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©2000-2004 Dynojet Research, Inc. All Rights Reserved.
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. 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: 98295110 Version 6 (11/2004)
Page 3
T
ABLE OF
C
ONTENTS
Chapter 1 Air Fuel Ratio Module Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Installing the Air Fuel Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Air Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Setting Up the Air Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Chapter 2 Using the Air Fuel Ratio Module
Module and Pump Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Sample and View Air Fuel Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Sampling Air Fuel Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Viewing and Graphing Air/Fuel Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Air Pump Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .2-7
Sensor Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Correcting Lean Air Fuel Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
If Water is Collecting in the Filter Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Cleaning the Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Filter Assembly Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Pump Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Emptying the Exhaust Collection Bottles . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Appendix A Air Fuel Ratios with WinPEP 6
Sample and View Air Fuel Ratios Using WinPEP 6 . . . . . . . . . . . . . . . . . . .A-2
Sampling Air Fuel Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Viewing and Graphing Air/Fuel Runs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Air Fuel Ratio Module Installation and User Guide
i
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C HAPTER
1
AIR F
This document provides instructions for installing and using the Air Fuel Ratio
Module and version three of the Air Pump Assembly with WinPEP 7. Appendix A
includes instructions for using the Air Fuel Ratio Module with WinPEP 6. 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 and troubleshoot your air pump.
Document Part Number: 98295110
Version 6
Last Updated: 11-02-04
This chapter is divided into the following categories:
•Introduction, page 1-2
•Installation, page 1-4
• Air Pump Assembly, page 1-6
UEL
R
ATIO
M
ODULE INSTALLATION
Air Fuel Ratio Module Installation and User Guide
1-1
Page 6
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.
Note: The Air Pump Assembly has a one year warranty.
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.
The sensor is not covered by a warranty. Be sure to read and understand the Air
Fuel Ratio Module Installation and User manual.
Running the pump with the filter clogged, hose kinked, or filter removed will
damage the pump and void the warranty.
Before turning the pump on, verify there is no water in the filter bowl. Always
empty the bowl before turning the pump on.
Do not allow the filter bowl to fill with water during operation.
Warm up the vehicle before placing the copper sample tube in the exhaust to
avoid drawing excess water through the pump assembly.
Keep the air pump assembly upright. Tipping the pump assembly may result in
damage to the sensor.
Leaks in the system will result in erroneous readings. Verify there are no cracks
or holes in the hoses and filter bowl. Verify the sensor is seated properly in the
sensor block.
To ensure accurate readings, pump head maintenance should be performed
every six months, or sooner, depending on usage. Refer to “Pump Head
Maintenance” on page 2-12 for more information.
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Air Fuel Ratio Module Installation and User Guide
Page 7
AIR FUEL RATIO MODULE INSTALLATION
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.
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
Introduction
Bold
!
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, 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.
Highlights items you can select on in the software
interface, including buttons and menus.
The arrow indicates a menu choice. For example,
“select File
then select the Open choice on the File menu.”
!
Open” means “select the File menu,
Vers ion 6 Air Fuel Ratio Module Installation and User Guide
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CHAPTER 1
Installation
INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section describes installation procedures for the Air Fuel Ratio Module.
PARTS LIST
The following table lists all of the parts included in the Air Fuel Ratio 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.
Part Number Description Quantity
64193007
or
64193008
66493002 Air Fuel Ratio Module 1
43432301 Module Tie Straps 2
48292000 Sensor 1
76950701 Cable, Air/Fuel Sensor 1
INSTALLING THE AIR FUEL MODULE
Air Pump and Filter Assembly (Domestic)
Air Pump and Filter Assembly (European)
1
1 Turn off the main power switch on the CPU Module on the dyno electronics and
unplug the power cord.
2 Remove the dust cover from the existing top module.
dust cover
power cord
input
power switch
Figure 1-1: Remove Dust Cover
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AIR FUEL RATIO MODULE INSTALLATION
Installation
3 Loosen the top right screw on the back of the existing top module.
4 Plug the Air Fuel Module into the existing top module. Place the dust cover,
removed in step 2, on the Air Fuel Module.
5 Secure the grounding strap on the back of the Air Fuel Module to the existing top
module.
grounding strap
Figure 1-2: Secure Grounding Strap
6 Secure the Air Fuel Module to the stack with the plastic tie straps (one on each
side).
