©2000-2005 Dynojet Research, Inc. All Rights Reserved. Torque Module Installation and User Guide for model 250i 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 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 1 TORQUE MODULE INSTALLATION This document provides instructions for installing and 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. This chapter will walk you through installing the load cell and installing the Torque Module.
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 Introduction CONNECTING AND DISCONNECTING POWER TO THE DYNO Many instructions in this guide will require you to connect or disconnect the power to the dyno as part of the installation process. Use the following steps to connect and disconnect power to the dyno. 1 2 3 Use the main breaker to turn power on and off to the dyno. The main breaker is located inside the power distribution assembly.
CHAPTER 1 Load Cell Installation LOAD CELL INSTALLATION ................................... This section describes how to remove the top covers, install the load cell, and replace the top covers. REMOVING THE CARRIAGE AND DYNO TOP COVER You will need to remove the tire carriage and top cover in order to route the load cell cable to the dyno electronics. 1 2 Using a 5/32-inch allen wrench, remove the two button-head screws securing the carriage screw support bracket 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 3 Using the hand crank or power carriage, unscrew the carriage screw until it is free from the nut block. Slide the carriage off the dyno. hand crank Figure 1-3: Remove the Carriage 4 5 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. Using a 1/2-inch wrench, remove the bolts and washers securing the nut block and carriage clamps and set aside.
CHAPTER 1 Load Cell Installation 6 Remove the six 1/4-inch screws securing the top cover on the dyno and set aside. Note: Dynojet recommends using a hardened 5/32-inch hex driver (such as SnapOn FA5E) to remove the 1/4-inch screws. A standard allen key may round off in the shallow screw head. 7 Remove the cover 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 REMOVING THE EDDY CURRENT BRAKE TOP COVER 1 2 3 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. Remove the six screws securing the eddy current brake top cover and set aside. Disconnect the battery ground cable.
CHAPTER 1 Load Cell Installation INSTALLING THE LOAD CELL 1 2 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. Remove the two bolts and nuts securing the existing bar on the eddy current brake and remove the bar. Set the bolts and nuts 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 3 Install the load cell. 3a Verify the eyelets on the load cell are spaced the same as the bar removed earlier. Adjust the load cell spacing by loosening the lock nut and turning the eyelet. eyelet bar lock nut distance must be the same Figure 1-8: Verify Load Cell Spacing 3b Orient the load cell so the cable faces the dynamometer. 3c Secure the load cell to the mounting bracket using the two bolts and nuts removed earlier.
CHAPTER 1 Torque Module Installation TORQUE MODULE INSTALLATION ................................... This section describes how to install the Torque Module, route the load cell cable, replace the carriage, and replace the brake cover. ACCESSING THE DYNO ELECTRONICS You will need to access your dyno electronics in order to add the torque module. Use the following steps to access the dyno electronics. 1 Turn off the main power to the dyno.
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 4 Remove the twelve screws securing the cover and lift the cover off. Figure 1-11: Remove Electronics Enclosure Cover 5 6 Add the torque module to the top of the dyno electronics. Refer to “Installing the Torque Module” on page 1-12. Leave the dyno electronics enclosure out. You will need to route the load cell cable to the Torque Module later.
CHAPTER 1 Torque Module Installation INSTALLING THE TORQUE MODULE 1 2 3 Verify the main dyno power is disconnected. Refer to page 1-3 for more information. 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 1-13: Remove Dust Cover 4 5 6 Loosen the top right screw on the back of the existing top module. Plug the Torque Module into the existing top 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 7 Secure the Torque Module to the dyno electronics with the plastic tie straps (one on each side). Note: Do not attach the load cell cable at this time.
CHAPTER 1 Torque Module Installation ROUTING THE LOAD CELL CABLE 1 Route the load cell cable from the eddy current brake through the air hole in the drum bulkhead, under the carriage assembly bulkhead, and over to the dyno electronics. Make sure the load cell cable is clear of any power cables or hot or rotating objects. 2 Secure the load cell cable with a zip tie to the underside of the carriage assembly bulkhead.
