AEM PERFORMANCE ELECTRONICS 30-48XX Dyno Shaft Kit Instruction Manual

AEM PERFORMANCE ELECTRONICS 30-48XX Dyno Shaft Kit

WARNING: Dyno-Shaft On-Vehicle Dynamometer is a valuable diagnostic tool that must only be used in a safe manner and in compliance with all applicable laws, rules and regulations. All users of this product agree that AEM shall not be responsible or liable for any personal injury, property or any other type or kind of damage(s) resulting, directly or indirectly, from non- compliance.

AEM Performance Electronics
2205 126th Street Unit A, Ha wthorne, CA. 90250 Phone: 310-484-2322 Fax: 310-484-0152 http://www.aemelectronics.com Instruction Part Number: 10-4800 Rev D © 2012 AEM Performance Electronics

KIT CONTENTS

• 1 x 35-4740 Dyno-Shaft Controller Assembly
• 1 x 35-46XX Yoke Assembly (Style and P/N depends on kit purchased) 1 x 35-4780 Dyno-Shaft/AEMnet “Y” Harness
• 1 x Instruction Manual
• Transmission Adapters (quantity and version depend on kit purchased)

INSTALLATION TIPS

1. Read the entire manual and instructions before beginning the installation.
2. Disconnect the negative battery cable(s) before beginning any work.
3. Make sure all connectors are fully seated and inserted.
4. Make sure all cables are routed away from heat sources or sharp objects.

DYNO-SHAFT DESCRIPTION
The AEM Dyno-Shaft is a device that measures actual driveshaft torque from yoke mounted strain gauges. This is not an inaccurate accelerometer based software application, the AEM Dyno-Shaft provides repeatable, accurate measurement of driveline torque and horsepower. It is unaffected by headwind, crosswinds, tailwinds, vehicle weight discrepancies, up-hills, down-hills, road surface changes, wheel spin or proximity to other vehicles because the Dyno-Shaft actually measures driveline torque and RPM, it doesn’t attempt to estimate it. The AEM Dyno-Shaft is zero maintenance. Power is supplied to the rotating sensor unit via an air-core transformer which is formed by the coil on the controller housing and a matching coil on the sensor. The sensor sends data back to the controller via the same mechanism. There are no batteries to die, no temperamental slip rings to wear out.

DYNO-SHAFT KIT DIFFERENCES
The Sportsman level kit is designed for applications where a cast iron style transmission slip yoke is acceptable. The Pro kit is designed for the most demanding applications and is based around a CNC machined, 4340 chrome-moly yoke.

DYNO-SHAFT INSTALLATION

Make sure that all the work described below is performed 100% per the manufacturer’s service instructions. If you do not have the proper tools and knowledge to perform the driveshaft work then take the driveshaft to a machine shop that can perform the work for you. Absolutely do not attempt to do this work without the proper tools as driveshaft imbalance or even complete driveline failure is a possibility. Raise the vehicle per the manufacturer’s instructions. A vehicle hoist is probably best. Make 100% sure that the vehicle is secure before beginning any work underneath it.

MOUNTING THE DYNO-SHAFT SENSOR
Before attempting to mount the Dyno-Shaft to your vehicle you need to check to make sure there is proper clearance to fit the device. Confirm that at least 1.5” of your existing slip yoke’s shaft remains available outside of your transmission tail housing under all vehicle operating conditions. If it doesn’t maintain at least this amount then do not attempt the installation. Shortening the driveshaft or minimizing the driveshaft movement is required before proceeding. Confirm that there are no obstructions to mounting the controller behind the transmission tail shaft housing (see picture).

Dyno-Shaft Chassis/Body Clearance Requirements
At least 1.5″ slip yoke shaft protrusion when vehicle is in operation.If not, the driveshaft may need to be shortened. At least 5″ diameter clearance surrounding the U-Joint for a minimum of 4″ behind the transmission.

Once you are confident the Dyno-Shaft will fit on your vehicle you can proceed to remove the driveshaft from the vehicle. Remove the transmission slip yoke from the driveshaft. This may be a good time to replace the u-joint with a new unit as they are a high wear item and are inexpensive. In some cases a conversion u-joint may be necessary to connect the Dyno-Shaft supplied slip yoke to the driveshaft. Compare which series u-joint your Dyno-Shaft kit is designed for against your existing u-joint to make sure you purchase the correct u-joint. The Dyno-Shaft application guide (http://www.aemelectronics.com/images/Dyno-Shaft_Application_Guide.pdf) lists the various Dyno-Shaft kits and their associated u-joint series. Replace the slip yoke on the driveshaft with the supplied Dyno-Shaft yoke.

