure 4 Appendix A The motor side of the 224 AWD should be facing away from the 248 dyno See Figure 5 Appendix A Document 498210104 3 3 Note Step 9 Install the two rail clamps with the 3 8 bolts and spacers Once the bolts are tight roll the dyno back and forth to ensure the rail clamps are not binding Move the Clamps up and down to ensure that they are free to move If the clamps are binding you will need to loosen the allen head bolts Be sure to add thread lock to ensure that the bolts are secure Step 10 Secure the cable carrier to the rail tie with two 1 4 button head screws and lock washers Document 498210104 Wiring Note The 248 Dyno comes with a Standard brake but Dynojet does offer an optional Prop Air brake For convenience both installation procedures are outlined in the next few pages Follow each step carefully some steps are designated as Prop Air only Step 1 Lay out the cables to become oriented with their placement Note Run the cables hose through the conduit to the outside of the pit Document 498210104 3 5 A 25 Pin Cable 20 Connect
13. Uncrating the 5 22 1 8 enl ra Pee 1 9 Railway ecd re nette Henn Hs 1 9 Grating Components 1 11 Box Contents c are arme 1 12 Pit Covers and Hardware 1 14 Chapter 2 2 A Hardware Installation DynoWare 2 1 Atmospheric Sensing Module 2 1 RPM Modyule s teet 2 2 Dynamometer Input Output Module 2 3 CPU EE 2 4 Connecting The DynoWare 2 5 Revision A 4 12 00 Document 98210104 Chapter Installing the 224 4WD Dynamometer Track Placement ei 3 1 jg eec 3 5 Connect the Air Supply 3 8 Prop Air WIFmng s ss 3 9 Testing the Movement of the Dyno 3 10 Final Assembly coti oec tiet 3 11 Installing the Dyno Covers 3 14 Setting Up the 224 Grating 3 15
14. 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 Document 498226100 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 498226100 Master 2 3 2 4 Master 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
15. ew the computer monitor and the DynoWare EX during a run If you will be running both front and rear wheel drive vehicles you will need to find a way for the driver to see them both Computer Position Facing Door 224 4WD 248 FRONT VM pendant Data Aquisition RPM Pickup Computer Monitor Dynoware EX Cable 7 This image represents the location of the computer and DynoWare EX for a car that is backed into the dyno room Computer Position Facing away from Door 224 4WD 248 Front Pendant Data Acquisition gt 44 RPM Cable DynoWare EX PC Cable Computer Monitor 4 p This image represents the location of the computer DynoWare EX for a car driven straight into the dyno room A possible solution would be to place the computer and the DynoWare EX modules on a movable cart Document 98210104 Requirements to Pit Requirements 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 inches wide by 6 feet long It must be capable of lifting and moving at least 8000 pounds 3642 KG 224 4WD Dyno You must provide a dyno pit Dyno pit dimensions are provided in the technical drawing 4WD Dyno Specifications Be sure to contact your local contractor for code specifications before digging a pit Follow the tech
16. 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 Document 98226100 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 Note Use the cables that came in the DynoWare package to make the following connections 9 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 The DynoWare EX stack must be mounted in your shop so as to be easily seen while making dyno runs Document 98226100 Master 2 5 Primary Inductive Pickup Cable Remote Switch not shown Breakout Board to DynoWare Cable Cord
17. located on top of air can opposite the motor control box side of dyno When the rail brake is on pressure going to air can there should be no continuity When the rail brake is off no pressure to air can give it a couple of seconds to bleed all the air pressure off there should be continuity Document 98210104 Appendix A 9
18. nical drawings 224 4WD CAR DYNO FINISHED PIT DIMENSIONS Your Sales Contact can provide you with these drawings if you don t already have them Document 498210104 1 5 Requirements to Install the Dynamometer When you install the dynamometer you need equipment capable of lifting and moving at least 8000 pounds 1821 KG 224 4WD Dyno Other Requirements Shop Air The dyno air brake requires a air hose with a minimum pressure of 100 psi You must provide 3 3 air line that will reach both the 224 and 248 Dynamometers Computer You must provide a compatible computer and printer The system must meet the following minimum requirements 6 Document 98210104 Pentium P5 100 or faster Pentium computer Windows 95 800 megabyte HD Eight megabytes of RAM 640 x 480 SVGA 16k color video One high density floppy disk drive 3 lj Color Printer HP Deskjet color series recommended Optional Accessories Extended Pendant Cable 40 foot 12 2 meter Pendant cable Part Number DC100 104L Document 498210104 1 7 Uncrating the Dynos Step 1 Use a crowbar or the like to remove the plywood shipping shell from the 224 Dynamometer Remove the top of the crate Remove the sides of the crate 8 Document 498210104 Contents Railway Components 2 Sets Grating Support Channels Front and Rear 2 Rail Assembly Ends 10 Rail Tie Clips Document 9821
