Sensor Docking Station SENSOR DOCKING STATION MANUAL 40385 40383 40384 Part # 40383 40384 40385 Sensor Docking Station Sensor Docking Station with Pyrometer Sensor Docking Station with Air/Fuel Works with the following products 40420 Triple Dog GT Diesel 40425 Triple Dog GT Diesel (50 state legal version) 40410 50 State Legal GT Gas 40400 WatchDog (white) 40415 Triple Dog GT Gas 40430 GT for Hemi Plus 40440 GT for Jeep Plus 40450 GT T+ for Toyota 40402 WatchDog (black) (Units must be at software ve
Sensor Docking Station Introduction The Bully Dog Sensor Docking Station connects aftermarket sensors to your GT or WatchDog. The Sensor Docking Station does not work with monitoring or tuning products that are not manufactured by Bully Dog. See page 9 for information about the types of sensors that will work with the Sensor Docking station. IMPORTANT NOTE: To work properly with the Sensor Docking Station, all GTs and WatchDogs must be updated to the following software version (or newer): Light Duty: 1.1.
Sensor Docking Station Parts List 40383 (No O2 sensor support - Pyrometer not included) Sensor Docking Station with Power Harness.................. (4-40383) Ring Terminal........................................................ (40383-4) Fuse Tap................................................................ (40400-20) Spade.................................................................... (40400-21) Dielectric Grease...................................................
Sensor Docking Station 40385 (O2 sensor support - Pyrometer not included) Sensor Docking Station O Support and Power Harness...... (4-40385) Ring Terminal........................................................ (40383-4) Fuse Tap................................................................ (40400-20) Spade.................................................................... (40400-21) Dielectric Grease................................................... (40383-3) 2″ Square Hook and Loop Fastener..........
Sensor Docking Station Parts Description Sensor Docking Station (40383 and 40384) The Sensor Docking Station provides a way to connect your GT or WatchDog to aftermarket sensors that you have installed on your vehicle. In addition to the docking ports (which are explained on page 9), the Sensor Docking Station has five important features which are clearly labeled on the photograph below.
Sensor Docking Station Sensor Docking Station (40385) The Sensor Docking Station provides a way to connect your GT or WatchDog to aftermarket sensors that you have installed on your vehicle. In addition to the docking ports (which are explained on page 9), the Sensor Docking Station has six important features which are clearly labeled on the photograph below.
Sensor Docking Station Power Harness The power harness connects the Sensor Docking Station to the fuse box and the battery and chassis grounds in your vehicle. For more information about installing the power harness, see page 14. Power Wire Ground Wires POWER Harness Plug O2 Sensor Cable NOTE: This part is only included with 40385. The O2 Sensor cable connects a Bosch oxygen sensor (see page10) to the Sensor Docking Station .
Sensor Docking Station Pyrometer This analog sensor will measure exhaust gas temperature. The Bully Dog pyrometer has three important features: (1) the temperature probe with the top nut, (2) the fitting and (3) the sensor wires that connect to the Sensor Docking Station. NOTE: The pyrometer cannot be extended with ordinary wire. IMPORTANT NOTE: It is possible to accidentally reverse the fitting.
Sensor Docking Station Ring Terminal The ring terminal provides a secure ground connection for the ground wires in the power harness. Fuse Tap and Spade Use these to connect the power cable to your vehicle’s fuse box. For step-by-step instructions, see page 17. Dielectric Grease Use the dielectric grease to prepare the power harness plug and create a water resistant connection.
Sensor Docking Station Docking Ports and Sensors The Sensor Docking Station has 12 ports that will accept 22-12 gauge wire (stripped). The length of exposed wire for successful docking is 3/8″. NOTE: For information about purchasing compatible sensors, go to page 37. P1 P2 AN1 AN3 OUT + - + - F +5v IN Y+ R- Y+ R- + - AN2 P1 and P2: These are pyrometer docking ports; they will appear as Pyro 1 and Pyro 2 on the GT or WatchDog Gauge Setup menu. Use this port to connect a Bully Dog pyrometer probe.