Re-balance the driveshaft if very high driveshaft RPM (7,000+) is expected.

MOUNTING THE DYNO-SHAFT CONTROLLER

Measure the OD of the transmission tail shaft housing and select the proper adapter. All of the adapters are identical except for the inner diameter. Select an adapter that fits over the tail shaft housing without having to be distorted or opened up. Place the adapter inside the clamp area of the Dyno- Shaft controller and install on the tail shaft housing. The locating ribs on the adapters are designed to fit into the cavity between the clamp arms and controller body. Do not attempt to pry the Dyno-Shaft clamp area open to make things fit, select a larger ID adapter instead.In some cases (notably some T400 and T56 Magnum tail shaft housing castings) the OD of the housing is just slightly smaller than the ID of the Dynoshaft controller. In this situation, no split adapter can work and a thin, flat, elastic band is supplied to shim up the OD and act as the adapter and vibration isolation.

This is a precision electronic measuring device, therefore you must ensure that the hot exhaust is not the nearby controller. If there is a heat source near the controller you MUST install a shield between the Dyno-Shaft and the hot component. To protect itself, the Dyno-Shaft controller will automatically shut down when its driver circuit reaches 250 degrees F. The parameter ”Control Temp” reports this temperature and can be monitored to make sure the controller does not overheat. If the controller does overheat and automatically shut down, it will automatically reactivate when the controller temperature drops to 165 degrees. During the over temp shutdown, the controller will continue to report the “Control Temp” parameter. Parameters such as, Speed, Torque, Power, Tank Volts, Sensor Volts, Power Level, Sensor Temp, S-Firm Error, Zero Offset Ok, Good Cal, and LED Aligned, will stop reporting. Orient the controller so the harness connector is at the top of the transmission unless there is a heat source nearby. If there is, then orient the controller so the connector is as far away from the heat source as possible. Reinstall the driveshaft per the mfg instructions.

Verify that the Dyno-Shaft sensor unit on the slip yoke is roughly in the middle of the controller housing. Adjust the placement of the controller housing front to rear as necessary. Excessive in/out driveshaft movement may cause the sensor signal to drop out so ensure this is correct. Also confirm the controller is centered within the sensor body. At this point make 100% sure that there is no possibility the rotating sensor can contact the transmission tail shaft housing or seal under any operating conditions. If you fail to do this you may permanently damage the sensor! Attach the supplied cable and route it to the monitoring device. Make sure it is routed securely, away from heat sources and moving parts. The plug must be oriented correctly in the socket. Although it is a keyed plug, it is possible to install it incorrectly. The release tab is toward the outside of the controller.

CONNECTING THE DYNO-SHAFT

The Dyno-Shaft uses the AEMnet electrical interface. AEMnet is an open architecture software and hardware interface based on the CAN 2.0 specification, which provides the ability for multiple enabled devices to easily communicate with each other through a single cable. The hardware connection is made through a Deutsch 4P DTM connector and contains 12-volt switched power and ground (2A max) as well as the CAN data lines. Devices connected to the AEMnet transmit data through this one connection and most of these devices receive power from this same connection as well. The preferred connection for the Dyno-Shaft is the AEM AQ-1 Data Logger. It includes the mating connector in its harness and no wiring is required.

CONNECTING THE DYNO-SHAFT TO AN AQ-1 DATA LOGGER
The preferred device for configuring & logging the Dyno-Shaft is the 30-2500, AQ-1 Data Logger (sold separately). This logger has been pre-configured for the Dyno-Shaft and already has the AEMnet connector preinstalled so there is no wiring required. If using the AQ-1 Data Logger, simply connect the Dyno- Shaft connector to the AEMnet connector on the AQ-1 Harness. Within the AQ-1 setup software, the AEMnet page is used to select what parameters are logged from the AEMnet. Devices connected to AEMnet are automatically detected and configured when the Auto Discover button is pressed.