7 Attach the 15-pin connector on the sensor cable to the front of the Air Fuel
Module and tighten down the screws.
8 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.
air fuel module
tie strap
green LED light
sensor cable and port
Figure 1-3: Attach Air Fuel Module and Sensor Cable
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CHAPTER 1
Air Pump Assembly
AIR PUMP ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section describes how to set up the Air Pump Assembly. Dynojet recommends
running the pump between dyno runs to help reduce the chance of moisture
contamination on the sensor. Always keep the pump in the upright position.
Refer to “Air Pump Maintenance and Troubleshooting” on page 2-7 for more
information.
POWER REQUIREMENTS
The Air Pump Assembly is supplied with either a 120 volt standard power plug or 240
volt European power plug. The current draw for both is less than 2.0 amps. Both
power plugs use a 3 amp 250 volt 5x20 mm fuse.
STANDARD EUROPEAN POWER PLUG
The Interpower™ Schuko power cord is suitable for use in Germany, Austria, Norway,
Sweden, Finland, the Netherlands, Belgium, France, Portugal, and Spain. You must
install the appropriate power plug specifically for your country to ensure proper
grounding.
filter assembly
power switch
power cord plug
SETTING UP THE AIR PUMP ASSEMBLY
The Air Pump Assembly comes pre-assembled and ready to use.
1 Attach the power cord to an outlet.
2 Secure the sensor to the pump assembly.
3 Turn on the main power switch.
sensor
Figure 1-4: Air Pump Assembly
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Air Fuel Ratio Module Installation and User Guide
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U
SING THE
AIR F
UEL
R
ATIO
C HAPTER
2
M
ODULE
This chapter will walk you through the set up procedures, sampling and viewing air
fuel ratios, and how to maintain and troubleshoot your air pump. To ensure safety
and accuracy in the procedures, perform the procedures as they are described.
This chapter is divided into the following categories:
•Module and Pump Set Up, page 2-2
• Sample and View Air Fuel Ratios, page 2-3
• Air Pump Maintenance and Troubleshooting, page 2-7
Air Fuel Ratio Module Installation and User Guide
2-1
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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 Air
Pump Assembly.
1 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.
2 Place the copper sample tube in the exhaust pipe of the test vehicle.
copper sample
tube
Figure 2-1: Sample Tube Placement
3 Turn on the dyno electronics power. Verify the Air Fuel Ratio Module power
light is on.
4 Turn on the Air Pump Assembly power.
Note: Always keep the pump assembly in the upright position.
air fuel ratio
module
power light
sensor cable
power
power
Figure 2-2: Dyno Electronics and Air Pump Assembly Power
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Air Fuel Ratio Module Installation and User Guide
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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. If you are using WinPEP 6, refer to Appendix A.
Note: Allow the sensor to preheat before making a run. An orange LED light on
the Air Fuel Ratio Module will light up continuously when the sensor is ready to
make a run.
SAMPLING AIR FUEL RATIOS
1 Verify you are in the MakeRun screen.
2Click the MakeRun Configuration button .
3 In the MakeRun Configuration dialog box, verify the Air/Fuel Heater is on and
click OK.
The Air/Fuel Heater will be on by default when the Air Fuel Ratio Module is added
to the dyno electronics.
Note: To ensure repeatable and accurate measurements, the Air/Fuel Heater must
be allowed to heat up to temperature. An orange LED light on the Air Fuel Ratio
Module will light up continuously when the sensor is ready to make a run.
Figure 2-3: MakeRun Configuration Window—Air/Fuel Heater
air/fuel heater
must be on
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CHAPTER 2
Sample and View Air Fuel Ratios
4 Verify the Air Pump Assembly is on.
5 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/manuals.shtml) or the
WinPEP 7 Online Help.
6 Press the sample button a second time to stop sampling.
air/fuel gauge
7 Once you have completed your runs, allow the air pump to run for five minutes.
Always allow the air pump to run after the dyno runs are complete to clear all
water from the filter bowl and allow the air pump to cool.
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Air Fuel Ratio Module Installation and User Guide
Be sure to turn the Air Fuel Heater off when not in use for long periods of time.