Sensor Docking Station F (IN): The F/IN port supports 5 volt and 5000 Hertz pulse output sensors; it will appear as FREQUENCY in the Gauge Setup menu on the GT or WatchDog. A two-wire speed sensor (optical or magnetic) is the typical sensor type that would be used with this port. NOTE: For the information from frequency sensors to be displayed properly, further setup and specifications from the sensor manufacturer are required.
Sensor Docking Station Pyrometer Installation Installing a pyrometer can be difficult because the exhaust system must be drilled and tapped. Bully Dog recommends that you utilize professional assistance if you have not had experience with drilling and tapping. Choosing a Location: Pre-Turbo vs. Post-Turbo The location of the pyrometer probe will make a significant difference in the exhaust gas temperature that is measured and displayed on the GT or WatchDog.
Sensor Docking Station Post-Turbo Pre-Turbo Installing the Pyrometer Pre-Turbo 1. Choose the pyrometer location. It should be about 3″ in front of the turbo charger exhaust inlet where all the exhaust runners of the manifold have come together into a single pipe. Try to be within 1″ of the 3″ target. 2. Drill a 5/16″ hole into the exhaust system. (See the tool tips on page 13 for important strategic hints.) 3. Use a 1/8″ pipe tap to thread the hole. 4. Place the pyrometer probe in the hole. 5.
Sensor Docking Station 7. Run the pyrometer cable through the engine bay to the place where it will be connected to the Sensor Docking Station. • Be sure to protect the cable from extreme heat and moving parts. • Use some of the included zip ties to keep the cable secure inside the engine bay. (You may want to set some zip ties set aside for mounting the Sensor Docking Station.) Tool Tips: When drilling into the exhaust manifold, debris like metal shavings and broken drill bits can fall inside.
Sensor Docking Station Post-Turbo 1. Choose the pyrometer location. It should be about 3″ downstream from the turbocharger exhaust outlet. Try to be within 1″ of the 3″ target. 2. Drill a 5⁄16″ hole into the exhaust downpipe. 3. Use a 1⁄8″ pipe tap to thread the hole. 4. Mount the pyrometer probe in the hole. 5. Use a 9⁄16″ wrench to tighten the tapered end of the fitting to the exhaust downpipe. 6. Use a 5⁄8″ wrench to tighten the top nut on the pyrometer to the fitting. 7.
Sensor Docking Station Sensor Docking Station Installation IMPORTANT: Physical installation of the Sensor Docking Station should always begin with installing the pyrometer (and any other sensors). This is because the pyrometer cable length is limited and will affect the final position of the sensor docking station. For more information on installing the pyrometer, see pages 11-14. 1. Prepare the power harness. a. Crimp a ring terminal on the black chassis ground wire. b.
Sensor Docking Station 3. Locate a firewall hole. a. You will need to run a USB cable from the Sensor Docking Station in the engine compartment to your GT or WatchDog in the cab. b. An unused firewall hole might be covered with a rubber grommet. If so, it might be necessary to use a straightened wire hanger to punch through. 4. Choose a secure location for the Sensor Docking Station. a. All of the wires must reach the location (pyrometer, power and additional sensors). b.
Sensor Docking Station 7. Attach the power harness ground connections. a. Fasten the black chassis ground wire to the vehicle frame. • Use the designated ground bolt. • If the designated ground bolt is not available, use a stock frame bolt. b. Fasten the white battery ground wire to the negative battery terminal. 8. Connect the power harness to the fuse box. a. Remove the key-on fuse that you located during Set Up (see page 15). b. Slide the fuse tap over one metal prong on the fuse. c.
Sensor Docking Station Power wire harness Installation Diagram 10. Connect the sensor(s) to the Sensor Docking Station. a. Simply insert the bare wire leads straight into the docking ports. b. An internal mechanism will clamp down on the leads to hold them in place.
Sensor Docking Station 11. Connect the Sensor Docking Station to the Adapter Plug for your GT or WatchDog. DO NOT connect the Mini-USB plug directly to the GT or WatchDog. c. Run the USB cable through the firewall hole. d. Light Duty: Insert the Mini-USB plug into the port on the adapter plug for the GT or WatchDog.