AEMnet Dyno-Shaft Parameters

• Speed – Driveshaft speed in rpm
• Torque – Driveshaft torque in ft-lbs
• Power – Driveshaft power in HP
• Control Volts – Voltage measured at the controller, volts
• Tank Volts – Charge voltage for transformer circuit, volts
• Sensor Volts – Voltage level generated in the sensor, volts
• Power Level – Power transmitted to sensor from controller, percent
• Sensor Temp – Temperature measured inside the sensor, degrees F
• Frequency – Drive frequency of the transformer circuit, Hz
• Control Temp – Temperature measured inside the controller, degrees F
• S-Firm Error – Indicates if there is a firmware error in the sensor 1 = Yes, 0 = No
• C-Firm Error – Indicates if there is a firmware error in the controller 1 = Yes, 0 = No Zero Offset OK – Indicates the Auto Zero was successful, 1 = Yes, 0 = No
• Good Cal – Indicates the sensor calibration was successfully read 1 = Yes, 0 = No
• LED Aligned – Indicates optical pickups on sensor and controller are aligned, 1 = Aligned, 0 = not aligned
• Auto Zero – Auto Zero on or off, 1 = On, 0 = Off

Using the Dyno-Shaft
After the first few times the Dyno-Shaft is used, the sensor’s zero value will need to be reset as brand-new yokes will twist slightly before they take a final set. This is especially prevalent on the sportsman yokes. You can check to see if the Dyno-Shaft needs to be zeroed by putting the vehicle in neutral, brakes off, and monitoring the torque value with no load applied to the driveshaft. A typical value will be less then +/- 2 ft-lbs. Resetting the zero value is discussed in the section on Dyno-Shaft configuration. New Dyno-Shafts can take an initial set of 100 lbs or more after the first few hard pulls but then settle down to a repeatable value quickly thereafter.

Configuring the Dyno-Shaft
The Dyno-Shaft is configured using the AEM Dyno-Shaft Configuration window. To access the configuration window, right-click on the Dyno-Shaft in the AEMnet page window and select Config.

The AEM Dyno-Shaft Configuration window lists the firmware/hardware versions, as well as the zero options. The “Zero” button is used to manually reset the zero value of the Dyno-Shaft. The Auto Zero function allows the Dyno-Shaft to automatically reset the zero value on power up. Auto Zero Mode is used to turn the Auto Zero function on or off. The Auto Zero Threshold option sets the threshold for which Auto Zeroing is active. Auto Zero Threshold is a digital value in “counts”, where three counts is approximately 1 ft-lb of torque. The Dyno-Shaft will not Auto Zero if the initial torque reading exceeds the Auto Zero Threshold.

Viewing Dyno Plots Created by the AQ-1
The AQ-1 data log file is viewed from within AEMData. The Dyno Plot view allows multiple vehicle power and torque data set to be overlaid in a special “Dyno Plot” configuration for use with AEM’s Dyno-Shaft drive line torque measurement system. Also, two additional channels may be plotted against the same X-axis in a separate graph area.

Configuration
To display the configuration dialog, click the configure button on the Dyno Plot window or right-click on the view and select ‘Configure Dyno Plot…’.

Channel Options
Channel settings are displayed on the first tab of the Dyno Plot Configuration dialog.

The channels that are used to generate the plot are selected from here.

• Drive Power – Defaults to “DS Power”. This is the log channel that contains the calculated power data.

• Drive Torque – Defaults to “DS Torque”. This is the log channel that contains the measured torque data.

• Drive Speed – Defaults to “DS Speed”. log channel that contains the drive shaft RPM.

• Engine Power – Not currently used.

• Engine Torque – Not currently used.

• Engine Speed – This channel contains the engine RPM data. If this data is available then it is used to dynamically calculate engine torque & horsepower. If this channel is not available then engine torque & horsepower will only be available in a single gear using a user-specified transmission ratio.

• 2nd Plot A – The 1st of 2 log channels that will be displayed on the secondary graph.

• 2nd Plot B – The 2nd of 2 log channels that will be displayed on the secondary graph.
  Plot Mode X – Defaults to “Drive Shaft Speed”. There are four options for the X-Axis:

• Drive Shaft Speed, where the Power and Torque will be plotted on the Y-axis vs drive shaft speed on the X-axis. This is the default setting.

• Engine Speed, Power and Torque will be plotted on the Y-axis versus engine RPM on the X-axis. For this mode to be used either an Engine Speed channel has to be
  defined above or a transmission ratio must be specified. The transmission losses specified by the user will be used to correct the engine torque values.

• Vehicle Speed, Power and Torque is plotted versus vehicle speed on the X-axis. For this mode to be used the final drive ratio and tire diameter must be specified.