Figure 2-4: MakeRun Screen—Sampling
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browse
directories
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/manuals.shtml) or the WinPEP 7
Online Help.
1 Verify you are in the Graph screen.
2Select File
3 Browse the directory and select a run file. You may also select multiple run files.
A preview of the graph will appear. The graph preview is configurable but not
required to open the run file.
4 Once you have found the run and configured the graph preview (optional),
click Open.
!
Open.
USING THE AIR FUEL RATIO MODULE
Sample and View Air Fuel Ratios
run file
graph preview
Figure 2-5: Graph Screen—Open Dialog Box
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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.
axis channel
label
choose air/fuel from
the list of options
Figure 2-6: Main Graph Display with Air/Fuel
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Air Fuel Ratio Module Installation and User Guide
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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 Air Pump Assembly.
Note: Make sure you are aware of the following items:
• The Air Pump Assembly has a one year warranty.
• Keep the air pump upright. Tipping the pump may result in damage to the
sensor.
• Leaks in the system will result in erroneous readings. Verify there are no cracks
or holes in the hoses and filter bowl. Verify the sensor is seated properly in the
sensor block.
• Do not allow the filter bowl to fill with water during operation.
SENSOR INFORMATION
The sensor is calibrated by Dynojet prior to shipping. Under optimal conditions, the
sensor life can exceed 1500 hours. When using leaded race fuel, 2.5 grams of lead per
gallon of fuel will reduce the expected life of the sensor to less than 100 hours.
The sensor is not covered by a warranty. Be sure to read and understand the Air
Fuel Ratio Module Installation and User manual.
CORRECTING LEAN AIR FUEL READINGS
Refer to the instructions below if you are experiencing air fuel ratio readings that are
leaner than you expected.
1 Verify the pump is running.
2 Check the system for restrictions in the air flow such as a clogged filter or kinked
hose.
3 Verify the copper sample tube is not kinked or clogged and is inserted into the
exhaust as far as possible. Refer to Figure 2-1.
4 Check for leaks in the system.
4a Verify all hoses are securely attached to the fittings.
Note: You may need to remove the pump head service cover and verify the hoses
are securely attached to the pump. Refer to Figure 2-8.
4b Verify there are no cracks or holes in the hoses and filter bowl.
4c Verify the sensor is seated properly in the sensor block.
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CHAPTER 2
Air Pump Maintenance and Troubleshooting
IF WATER IS COLLECTING IN THE FILTER BOWL
Do not allow the filter bowl to fill with water during operation. Use the following
instructions to troubleshoot excess water in the filter bowl.
1 Unscrew the filter bowl from the filter housing and verify there is no blockage in
the filter bowl.
2 Verify the fitting at the bottom of the bowl is not clogged. Clean if necessary.
3 Turn the pump on and check for air flow through the small hose. If you do not
have air flow through this hose, continue with the next step.
filter bowl
fitting
Figure 2-7: Check Filter Bowl and Air Flow
4 Remove the pump head service cover.
pump head
service cover
Figure 2-8: Remove the Pump Head Service Cover
small hose
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Air Fuel Ratio Module Installation and User Guide
Page 19
5 Remove the small hose from the fitting on the pump head.
6 Turn the pump on and check for air flow into the pump head. If there is no air
7 Turn the pump off and disconnect the power cable from the pump assembly.
8 Remove the small hose from the pump assembly.
9 Clear the hose of any obstructions. Verify there are no cracks or holes in the hose.
10 Use the string to pull the hose back through the assembly.
11 Secure the hose to the pump head fitting.
12 Connect the power cable to the pump assembly and turn the pump on.
13 Check for air flow.
pump head fitting
USING THE AIR FUEL RATIO MODULE
Air Pump Maintenance and Troubleshooting
flow at the pump head, refer to “Pump Head Maintenance” on page 2-12. If there
is air flow, continue with the next step.
Note: Before continuing with the next step, tie a piece of string or wire to one
end of the small hose. Make sure the string is long enough so you can remove the
hose from the pump assembly, but still use the string to pull the hose back
through the pump assembly.
