©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.
TABLE OF CONTENTS Chapter 1 Torque Module Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Torque Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Parts List . . . . . . . . .
CHAPTER 1 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, installing the load cell, and assembling the calibration arm.
CHAPTER 1 Introduction INTRODUCTION ................................... The Torque Module, when added to Dynojet’s market leading inertia dynamometer, results in a complete vehicle performance test. CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. example of convention description The Caution icon indicates a potential hazard to the dynamometer equipment.
TO R Q U E M O D U L E I N S T A L L A T I O N Torque Module Installation TORQUE MODULE INSTALLATION ................................... This section describes how to install the Torque Module. PARTS LIST The following table lists all of the parts included in the Torque 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.
CHAPTER 1 Torque Module Installation INSTALLING THE TORQUE MODULE 1 2 Turn off the main power switch on the CPU Module on the dyno electronics and unplug the power cord. Remove the dust cover from the existing top module. dust cover power cord input power switch Figure 1-1: Remove Dust Cover 3 4 5 Loosen the top right screw on the back of the existing top module. Plug the Torque Module into the existing top module. Place the dust cover, removed in step 2, on the Torque Module.
TO R Q U E M O D U L E I N S T A L L A T I O N Torque Module Installation 6 7 8 Secure the Torque Module to the dyno electronics with the plastic tie straps (one on each side). Attach the 9-pin connector on the load cell cable to the front of the Torque Module and tighten down the screws. Attach the power cord to the dyno electronics and turn the power switch on. The green LED light on the Torque Module should now be on.
CHAPTER 1 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 2 Disconnect all power to the dyno. 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.
TO R Q U E M O D U L E I N S T A L L A T I O N Load Cell Installation INSTALLING THE LOAD CELL 1 Remove the two bolts securing the existing bar on the eddy current brake and remove the bar. bar 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.
CHAPTER 1 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.
TO R Q U E M O D U L E I N S T A L L A T I O N Load Cell Installation 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.
CHAPTER 1 Load Cell Installation REPLACING THE HOOD 1 2 Replace the hood on the dyno leaving it propped up. Secure the key switch, if present, and connect the battery. Lower and secure the hood using the four bolts you removed earlier. key switch Figure 1-12: Replace the Hood 3 4 Secure the hood clamps to the brake using the two bolts you removed earlier. Replace the brake cover and secure using the four bolts you removed earlier.
TO R Q U E M O D U L E I N S T A L L A T I O N 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 2 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. Insert two 3/8-16 x 2.
CHAPTER 2 USING THE TORQUE MODULE This chapter provides instructions for using the Torque Module with WinPEP 7. Appendix A includes instructions for using the Torque Module with WinPEP 6. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 2 Torque Cell Calibration TORQUE CELL CALIBRATION ................................... The Torque Module must be calibrated prior to use. Follow the directions on the screen exactly. Failure to perform the directions accurately will result in improper torque values. 1 2 Verify you are in the MakeRun screen. Verify you are connected to the dyno electronics. Note: For more information on connecting to the dyno electronics, refer to the WinPEP 7 User Guide (on your WinPEP CD or at www.dynojet.
U S I N G T H E TO R Q U E M O D U L E Torque Cell Calibration Once the Zero Calibration is complete, the Calibration Mass window will appear. 5 Enter the Torque Module calibration value. Refer to Figure 2-3. Note: You must perform this step the first time you calibrate the load cell. Or If you are only performing a Zero Calibration, click Finish. Figure 2-2: Calibration Mass Window Enter the calibration number stamped on the calibration arm extension.
CHAPTER 2 Torque Cell Calibration 6 Click Next to continue. The Span Calibration window will appear. 7 Install the calibration arm and weights. Refer to step 8 and Figure 2-5 on page 2-5.
U S I N G T H E TO R Q U E M O D U L E Torque Cell Calibration 8 Install the calibration arm and weights. 8a 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. 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.
CHAPTER 2 Torque Cell Calibration While installing the calibration weights, you should notice the Torque Gauge on the DynoTrac Window moving from 0 to about 500 foot-pounds. Note: The Torque Gauge may or may not be in this range. If the torque cell has been previously calibrated incorrectly or has not been calibrated for a while, the gauge may show values out of this range until calibration is complete. Note: Let the torque gauge needle stabilize before clicking Next.
APPENDIX A THE TORQUE MODULE AND WINPEP 6 This appendix provides instructions for using the Torque Module with WinPEP 6. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIXA Torque Module Calibration TORQUE MODULE CALIBRATION ................................... After initial calibration, the Torque Module should be Zero Calibrated approximately every thirty hours of use. Before proceeding, be sure the eddy current brake (retarder) is free and clear of any obstructions. There should not be anything resting on the eddy current brake or the dynamometer drum during this procedure. 1 Launch WinPEP and click the DynoTrac icon.
T H E TO R Q U E M O D U L E A N D W I N P E P 6 Torque Module Calibration 3 Select Options Calibrate. Note: Before proceeding, be sure the eddy current brake is free and clear of any obstructions. There should not be anything resting on the eddy current brake or the dynamometer drum during this procedure. 4 Enter the Torque Module calibration value. 4a Enter the calibration number stamped on the calibration arm extension.
APPENDIXA Torque Module Calibration The Zero Calibration is now being performed. 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.
T H E TO R Q U E M O D U L E A N D W I N P E P 6 Torque Module Calibration 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.
APPENDIXA Torque Module Calibration While installing the calibration weights, you should notice the Torque Gauge on the DynoTrac Window moving from 0 to about 500 ft.-lbs. The gauge is for display purposes only and may not read correctly. 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 9 From the Span Calibration window (Figure A-6), click Next to continue.
INDEX 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 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 torque cell calibration 2-2–2-6 calibration number 2-3 torque gauge 2-