19. ontrol Pendant Cord pg 3 22 letter E with the three pin connector Document 498210104 3 9 Testing the Movement of the Dynos Step 1 Connect the remaining wires to the Hardware Stack as described in Chapter 2 page 2 5 Step 2 Turn the Hardware Stack on Step 3 Press the red button on the Pendant it should light up this indicates that the brakes are activated Cycle the brakes a few times by pressing the red button to ensure that they work properly Note The red button will control the brakes on BOTH dynos Step 3 While the brakes are on press the In button on the Control Pendant pg 3 22 letter E You should hear air venting and the the rail clamps releasing Keep holding the button down until you see the motor shaft begin to turn Repeat this procedure again only this time hold down the Out button Note If the Control Pendant fails to activate the motor see the Trouble Shooting Guide in Appendix A Page 9 10 Document 498210104 Final Assembly Step 1 Install the sprockets with 1 2 bolts and spacers Note Be sure that you have the spacers oriented properly see the picture below Spacers the chain so that it wraps around the drive sprocket and under each idler sprocket Document 498210104 3 11 Step 2 Attach the chain to the end rail tie on the front and back Secure the chains with Ip lock washers and nuts Step 3 A
20. ssemble the C channel Cross Brace with 3 x1 bolts but don t tighten them down yet Step 4 Place the two assembled cross members 1n the pit See Figure 6 in Appendix A Note Move the dyno back and forth from front to back The dyno should not touch the cross members if it does you ll need to move the cross members for clearance Document 498210104 Step 5 Adjust the width of the C channel assembly until it is as wide as the pit Secure the left and right sides of the C channel with the cement anchors When the sides are anchored tighten down the center bolts Step 6 Move the dyno through its full range of motion Be sure that the dyno is free to move and there are no obstructions When you press the in or out button on the pendant you should hear the air release to unlock the rail clamps After a few seconds the dyno should begin to move Document 498210104 3 Install the Dyno Covers Use the following steps to install the dyno cover s Step 1 Check the anchor bolts and lateral supports to make sure they are tight Install the dyno cover 2 Install the cover plates over your dyno sample layout drawing for the auxiliary covers is provided in Figure 7 Appendix A 14 Document 98210104 Setting Up the 224 4WD Grating Note Refer to Appendix A Figure 8 to become familiar with the layout of the grating Step 1 Place the Grates on the motor side of the dyno so
21. the 25 Pin Cable to the Hardware Stack B Data Acquisition Cable 40 Connect the Data Acquisition Cable to the Pick Up Card on the 248 dyno Run into 248 pit Multi Purpose Wire Brake Power Cord 40 Connect to the spade connector on the new 248 air assembly Prop Air Cable 40 optional for load control system attaches to the EPR Temp Sensor Cable optional part of the Prop Air load control system D 224 AWD Power Cord 207 Plug the 224 AWD Power Cord into the Power Supply E Control Pendant 20 Connect to the Control Pendant The Control Pendant moves the 224 4WD dyno F Air Hose 20 Connect the Air Hose to a 100 120 psi air supply with clean dry air Step 2 Plug the two pin connector from the Model 224 4WD dyno pg 3 22 letter C into the 2 black wires on the air assembly of the 248 dyno Step 3 Prop Air Only Install the Temperature Sensor on the left 4 X4 post Locate the temperature sensor bracket on the left side 4 X 4 post Document 98210104 Install the temperature sensor so it is approximately 3 from the surface of the drum Top View Run the Temperature Sensor Cable pg 3 22 letter H from the 224 4WD Dyno and plug it into the connector on the end of the Temperature Sensor Step 4 Run the data acquisition cable pg 3 22 letter B from the Model 224 4WD dyno and plug it into the the pick up card on the
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