Replace the hose if necessary.
small hose
tie string to
small hose
Figure 2-9: Check for Air Flow in Small Hose
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CHAPTER 2
Air Pump Maintenance and Troubleshooting
CLEANING THE FILTER ASSEMBLY
The air pump filter should be cleaned daily or more often depending on usage. The
filter should be cleaned more often when the Air Fuel Ratio Module is used with twostroke engines, new silencers, or any other condition that introduces solids into the
exhaust flow.
Running the pump with the filter clogged, hose kinked, or filter removed will
damage the pump and void the warranty.
1 Remove the small hose from the fitting at the bottom of the filter bowl.
2 Unscrew the filter bowl from the filter housing.
3 Unscrew the filter stem from the filter housing.
4 Slide the filter element off the filter stem.
5 Rinse the filter element with water.
6 Dry the filter element with a paper towel or carefully with compressed air.
Note: You may want to rotate between two filter elements. This will allow one
filter element to be cleaned and drying while the other is in use.
7 If there is residue in the filter bowl, clean the bowl, fitting, and filter housing.
8 Lubricate the threads on the filter stem and filter bowl.
Before assembling the filter, lubricate the threads on the filter stem and filter
bowl using the grease provided or a similar grease. Do not use silicone. The
filter stem may break if not lubricated.
9 Replace the filter element on the filter stem.
10 Secure the filter stem and the filter bowl to the filter housing.
If cleaning the filter element does not result in free air flow, replace the filter.
filter housing
filter element
filter stem
filter bowl
fitting
2-10
Air Fuel Ratio Module Installation and User Guide
Figure 2-10: Cleaning the Filter Assembly
Page 21
FILTER ASSEMBLY REPLACEMENT PARTS
Refer to the table below and Figure 2-11 when ordering replacement parts.
part number description
The following parts are common replacements:
29909000 filter bowl (poly carbonate)
29909001 filter bowl (metal)
34491000 filter element (includes seals)
34111220 1/4" fitting (filter housing)
34111213 1/8" fitting (bottom of filter bowl)
34492000 filter stem
11108800 silicone tube (not shown)
24730300 copper sample tube (not shown)
The following parts are included in P/N 34420001:
• filter housing • filter element
•filter stem •seal (2)
• filter bowl (poly) • deflector
USING THE AIR FUEL RATIO MODULE
Air Pump Maintenance and Troubleshooting
filter housing
seal
filter element
filter stem
filter bowl
1/8" fitting
1/4" fitting
deflector
seal
P/N 34420001 Assembly
Figure 2-11: Filter Assembly Replacement Parts
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CHAPTER 2
Air Pump Maintenance and Troubleshooting
PUMP HEAD MAINTENANCE
To ensure accurate readings, pump head maintenance should be performed every six
months, or sooner, depending on usage. One pump head maintenance kit
(P/N 79190003) has been included with your pump purchase. Disregard the foam
insert included in the kit.
The pump has two pump heads. Use the following instructions to clean and maintain
each pump head.
Note: Dynojet recommends cleaning one pump head at a time.
1 Remove the sensor.
2 Remove the four No. 2 phillips head screws securing the pump head service cover
and remove the cover.
pump head
service cover
3 Remove the hoses from the fittings on the pump heads.
pump heads
2-12
Air Fuel Ratio Module Installation and User Guide
Figure 2-12: Remove the Pump Head Service Cover
Figure 2-13: Remove Hoses from Pump Heads
Page 23
USING THE AIR FUEL RATIO MODULE
Air Pump Maintenance and Troubleshooting
4 Note the orientation of the pump heads using the stickers or the letters on the top
of the head as a marker. The inlet side of each head is labeled B while the outlet
side is labeled A
Note: The pump head must be re-installed correctly or the pump will not
function properly.
5 Using a T-20 Torx driver, remove the four screws securing the pump head and
remove the head.
Note: Do not remove the pump from the housing. For clarity, the pump housing
is not shown.
inlet labeled B
outlet labeled A
letter
pump head
Figure 2-14: Remove the Pump Head
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CHAPTER 2
Air Pump Maintenance and Troubleshooting
6 Mark the orientation of the valve plate with the pump head before removing the
valve plate.
You may also use the letters on the top of the pump head to ensure correct
orientation.
Note: The valve plate must be re-installed correctly or the pump will not function
properly.