• Wheel Speed, Power and Torque is plotted versus wheel RPM on the X-axis. For this mode to be used the final drive ratio must be specified

Plot Mode Y – Defaults to “Drive Torque/Power”. There are two options for the X-Axis:

• Drive Torque/Power, Plots raw drive shaft torque values. These values will typically be much higher than the engine values due to the gear reduction in lower gears.
• Engine Torque/Power, Plots calculated engine torque and power. Requires either an Engine Speed log channel or gear ratio to be entered as well as transmission losses.
  • Smoothing – Applies a smoothing factor to the data.
  • 2nd Plot Split – Defines how much of the plot height is devoted to the primary plot.
  • Draw Legend – If checked then the summary info is shown on the bottom of the plot.
  • Atmospheric Power Correction – The method of power correction due to atmospheric conditions is selected here.

Drive train Options
The drive train options are set on the Drive Tab.

Transmission Ratios

• Engine/Drive Ratio – If you don’t have an engine RPM log channel selected in Engine Speed (above) but you want to get engine Power and Torque values you can enter a gear ratio here for the gear used to test in. Overdrive gears are less than 1. If this method is used the Engine power and torque values are only accurate in that gear.
• Final Drive Ratio – Enter the final drive ratio here if you want to plot versus vehicle speed or wheel speed. Example numbers: 4.11, 3.73, etc…
• Tire Diameter – Enter the tire diameter here if you want to plot versus vehicle speed.

Transmission Losses

• Percentage – This amount of power is assumed to be consumed by the transmission. Default is 12%
• Run Options – Data file to be used is selected in the Run 1 and Run 2 tabs.
• Plot Run 1/Plot Run 2 – Defines if this data is displayed on the plot.
• Data – Select the log file you wish to use. Using the selection tool, highlight the area of a trace/graph. Once selected, click “fixed range” to lock in the time span.
• Run Info – The date from the source file is entered but you can also override it.

Atmospheric Conditions

• Temperature – Enter the ambient test temperature here.
• Pressure – Enter the ambient pressure during the test here.
• Relative Humidity – Enter the relative humidity during the test here.
• Axis – The min & max value for all axis can be set under the Axis tab.
• Colors – The chart colors can be defined on the Colors tabs.

Print Options – A user defined logo can be added to the hard copy of the dyno printout. This is selected on the Print Options. A formatted Dyno Plot can be sent directly to a printer by right clicking on the Dyno Plot window and selecting Print Dyno Plot. A specially formatted screen capture can be saved as a png graphics file as well. Right click on the Dyno Plot window and select Print to File.

CONNECTING THE DYNO-SHAFT TO A SERIES 2 EMS
When hooking the Dyno-Shaft to a Series 2 EMS, it is easiest to use the optional flying lead adapters AEM has created that have been pre-pinned with the correct ECU terminals for the CAN Bus pins.

AEM Series 2 EMS| AEMnet Adaptor P/N| CAN1L

Pin Location

| CAN1H

Pin Location

---|---|---|---
30-6030| 30-3430| C22| C21
30-6040| 30-3431| A22| C2
30-6050| 30-3432| D14| D10
30-6051| 30-3432| D14| D10
30-6052| 30-3432| D14| D10
30-6053| 30-3432| D14| D10
30-6060| 30-3432| C28| C29
---|---|---|---
30-6100| 30-3433| 11A| 12A
30-6101| 30-3433| 11A| 12A
30-6300| 30-3434| 75| 13
30-6310| 30-3431| 77| 87
30-6311| 30-3431| 57/77| 67/87
30-6320| 30-3435| 33| 13
30-6600| 30-3436| 42| 12
30-6601| 30-3436| 42| 12
30-6610| 30-3437| 12| 69
30-6611| 30-3437| 12| 69
30-6620| 30-3437| 57| 40
30-6820| 30-3438| B29| B28
30-6821| 30-3438| B29| B28

Selecting the Dyno-Shaft from the wizards in AEMTuner will auto-configure the CAN bus receive channels. The data recorded will be available as standard channels within the data log file. The power and ground pins on the adapter should be connected to a Switched 12V source and Ground capable of providing a sustained 1 amp current.