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 3 4 5 Route the load cell cable through the cable clamp on the back of the dyno electronics enclosure. 3a Loosen the two screws and lift the clamp up to slide the load cell cable through. 3b Secure the clamp with the two screws. 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.
CHAPTER 1 Torque Module Installation 6 7 Plug the main power cord for the dyno in and place the breaker inside the power distribution enclosure to the on position. Refer to page 1-3 for more information. The green LED light on the Torque Module should now be on. torque module green LED light tie strap load cell cable and port do not attach at this time Figure 1-18: Attach Torque Module and Load Cell Cable 8 9 Replace the dyno electronics cover. Refer to Figure 1-11 on page 1-11.
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 REPLACING THE DYNO TOP COVER AND CARRIAGE 1 Secure the top cover to the dyno using the six 1/4-inch screws removed earlier. Note: Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap-On FA5E) to remove the 1/4-inch screws. A standard allen key may round off in the shallow screw head.
CHAPTER 1 Torque Module Installation 2 Using a 1/2-inch wrench, install the shims, carriage clamps, and nut block using the bolts and washers removed earlier. Figure 1-20: Install the Shims, Carriage Clamps, and Nut Block 3 Using the hand crank or power carriage, screw the carriage through the nut bolck.
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 4 5 Install the screw support bracket. 4a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure 1-22. 4b Place the screw support bracket in front of the carriage screw. The two threaded holes in the bracket should face the two matching holes in the carriage. Loosely install the two 1/4 x 1/2-inch button-head screws.
CHAPTER 1 Torque Module Installation REPLACING THE EDDY CURRENT BRAKE TOP COVER Before replacing the top cover, be sure to calibrate your load cell. Refer to Chapter 2 "Using the Torque Module". 1 2 Connect the battery ground cable. Secure the eddy current brake top cover using the six bolts removed earlier. Note: Before replacing the top cover, be sure to calibrate your load cell. Refer to Chapter 2 "Using the Torque Module".
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 near the bolt pattern at the end of the calibration arm.
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 using the bolt pattern at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm. Refer to Figure 2-6 on page 2-6. 8a 8b Secure the calibration arm to the eddy current brake using the handle to tighten the bolt. Gently place the weights on the calibration arm.
CHAPTER 2 Torque Cell Calibration If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in Figure 2-6.
U S I N G T H E TO R Q U E M O D U L E 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.
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. Enter the calibration number stamped near the bolt pattern at the end of the calibration arm.
APPENDIXA Torque Module Calibration 5 Click Next to continue. Figure A-4: Calibration Mass Window The Zero Calibration is now being performed. Figure A-5: Zero Calibration Window The Span Calibration window will appear.
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 6 Install the calibration arm and weights. Refer to step 7 and Figure 7 on page 6. 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.
APPENDIXA Torque Module Calibration 7 Install the calibration arm and weights using the bolt pattern at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm. Refer to Figure A-8 on page A-7. 7a 7b Secure the calibration arm to the eddy current brake using the handle to tighten the bolt. Gently place the weights on the calibration arm. The calibration weights are very heavy.
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 If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in Figure A-8.
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 foot-pounds. The gauge is for display purposes only and may not read correctly. The gauge remains uncalibrated until the calibration process is complete. • 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.
INDEX A N B P accessing dyno electronics 1-10 battery ground cable 1-7, 1-20 belleville washers 1-4, 1-19 brake cover removing 1-7 replacing 1-20 C cable clamp 1-15 calibration arm 2-3, A-3 number 2-3, A-3 weights 2-5, A-6 carriage assembly bulkhead 1-14 carriage clamps 1-5, 1-18 conventions 1-2 D document part number 1-1 drum bulkhead 1-14 dyno electronics accessing 1-10 cable clamp 1-15 dyno top cover removing 1-6 replacing 1-17 E eddy current brake cover removing 1-7 replacing 1-20 L load c