7 Remove the four No. 2 phillips head screws securing the valve plate and remove
the plate.
Note: If you need to pry the valve plate from the pump head, be sure not to
scratch or damage the plate. You will need to replace the valve plate
(P/N 21299105) if damaged.
outlet labeled A
inlet labeled B
valve plate
mark orientation
valve plate
pump head
inlet labeled B
outlet labeled A
Figure 2-15: Mark and Remove Valve Plate
gasket
pump head
2-14
Air Fuel Ratio Module Installation and User Guide
Page 25
USING THE AIR FUEL RATIO MODULE
Air Pump Maintenance and Troubleshooting
8 Mark the orientation of each reed valve with the valve plate.
Note: The reed valve must be re-installed correctly or the pump will not function
properly.
Note: Dynojet recommends you remove and clean one reed valve at a time.
9 Using a flat-head screwdriver, remove the screw securing the reed valve. Remove
the washer and valve.
10 Carefully clean the area where the reed valve seats.
11 Carefully clean the reed valve.
If you purchased the pump head maintenance kit (P/N 79190003), replace each
reed valve. Disregard the foam insert included in the kit.
12 Secure the reed valve and washer with the screw you removed earlier. Be sure to
align the reed valve with the valve plate using the marks you made earlier.
13 Following steps 8-12, remove and clean the reed valve on the other side of the
valve plate.
screw
valve plate
reed valve
mark orientation
Figure 2-16: Mark and Remove the Reed Valve
14 Secure the valve plate to the pump head using the four screws removed earlier.
Refer to Figure 2-15.
Note: Be sure to align the valve plate with the pump head using the marks you
made earlier.
washer
reed valve
valve plate
clean where
valve seats
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CHAPTER 2
Air Pump Maintenance and Troubleshooting
15 Check the condition of the diaphragm. If the diaphragm is cracked or
deteriorated, replace the diaphragm.
15a Remove the four No. 2 phillips head screws securing the mounting plate and
remove the plate.
15b Inspect the diaphragm and replace if necessary.
15c Secure the mounting plate with the screws you removed earlier.
Note: Be sure the screws securing the mounting plate are the smaller of the flat-
head screws. The pump will not function properly if the longer screws are used.
16 Secure the pump head with the screws you removed earlier. Refer to Figure 2-14.
Note: Be sure to replace the pump head with the correct inlet/outlet orientation
or the pump will not function properly.
outlet labeled A
inlet labeled B
mounting plate
diaphragm
2-16
Air Fuel Ratio Module Installation and User Guide
Figure 2-17: Inspect the Diaphragm
Page 27
REPLACING THE FUSE
The air pump has a 3 amp 250 volt 5mm fuse located in a drawer just above the power
cord plug in. The fuse drawer contains the fuse and a spare fuse. Once you use the
spare fuse, remember to replace it with a new one.
1 Disconnect the power cable from the Air Pump Assembly. The fuse drawer will not
come out until the power cable is removed.
2 Using a flat screwdriver, gently pry the fuse drawer from the pump assembly.
pry with
screwdriver
fuse drawer
USING THE AIR FUEL RATIO MODULE
Air Pump Maintenance and Troubleshooting
Figure 2-18: Removing the Fuse Drawer
3 Remove the blown fuse.
4 Replace the blown fuse with the spare fuse located in the housing behind the fuse
holder.
Note: Be sure to replace the spare fuse with a new 3 amp 250 volt 5mm fuse
(Dynojet P/N 54210300 or equivalent).
For continued protection against risk of fire, replace only with fuse of the
specified type and current ratings.
spare fuse
housing
spare fuse
blown fuse
fuse holder
Figure 2-19: Replacing the Fuse
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CHAPTER 2
Air Pump Maintenance and Troubleshooting
EMPTYING THE EXHAUST COLLECTION BOTTLES
Remember to remove and empty the exhaust collection bottles located at the back of
the Air Pump Assembly regularly.
exhaust collection
bottles
Figure 2-20: Empty the Exhaust Collection Bottles
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Air Fuel Ratio Module Installation and User Guide
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A PPENDIX
A
AIR F
This appendix provides instructions for using the Air Fuel Ratio Module with
WinPEP 6. To ensure safety and accuracy in the procedures, perform the procedures
as they are described.
