1993-2002 Dynojet Research, Inc. All Rights Reserved. for Motorcycle Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual 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 respective companies. Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89031, USA. Printed in USA. Part Number: 98123101 Version 3 (01/02)
TABLE OF CONTENTS List of Figures............................................. iii DynoWare EX+ Upgrade Conventions Used In This Manual................................... 1 Technical Support................................................ 1 Parts List........................................................ 2 Installation...................................................... 3 Removing the Hood............................................ 3 Removing the Original Hardware.................................. 4 Installing the Pickup Card........................................ 5 Air Brake Modifications.......................................... 7 Drilling the Mounting Holes...................................... 8 Installing the Breakout Board...................................... 9 Wiring the DynoWare EX+ Modules............................... 11 Replacing the Hood............................................ 12 i
LIST OF FIGURES Figure 1: Components Included In the Upgrade Kit.................... 2 Figure 2: DynoWare EX+ Modules................................... 3 Figure 3: Remove the Hood........................................ 3 Figure 4: Disconnect the Cables from the Pickup Card.................. 4 Figure 5a: Remove the RPM Box.................................... 4 Figure 5b: Remove the RPM Box.................................... 4 Figure 6: Install the Pickup Card Bracket.............................. 5 Figure 7: Install the Pickup Card.................................... 5 Figure 8: Optical Pickup Alignment.................................. 6 Figure 9: Breakout Board Wiring Pickup Card........................ 6 Figure 10: Remove the Air Brake Solenoid Wires....................... 7 Figure 11: Breakout Board Wiring Air Brake.......................... 7 Figure 12: Template Placement..................................... 8 Figure 13: Install the Vibration Dampening Mounts.................... 9 Figure 14: Secure the Breakout Board and Cover....................... 9 Figure 15: Attach and Route the Cables............................. 10 Figure 16: Attach the DynoWare EX+ Cables......................... 11 Figure 17: Replace the Hood...................................... 12 iii
DYNOWARE EX+ UPGRADE This document provides instructions for installing the DynoWare EX+ components. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This manual will walk you through removing the original hardware, installing the DynoWare EX+ components, and making air brake modifications. Document Part Number: 98123101 Version 3 Last Updated: 08 January 2002 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. TECHNICAL SUPPORT For assistance, please contact Dynojet Technical Support at 1-800-992-4993, or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89031. 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. 1
DYNOWARE EX+ UPGRADE Parts List PARTS LIST................................... The following table lists all of the parts included in the DynoWare EX+ Upgrade 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 quantity 66191001, 66192001, 66193001, 66493001, 21646100 DynoWare EX+ Four Basic Modules plus Mounting Base 1 each 761900001 Power Supply 1 318110301 Power Cord, 125V, 10A 1 65291001 Breakout Board 1 327-800-001 Dyno Pickup Card 1 66954001 Dyno Pickup Card Cable (Data Acq. Cable) 1 DM104-001 Dyno Pickup Card Bracket 1 A10Z2-304A Rubber Vibration Dampener Mounts 4 36540643 #8-32 Screws 6 134490301 #8-32 Nuts 4 91114A009 #8 Lock washers 6 DE100-109S Inductive Pickup Cable 1 DE100-104N Remote Switch 1 42924090 Breakout Board to DynoWare Cable 1 42924250 DynoWare to Computer Serial Port Cable 1 inductive pickup cable pickup card bracket Breakout board power supply DynoWare EX+ modules Breakout board to DynoWare cable power cord DynoWare to PC cable pickup card remote switch screws, nuts, lock washers, dampening mounts pickup card cable Figure 1: Components Included In the Upgrade Kit 2
INSTALLATION GUIDE Installation INSTALLATION................................... The DynoWare EX+ system is comprised of four modules: the CPU Module, the Dynamometer Input/Output Module, the RPM Module and the Atmospheric Sensing Module. The upgrade requires a new pickup card and Breakout board (the interface between the dyno and the new DynoWare EX+ hardware). This section will provide you with the information necessary to install and connect the new components. If you have an air brake you will need to make additional modifications; refer to Air Brake Modifications on page 7 for more information. atmospheric sensing module RPM module dynamometer input/output module CPU module Figure 2: DynoWare EX+ Modules REMOVING THE HOOD 1 Disconnect all power to the dyno. 2 Remove the four bolts securing the hood to the dyno. 3 Prop up the hood and disconnect all battery wires. 4 Remove the hood. Figure 3: Remove the Hood Version 3 3
DYNOWARE EX+ UPGRADE Installation REMOVING THE ORIGINAL HARDWARE 1 Disconnect the cables from the existing pickup card. Figure 4: Disconnect the Cables from the Pickup Card 2 Disconnect the cables from the RPM box, if present. 3 Remove the cable clamps securing the wiring harness under the front dyno cover. 4 Remove the old cables. Be sure to leave the starter cable in place. 5 Remove the RPM box, if present. 5a Remove the nut and washer from the vibration dampening mount on the right side of the RPM box. Note: This dampening mount will remain in place due to the difficulty of removing the screw that secures it to the frame. dampening mount RPM box Figure 5a: Remove the RPM Box 5b screws Remove the two screws securing the two remaining dampening mounts and remove the RPM box. this dampening mount will remain attached Figure 5b: Remove the RPM Box 6 Remove the two screws securing the pickup card and remove the card. 4