Sensor Docking Station Heavy Duty: Insert the Mini-USB plug into the pigtail port on the HDMI cable for the GT or Watchdog. If your HDMI cable does not have a pigtail, contact technical support (see page 38). HEAVY DUTY HDMI CABLE WITH Mini-USB PIGTAIL PORT Sensor Docking Station Mini-USB plug 12. Complete the System Status Check described in the next section (page 21).
Sensor Docking Station Status Check The Sensor Docking Station (SDS) has a green light that will light up in different ways depending on how the SDS is working and communicating with your GT or WatchDog. PWR Solid Green Light The Sensor Docking Station is working and communicating properly with the GT or WatchDog. Blinking Green Light The Sensor Docking Station is powered up and trying to communicate with the GT or WatchDog. • Check the connection to the GT or Watchdog.
Sensor Docking Station Sensor Setup and Calibration IMPORTANT NOTE: All Light Duty GTs and WatchDogs must be updated to software version 1.1.4.0 or later to work properly with the Sensor Docking Station. All Heavy Duty GTs and WatchDogs must be updated to software version 1.0.3.6 or later to work properly with the Sensor Docking Station. Pyrometer Wiring There are two openings on each pyrometer docking port. Plug the yellow wire into the Y+ opening. Plug the red wire into the R- opening.
Sensor Docking Station Pyrometer Setup There are two options for the pyrometer setting: factory or BD (Bully Dog) pyro. All GTs and Watchdogs have the factory pyro selected as a default setting and are only available for 2007.5 and newer. You will need to change this setting to have the GT or WatchDog display the temperature readings from the Bully Dog pyrometer and Sensor Docking Station. Light Duty Gas GT: 1. Choose Vehicle Settings from the Main Menu. 2.
Sensor Docking Station Heavy Duty Display Bully Dog Pyro on Main Screen: You may have to change the main screen to show at least two gauges. To do this, hold down the bottom left button until the screen shows the gauge arrangement that you prefer. 1. Press the lower left button to highlight the gauge spot where you want to display the Bully Dog pyrometer temperature. 2. Use the buttons on the right to scroll until BD Pyro 1 (or 2) is shown.
Sensor Docking Station Pyrometer Setup: Heavy Duty (continued) Use the Bully Dog Pyrometer for Warning Levels: You can use the Bully Dog pyrometers in addition to (or instead of) the factory installed pyrometers for the temperature warnings on your GT or WatchDog. 1. Choose Vehicle Setup or Vehicle Settings from the Main Menu. 2. Choose Set Warning Levels from the Vehicle Settings menu. 3. Use the buttons on the right to scroll through the options and highlight BD Pyro 1 (or 2) Temp. Level. 4.
Sensor Docking Station Pyrometer Calibration In order to prevent heat damage to your engine, use the following calibration procedure to determine the best temperature to use for your GT or WatchDog defueling or temperature warning level setting. 1. Make sure that your vehicle is running at stock horsepower. • If you have installed a tune it will need to be uninstalled (see your GT owner’s manual for more information on how to do this).
Sensor Docking Station Analog Sensor Wiring There are two openings on each analog sensor docking port. The AN+ dock supports a 0-5 volt signal wire from the sensor. The AN- dock is an optional ground connection; however, it is recommended that you use the chassis ground if a sensor requires a ground connection. (This should be the same chassis ground used for the power harness.) The diagram below illustrates the wiring configuration for a three-wire analog sensor. 1. Power in to the sensor.
Sensor Docking Station Analog Sensor Calibration The Bully Dog Sensor Docking Station is capable of supporting different brands of analog sensors. In order to make sure that the information from your particular sensor is being displayed correctly, you will need to change settings in your GT or WatchDog based on the specifications of your sensor. To calibrate the Sensor Docking Station for an analog pressure sensor, you will need to know the ratiometric output.
Sensor Docking Station Frequency Sensor Wiring There is only one opening for the frequency sensor docking port. The F IN dock supports a 5 volt, 5000 Hertz pulse output sensor. The ground wire on a typical two-wire frequency sensor should be connected to the same chassis ground that you used for the power harness. The diagram below illustrates the wiring configuration for a two-wire frequency sensor. 1. Signal out from the sensor (5 volt, 5000 Hertz). 2.