UEL
R
ATIOS WITH
W
IN
PEP 6
Air Fuel Ratio Module Installation and User Guide
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APPENDIXA
Sample and View Air Fuel Ratios Using WinPEP 6
SAMPLE AND VIEW AIR FUEL RATIOS USING WINPEP 6
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section describes the procedures to sample and view air fuel ratios using
WinPEP 6. For more information on making and graphing a run, refer to your
dynamometer user guide located on your WinPEP CD or at
www.dynojet.com/manuals.shtml.
Note: Allow the sensor to preheat before making a run. An orange LED light on
the Air Fuel Ratio Module will light up continuously when the sensor is ready to
make a run.
SAMPLING AIR FUEL RATIOS
1 Verify you are in the MakeRun screen.
2Click the MakeRun Configuration button.
3 In the MakeRun options dialog box, verify the Air/Fuel Module is on. To turn the
Air/Fuel Module on, double-click the field.
air fuel module
function
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Air Fuel Ratio Module Installation and User Guide
Figure A-1: MakeRun Options Window—Air Fuel Module
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AIR FUEL RATIOS WITH WINPEP 6
Sample and View Air Fuel Ratios Using WinPEP 6
4Click MakeRun.
The following speedometer and tachometer window appears. This window has an
air fuel ratio meter with a multi-colored meter and numerical value display. A
numerical air fuel ratio number higher than zero, or an orange light on the Air
Fuel Ratio Module, indicates that the sensor is ready for sampling.
air fuel ratio meter
Figure A-2: Speedometer/Tachometer Window—Air Fuel Ratio Meter
5 Verify the Air Pump Assembly is on.
6 Press the sample button on the pendent to begin recording data.
Note: For more information on how to make a run, refer to your dynamometer
user guide located on your WinPEP CD or at www.dynojet.com/manuals.shtml.
7 Press the sample button a second time to stop sampling.
8 Once you have completed your runs, allow the air pump to run for five minutes.
Always allow the air pump to run after the dyno runs are complete to clear all
water from the filter bowl and allow the air pump to cool.
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APPENDIXA
Sample and View Air Fuel Ratios Using WinPEP 6
UTILIZING DYNOTRAC
The following speedometer and tachometer window appears while utilizing DynoTrac
software for the Proportional Air Control or the Eddy Current Brake system. This
window has an air fuel ratio meter with a multi-colored meter and numerical value
display.
Note: Run data will not be recorded in this configuration.
air fuel ratio meter
Figure A-3: DynoTrac Speedometer/Tachometer Window—Air Fuel Ratio Meter
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Air Fuel Ratio Module Installation and User Guide
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VIEWING AND GRAPHING AIR/FUEL RUNS
Select the runs you wish to view on the graph. Refer your dynamometer user guide for
more information on viewing graphs.
1 Verify you are in the Graph screen.
2 Select and open the run file you wish to view.
3 Right click on the graph and select Graph Options.
4Click Axis Selection.
Note: You may want to deselect the Force Scaling option when looking at air fuel
ratios. Refer to your dynamometer user guide for more information on force
scaling.
AIR FUEL RATIOS WITH WINPEP 6
Sample and View Air Fuel Ratios Using WinPEP 6
force scaling
axis selection
5 Select an option from the list to graph on the left Y axis. Power was selected in
Figure A-4: Graph Options Window—Axis Selection
this example.
Figure A-5: Graph Options Window—Left Y Axis
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APPENDIXA
Sample and View Air Fuel Ratios Using WinPEP 6
6 Select an option from the list to graph on the right Y axis. Air/Fuel was selected in
this example.
Figure A-6: Graph Options Window—Right Y Axis
7 Select an option from the list to graph on the X axis. Engine RPM was selected in
this example.
Figure A-7: Graph Options Window—X Axis
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AIR FUEL RATIOS WITH WINPEP 6
Sample and View Air Fuel Ratios Using WinPEP 6
8 Select the gear ratio by clicking the right mouse button.
Note: This menu will only appear if you choose Engine RPM in step 7.
Figure A-8: Graph Options Window—Gear Ratio
The main graph containing the run and options you selected is now displayed.
Figure A-9: Main Graph Display
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