©2007-2010 Dynojet Research, Inc. All Rights Reserved. Compressed Air Air Fuel Ratio Module Installation and User Guide. 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 Air Fuel Ratio Module and Compressed Air Pump Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHAPTER 1 AIR FUEL RATIO MODULE AND COMPRESSED AIR PUMP INSTALLATION This document provides instructions for installing and using the Air Fuel Ratio Module and the Compressed Air Pump Assembly with WinPEP 7. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This manual will walk you through installation and set up procedures, sampling and viewing air fuel ratios, and how to maintain your air pump.
CHAPTER 1 Introduction INTRODUCTION ................................... The Air Fuel Ratio Module is designed to accurately sample air fuel ratios from engines burning petroleum based fuels. Be sure to read and follow all warnings found throughout this manual. WARNINGS The sensor and the copper sample tube are hot. Before touching the sensor or the sample tube, make sure it has cooled. Leaded racing fuels and two-stroke applications will contaminate the sensor and dramatically shorten its service life.
AIR FUEL RATIO MODULE AND COMPRESSED AIR PUMP INSTALLATION Introduction 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. Follow all procedures exactly as they are described and use care when performing all procedures.
CHAPTER 1 Air Fuel Module Installation AIR FUEL MODULE INSTALLATION ................................... This section describes installation procedures for the Air Fuel Ratio Module. INSTALLING THE AIR FUEL MODULE 1 2 3 Verify the main dyno power is disconnected. Turn off the main power switch on the CPU Module unplug the power cord. Remove the dust cover from the existing top module.
AIR FUEL RATIO MODULE AND COMPRESSED AIR PUMP INSTALLATION Air Fuel Module Installation 4 5 Loosen the top right screw on the back of the existing top module. Install the Air Fuel Module into the existing top module. Place the dust cover, removed in step 3, on the Air Fuel Module.
CHAPTER 1 Air Fuel Module Installation 6 7 Secure the grounding strap on the back of the Air Fuel Module to the existing top module. Secure the Air Fuel Module to the dyno electronics with the plastic tie straps (one on each side).
AIR FUEL RATIO MODULE AND COMPRESSED AIR PUMP INSTALLATION Air Fuel Module Installation 8 9 Attach the 15-pin connector on the sensor cable to the front of the Air Fuel 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 Air Fuel Module should now be on.
CHAPTER 1 Compressed Air Pump Assembly COMPRESSED AIR PUMP ASSEMBLY ................................... This section describes how to set up the compressed air pump assembly. Refer to Appendix A for on-board dyno installation instructions.
AIR FUEL RATIO MODULE AND COMPRESSED AIR PUMP INSTALLATION Compressed Air Pump Assembly INSTALLING THE PUMP ASSEMBLY ON THE STAND Use the following instructions to install the pump assembly on the stand. Refer to Appendix A for on-board dyno installation instructions. 1 2 3 Open the toggle clamp and slide the pump assembly on the upright. Close the toggle clamp to secure the pump in place. Secure the sensor(s) to the pump assembly. Note: Make sure the sensor is on top.
CHAPTER 1 Compressed Air Pump Assembly CONNECTING THE SOLENOID POWER—I SERIES DYNOS Attach the power cable (P/N 71950403) from PII in the CPI to the solenoid on the compressed air pump assembly. CONNECTING THE SOLENOID POWER—NON I SERIES DYNOS Use the Stand Alone Breakout Board Controlled Compressed Air Pump Remote Kit (P/N 76493010) to control the air pump assembly using the dyno brakes.
AIR FUEL RATIO MODULE AND COMPRESSED AIR PUMP INSTALLATION Compressed Air Pump Assembly secure the relay to one of the screws on the Breakout board/Advanced Breakout board connect to the dyno brake solenoid wires connect to the compressed air pump assembly solenoid wires connect to the BRAKE terminals on the Breakout board/Advanced Breakout board Breakout board Advanced Breakout board BRA brake brake c AP117 J2 J1 J2 J1 eddy current brake and digital brake digital brake only Figure 1-7: Routi
CHAPTER 1 Compressed Air Pump Assembly ADJUSTING THE AIR FLOW To ensure accurate readings, adjust the air flow as necessary to maintain 35L/min. If you are unable to adjust the air flow to 35L/min., clean the pump then try to adjust the air flow again. Refer to “Pump Maintenance—Stand Alone” on page 2-8 for more information. Adjust the air flow at the end of each exhaust probe to 35 L/min. 1 2 3 4 5 6 Attach six inches of the silicon tubing from the top port on the flow meter to the copper sample tube.
CHAPTER 2 USING THE AIR FUEL RATIO MODULE This chapter will walk you through the set up procedures, sampling and viewing air fuel ratios, and how to maintain and troubleshoot your pump assembly. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 2 Module and Pump Set Up MODULE AND PUMP SET UP ................................... This section describes the set up procedures for the Air Fuel Ratio Module and compressed air pump assembly. 1 2 Run the vehicle and allow the vehicle to warm up. Excess condensed water is produced during warm up which can damage the air pump assembly. Allowing the vehicle to warm up removes this excess water. Place the copper sample tube(s) in the exhaust pipe(s) of the test vehicle.