CONNECTING THE DYNO-SHAFT TO A 3rd PARTY DISPLAY OR LOGGER
Most displays and ECUs that can be configured to monitor user-defined CAN data can be used to capture Dyno-Shaft data as well. The Dyno-Shaft harness has an AEMnet “Y” adapter containing both male and female connectors of the AEMnet connector

• Connector Body: Deutsch DTM06-4S
• Terminals: Deutsch 1062-20-0222 with WM-4S Lock
• Connector Body: Deutsch DTM04-4P
• Terminals: Deutsch 1060-20-0222 with WM-4P Lock
• These two connectors are mates of each other so if you are wiring it into an external
• device pick one and use the P/N’s of the other to determine the required mate.

Dyno-Shaft/AEMnet Pin-out

• Pin 1, White, CAN High
• Pin 2, Green, CAN Low
• Pin 3, Red, Switched 12V. (draws up to 1 amp when active)
• Pin 4, Black, Battery Ground

DYNO-SHAFT CAN 2.0 MESSAGE STRUCTURE

Configure the CAN message receive function on your device according to the manufacturer’s specific directions using the following Dyno-Shaft message structure. CAN 2.0, 29 bit format, 500 kBit/sec, 8 data bytes, big Endian

• Message ID : 0x00000160
• Transmit Rate : Every 65 ms

1 rpm/bit

| 0|

0 to 65,535 RPM

1
2| Driveshaft Torque|

16 bit signed

|

1 ft‐lb/bit

| 0|

‐32,767 to +32,767 ft‐lb

3
4| Driveshaft Power|

16 bit signed

|

1 HP/bit

| 0|

‐32,767 to +32,767 HP

5
6| Torque Fraction| 8 bit unsigned| 0.00390625 ft‐lb/bit| 0| 0 to 0.99609375 ft‐lb
7| Power Fraction| 8 bit unsigned| 0.00390625 HP/bit| 0| 0 to 0.99609375 HP

• Message ID : 0x00000161
• Transmit Rate : Every 65 ms

1 rpm/bit

| 0|

0 to 65,535 RPM

1
2| Driveshaft Torque|

16 bit signed

|

0.00390625 ft‐lb/bit

| 0|

‐128 to +128 ft‐lb

3
4| Driveshaft Power|

16 bit signed

|

0.00390625 HP/bit

| 0|

‐128 to +128 HP

5
6| ‐‐‐| ‐‐‐| ‐‐‐| ‐‐‐| ‐‐‐
7| ‐‐‐| ‐‐‐| ‐‐‐| ‐‐‐| ‐‐‐

SPECIFICATIONS

Dyno-Shaft

driveshaft limit.

RECOMMENDED PARTS

• 30-2500 AQ-1 Data logger
• 30-2501 AQ-1 Data logger with OBD-2
• 30-2340 4 Channel UEGO Controller
• 30-5130 Analog Gauge Style UEGO Controller
• 30-4100 Digital Gauge Style UEGO Controller

REPLACEMENT PARTS

• 35-4780 Dyno-Shaft/AEMnet “Y” Harness

WARRANTY

12 MONTH LIMITED WARRANTY
Advanced Engine Management Inc. warrants to the consumer that all AEM High- Performance products will be free from defects in material and workmanship for twelve (12) months from the date of the original purchase. Products that fail within this 12-month warranty period will be repaired or replaced at AEM’s option when determined by AEM that the product failed due to defects in material or workmanship. This warranty is limited to the repair or replacement of the AEM part. In no event shall this warranty exceed the original purchase price of the AEM part nor shall AEM be responsible for special, incidental or consequential damages or costs incurred due to the failure of this product. Warranty claims to AEM must be transportation prepaid and accompanied by dated proof of purchase. This warranty applies only to the original purchaser of the product and is non-transferable. All implied warranties shall be limited in duration to the said 12-month warranty period. Improper use or installation, accident, abuse, unauthorized repairs or alterations void this warranty. AEM disclaims any liability for consequential damages due to breach of any written or implied warranty on all products manufactured by AEM. Warranty returns will only be accepted by AEM when accompanied by a valid Return Goods Authorization (RGA) number. The product must be received by AEM within 30 days of the date the RGA is issued. Please note that before AEM can issue an RGA for any product, it is first necessary for the installer or end user to contact the AEM Performance Electronics tech line at 1-800- 423-0046 to discuss the problem. Most issues can be resolved over the phone. Under no circumstances should a system be returned or an RGA requested before the above process transpires. Need additional help? Contact the AEM Performance Electronics tech department at 1-800-423-0046 or tech@aempower.com, or visit the AEM Performance Electronics forum at http://forum.aempower.com/forum/

References

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