Sensor Docking Station Frequency Sensor Set Up (on GT or WatchDog) Normally, your Sensor Docking Station and GT or WatchDog will display information from a frequency sensor on a 1:1 ratio. If you want to change the format of the information, you can multiply or divide that frequency. Light Duty The frequency sensor input settings are located under Set SENSOR Settings in the User Options menu.
Sensor Docking Station Frequency Sensor Setup (continued) The signals for multipliers and divisors can be adjusted from 1-60. Example(s) If your sensor provides data as pulses per second and you want to know how many pulses per minute, set a multiplier of 60. If your sensor provides data as pulses per hour and you want to know how many pulses per minute, set a divisor of 60. Go Back to Main Menu FREQUENCY Set Frequency Multiplier Modifies frequency input value. Up Use the Up/Down arrows to change.
Sensor Docking Station Temperature Sensor Wiring There is only one opening for the auxiliary temperature sensor docking port. The +5V OUT dock supports a 0-5 volt temperature sensor. The ground wire on a typical two-wire temperature sensor should be connected to the same chassis ground that you used for the power harness. The diagram below illustrates the wiring configuration for a two-wire temperature sensor. 1. Signal out from the sensor (0-5 volt). 2.
Sensor Docking Station Temperature Sensor Calibration Bully Dog recommends the GM Delphi 15326386 fluid temperature sensor; the Sensor Docking Station is calibrated for this sensor by default and no additional calibration is required. If a different temperature sensor has been installed, the GT or WatchDog settings need to be changed to the specifications of the sensor. Calibrating the Sensor Docking Station for a fluid temperature sensor requires the calibration resistance of the sensor.
Sensor Docking Station 3. Enter the new resistance value: • Change the digit above the cursor (right buttons). • Light Duty: Use the bottom left buttons to move the cursor left and right. RESISTANCE SAVE Enter the resistance below: 00000048 MOVE RIGHT MOVE LEFT • Heavy Duty: Use the bottom left button to move the cursor to the left. To change a digit to the right of the cursor, use the bottom left button to scroll through all the digits until the cursor is in the right place.
Sensor Docking Station O2 Sensor Installation NOTE: The compatible O2 sensor and bung are not included with the Sensor Docking Station and must be purchased separately. See page 37 for more information about purchasing the correct sensor. If your vehicle has a stock oxygen sensor, it may be possible to replace it with the Bosch sensor that is compatible with the Sensor Docking Station. Check your vehicle owner’s manual or consult a professional at your dealership or local muffler shop for more information.
Sensor Docking Station O2 Sensor Wiring Bully Dog part number 40385 includes a cable which will connect up to two Bosch oxygen sensors to the Sensor Docking Station. Connect the sensor(s) to one of the ports on the double-sided end of the cable. Then connect the plug on the other side of the cable to the Sensor Docking Station. Make sure that the clips on the cable click closed.
Sensor Docking Station Purchasing Compatible Sensors The only O2 sensor that the Sensor Docking Station supports is the Bosch LSU 4.9 wideband O2 sensor (manufacturer part #17025). If you are installing in a new location (rather than replacing a stock sensor), you will also need to purchase a bung; you can request a standard O2 bung from any muffler shop or purchase an M 18 mm x 1.5 mm threaded bung from a different source. This sensor is available online at www.bullydog.com (part #40388).
Sensor Docking Station More Information FAQ Q. Why is the green status check light still blinking? A. Sporadic blink: The power connection is not secure. Check and/or reseat the power cable connections. Constant blink: The GT or WatchDog is not connecting. Update the GT or WatchDog. Check and/or reseat the data connections. • If the light continues to blink, contact technical support. Contacting Technical Support Before Calling Technical Support complete the following steps: •Visit bullydog.
Sensor Docking Station Manual Doc #: 40383_40384_40385-99 v2.7 See More Products from Bully Dog Technologies Cold Air Intakes O2 Sensor #40288 Add the only compatible air/fuel sensor for the Sensor Docking Station. More air, colder and more dense air, more power, better efficiency. Custom Pod Mounts Accessories T-shirts Hoodies Hats Etc. Custom A-pillar and dash mounts for GTs, Watchdogs and PMTs. Free Technical Support at: 866-bullydog (866-285-5936) See More at: bullydog.