USING THE AIR FUEL RATIO MODULE Sample and View Air Fuel Ratios SAMPLE AND VIEW AIR FUEL RATIOS ................................... This section describes the procedures to sample and view air fuel ratios using WinPEP 7. Note: Allow the sensor to preheat before making a run. An orange LED light on the Air Fuel Ratio Module will light up continuously and the Air/Fuel gauge on the MakeRun screen will read 18 when the sensor is ready to make a run.
CHAPTER 2 Sample and View Air Fuel Ratios 5 6 Verify the air pump assembly is on. Press the green sample button on the pendent to begin recording data. Note: For more information on how to make a run, refer to the WinPEP 7 User Guide (on your WinPEP CD or at www.dynojet.com) or the WinPEP 7 Online Help. 7 Press the sample button a second time to stop sampling. air/fuel gauge Figure 2-3: MakeRun Screen—Sampling Be sure to turn the Air Fuel Heater off when not in use for long periods of time.
USING THE AIR FUEL RATIO MODULE Sample and View Air Fuel Ratios VIEWING AND GRAPHING AIR/FUEL RUNS For more information about graph functions and displays, refer to the WinPEP 7 User Guide (on your WinPEP CD or at www.dynojet.com) or the WinPEP 7 Online Help. 1 2 3 Verify you are in the Graph screen. Select File !Open. Browse the directory and select a run file. You may also select multiple run files. A preview of the graph will appear.
CHAPTER 2 Sample and View Air Fuel Ratios The run information is displayed in the ListView along with a graph of the run. 5 Click on the axis channel label and choose Air/Fuel from the list. Note: Available channels may differ depending on your dyno model and configuration. The graph will now display the run with air/fuel readings.
USING THE AIR FUEL RATIO MODULE Air Pump Maintenance and Troubleshooting AIR PUMP MAINTENANCE AND TROUBLESHOOTING ................................... This section contains sensor information and describes the procedures for maintaining and troubleshooting the pump assembly. Make sure you are aware of the following items: • Keep the air pump upright. Tipping the pump may result in damage to the sensor. • Leaks in the system will result in erroneous readings.
CHAPTER 2 Air Pump Maintenance and Troubleshooting PUMP MAINTENANCE—STAND ALONE To ensure accurate readings, pump maintenance should be performed every six months, or sooner, depending on usage. Periodically check the air flow and adjust as necessary to maintain 35 L/min for each sample tube. If you are unable to adjust the air flow to 35 L/min, clean the pump. Use a solvent to clean all pump pieces very carefully. 1 2 3 4 5 6 7 Remove the ball valve or solenoid (for pumps using the control pod).
USING THE AIR FUEL RATIO MODULE Air Pump Maintenance and Troubleshooting PUMP MAINTENANCE—ON DYNO To ensure accurate readings, pump maintenance should be performed every six months, or sooner, depending on usage. Periodically check the air flow and adjust as necessary to maintain 35 L/min for each sample tube. If you are unable to adjust the air flow to 35 L/min, clean the pump. Use a solvent to clean all pump pieces very carefully.
CHAPTER 2 Air Pump Maintenance and Troubleshooting 4 5 6 7 8 9 10 Remove the sensor(s) from the sensor block. Remove the sensor block. Remove the silicon tube from the sensor block. Loosen the vacuum generator lock nut. Remove the vacuum generator exhaust port and venturi body. Unscrew the venturi body from the solenoid. Use a solvent to carefully clean the vacuum generator exhaust port, venturi body, and sensor block. Note: Be careful not to damage the internal structure of the venturi body.
APPENDIX A ON-BOARD DYNO INSTALLATION This appendix provides instructions for installing the compressed air pump on your motorcycle dynamometer. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIX A Installation INSTALLATION ................................... This section describes how to install the compressed air pump assembly on your motorcycle dynamometer.
ON-BOARD DYNO INSTALLATION Installation 3 Run the provided air hose from the air pump assembly to the front of your dyno. If you have an air brake, refer to “Installing the Air Hose with the Air Brake” on page A-4. You will need to remove the carriage assembly and top center cover to route the air hose. Refer to your dyno installation guide for instruction on removing the top cover. 4 5 6 7 8 Route the air hose through the air access holes in the front of the dyno. Attach the hose to your air supply.
APPENDIX A Installation INSTALLING THE AIR HOSE WITH THE AIR BRAKE Use the following instructions to install the air hose when the air brake is installed. 1 2 3 4 5 6 Install the tee. 1a Cut the hose running from the air brake as shown in Figure A-3. 1b Slide a hose clamp over each piece of hose. 1c Insert the tee. 1d Secure the hose clamps. Measure the distance from the tee to the air pump assembly and cut a piece of hose. Attach the hose to the air pump assembly.
ON-BOARD DYNO INSTALLATION Installation ADJUSTING THE AIR FLOW To ensure accurate readings, adjust the air flow as necessary to maintain 35L/min. If you are unable to adjust the air flow to 35L/min. for each sample tube, clean the pump then try to adjust the air flow again. Refer to “Pump Maintenance—On Dyno” on page 2-9 for more information. Adjust the air flow at the end of the exhaust probe to 35 L/min.