INSTALLATION GUIDE Installation INSTALLING THE PICKUP CARD 1 Remove the two 5/8-inch nuts and washers from the bearing case and set aside. 2 Remove the existing pickup card bracket. 3 Install the new pickup card bracket and secure the bracket using the two 5/8-inch washers and nuts removed earlier. 4 Torque the nuts to approximately 150 ft. lb. Note: If you have a high inertia drum, install the extender bracket on your existing pickup card bracket. pickup card bracket extender bracket for high inertia drums Figure 6: Install the Pickup Card Bracket 5 Install the new pickup card in the notch on the new bracket using two No. 8 screws and lock washers. Do not tighten, the card must be aligned first. Figure 7: Install the Pickup Card Version 3 5
DYNOWARE EX+ UPGRADE Installation 6 Align the optical pickup with the tab on the dyno drum axle. Once aligned, tighten the screws to secure the pickup card in place. The optical pickup is very delicate. Be careful not to damage the optical pickup during alignment. pickup tab optical pickup pickup card Figure 8: Optical Pickup Alignment 7 Attach the small pickup cable to the Breakout board. The small pickup cable has four wires which connect to the wiring block labeled DRUM 1. Red wire connects to R1 White wire connects to W1 Black wire connects to B1 Ground wire connects to S1 8 Tighten the four screws in the top of the terminal block to secure the wires and set the Breakout board aside. Note: It is easier to attach the pickup cable wires to the Breakout board before securing the board to the dyno. drum 1 Figure 9: Breakout Board Wiring Pickup Card 6
INSTALLATION GUIDE Installation AIR BRAKE MODIFICATIONS If your dyno has an air brake, wiring modifications will need to be made before continuing with the installation. If you do not have an air brake, skip these instructions and continue with Drilling the Mounting Holes on page 8. 1 Locate the wiring block mounted on the cross member just to the front of the drum. 2 Loosen the two screws on the top left of the wiring block. 3 Remove the two wires that go to the air brake solenoid. Tighten the two screws. air brake solenoid wires loosen screws Figure 10: Remove the Air Brake Solenoid Wires 4 Route the two wires through the hole in the dyno over to the Breakout board. Note: You may need to extend these wires. 5 Attach the wires from the air brake solenoid to the wiring block labeled BRAKE on the Breakout board. Both wires are black and can attach in any order. 6 Tighten the two screws in the top of the terminal block to secure the wires. The brake will now be controlled from the remote pendant. brake Figure 11: Breakout Board Wiring Air Brake Version 3 7
DYNOWARE EX+ UPGRADE Installation DRILLING THE MOUNTING HOLES Depending on the age of your dyno, you may need to drill the holes needed to mount the Breakout board. If you dyno already has the required holes, skip these steps and continue with the installation. 1 Locate the Breakout Board Mounting Hole Drill Template found at the end of this manual. 2 Locate the existing holes in the dyno to the right of the pickup card bracket. 3 Align the template with the existing holes on the dyno and tape the template in place. 4 Mark and drill the four mounting holes to 3/16-inch (5 MM). Note: Before drilling the holes, place the Breakout board over the marked holes to verify correct hole placement. existing holes existing holes template Figure 12: Template Placement 8
INSTALLATION GUIDE Installation INSTALLING THE BREAKOUT BOARD 1 Install the four rubber vibration dampening mounts to the Breakout board using four No. 8 nuts. nuts breakout board dampening mounts Figure 13: Install the Vibration Dampening Mounts 2 Secure the Breakout board cover and board to the dyno using four No. 8 screws. Note: Be sure the large data plug on the Breakout board is facing towards the front of the dyno (away from the drum). Breakout board and cover Figure 14: Secure the Breakout Board and Cover Version 3 9
DYNOWARE EX+ UPGRADE Installation 3 Attach the pickup card cable from the Breakout board to the pickup card. 4 Attach the appropriate end of the large PC data cable to the Breakout board and secure with the plug screws (finger tight only). 5 Route the large PC data cable with the starter cable. Secure both cables back under the lip of the front dyno cover using the cable clamps you removed earlier. starter cable front dyno cover starter pendant to PC pickup card cable PC cable cable clamp Breakout board Figure 15: Attach and Route the Cables 10
INSTALLATION GUIDE Installation WIRING THE DYNOWARE EX+ MODULES 1 Place the DynoWare EX+ modules in a safe location in the shop that is close enough to the computer and the dyno for the cables to reach. 2 Attach the cables to the DynoWare EX+ modules. Refer to Figure 16 for cable placement. Attach the 9-pin shielded serial cable from the PC to the RS-232 socket on the CPU module. Tighten the screws. Attach the 25-pin shielded cable from the dynamometer to the Dynamometer Input/Output module. Tighten the screws. Attach the 9-pin connector from the hand-held pendant to the Dynamometer Input/Output module. Tighten the screws. Attach the 3-pin plug from the power supply to the CPU module with the flat side facing down. 3 Plug the power supply into an electrical outlet. 4 Turn the power switch on at the CPU module and verify operation with WinPEP. Note: If you have an air brake, the air brake is now controlled from the remote pendant. primary inductive pickup socket 25-pin socket power LEDs 9-pin, hand-held pendant 9-pin, RS-232 socket 3-pin power plug power switch Figure 16: Attach the DynoWare EX+ Cables Version 3 11
DYNOWARE EX+ UPGRADE Installation REPLACING THE HOOD 1 Gently place the hood on the dyno leaving the hood propped up. 2 Reconnect the battery. 3 Secure the hood to the dyno using the four bolts removed earlier. Figure 17: Replace the Hood 12
BREAKOUT BOARD MOUNTING HOLE DRILL TEMPLATE EXISTING HOLES 3.40IN (86.4mm) DRILL 4 HOLES AT 3/16" (5mm) 3.00IN (76.2mm) EXISTING HOLES P:\Templates\ b.o.b. drill template 12/13/01