©2003-2006 Dynojet Research, Inc. All Rights Reserved. Model 200i and 250i Motorcycle Dynamometer Installation Guide. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, and 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 Warnings Chapter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .vii Specifications and Operating Requirements Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Chapter 2 Installation Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Unpacking and Inspecting Your Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Routing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Positioning and Securing the Dyno . . . . . . .
TA B L E O F C O N T E N T S Chapter 3 Accessories Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Remove and Replace Dyno and Drum Covers . . . . . . . . . . . . . . . . . . . . . . 3-3 Removing the Drum Top and Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Removing the Center Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Chapter 4 Control Panel Interface Operation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Basic Control Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Appendix B Power Requirements Locations Using 60Hz Power (North America & Japan) . . . . . . . . . . . . . . B-2 Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 Hard Wiring to the Building . . . . . . . . . . . . . .
WARNINGS Disclaimers Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability for any particular purpose. Dynojet reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation of Dynojet to notify any person of such revision or changes.
WA R N I N G S Electrostatic Discharge Precautions Electrostatic Discharge Electrostatic Discharge (ESD), or static shock, can damage electronic components within the dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade the component, resulting in a premature component failure later. To avoid ESD damage, always practice good ESD control precautions when servicing the dynamometer.
WA R N I N G S Other Potential Hazards The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for disconnect before service. The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death. Always wear proper ear and eye protection when operating the dynamometer.
CHAPTER 1 SPECIFICATIONS AND OPERATING REQUIREMENTS Thank you for purchasing Dynojet’s Model 200i/250i Motorcycle Dynamometer. Dynojet’s software and dynamometers will give you the power to get the maximum performance out of vehicles you evaluate. Whether you are new to the benefits of a chassis dynamometer or an experienced performance leader, the repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer will give you the professional results you are looking for.
CHAPTER 1 Introduction INTRODUCTION ................................... Before installing your dyno, please take a moment to read this guide for installation instructions, dyno features, and other important information. This guide is designed to be a reference tool in your everyday work and includes the following chapters and information: SPECIFICATIONS AND OPERATING REQUIREMENTS This chapter describes the requirements and specifications for the dyno.
SPECIFICATIONS AND OPERATING REQUIREMENTS 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 RECORD # 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.
CHAPTER 1 Introduction Equalizer Box—If the air flow rate coming into the dyno room is greater than the air flow rate leaving the dyno room, the room will become pressurized. A pressurized dyno room will make measured power misleading. To compensate, you need an equalizer box. The equalizer box is a baffled (to reduce noise) vent to the outside of your dyno room. The size of the equalizer box is dependent on the size of your dyno room and the size of your fans.
SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS ................................... The following specifications and requirements will help you set up your dyno area and verify you have the requirements to operate your dyno safely. BATTERY REQUIREMENTS Your 200i/250i dyno is designed to carry a group 24 deep-cycle discharge series battery for operating the starter, power carriage, and optional wheel clamp.
CHAPTER 1 Dynamometer Specifications and Requirements model 200i carriage: allow 68.33 cm (26.9 in.) extended carriage: allow 119.38 cm (47.0 in.) 45.97 cm (18.10 in.) 152.40 cm (60.00 in.) 202.77 cm (79.83 in.) 106.68 cm (42.00 in.) model 250i 127.74 cm (50.29 in.) 72.92 cm (28.71 in.) carriage: allow 68.33 cm (26.9 in.) extended carriage: allow 119.38 cm (47.0 in.) 45.97 cm (18.10 in.) 179.60 cm (70.71 in.) 202.77 cm (79.83 in.
SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements COMPRESSED AIR REQUIREMENTS The following requirements are needed when the optional air brake is included. • regulator set to 65 psi max (450 kilopascal) • air dryer • shut off valve • gauge on the regulator • 1/4-inch NPT pipe thread connector (to attach air to the dyno) COMPUTER SPECIFICATIONS You will need to provide a computer system to run the WinPEP software. WinPEP 7 includes complete documentation in online Help.
CHAPTER 1 Dynamometer Specifications and Requirements ENVIRONMENTAL REQUIREMENTS description Temperature operating min./max storage min./max Humidity specifications 10°C/50°C (50°F/122°F) 0°C/60°C (32°F/140°F) 0 to 95% non condensing FORKLIFT REQUIREMENTS You will need to provide equipment capable of lifting a minimum of 1,133.98 kg (2,500 lbs.) to lift the dyno off the crate and into position in your dyno room. You will also need a pair of straps capable of supporting 1,133.98 kg (2,500 lbs.
SPECIFICATIONS AND OPERATING REQUIREMENTS Model 200i Motorcycle Dynamometer MODEL 200i MOTORCYCLE DYNAMOMETER ...................................
CHAPTER 1 Model 250i Motorcycle Dynamometer MODEL 250i MOTORCYCLE DYNAMOMETER ...................................
CHAPTER 2 INSTALLATION This chapter will walk you through unpacking and installing the dynamometer. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 2 Dyno Installation DYNO INSTALLATION ................................... The following directions describe how to unpack, and install your dyno. Follow the directions in the order that they are presented. UNPACKING AND INSPECTING YOUR DYNO When you receive your dyno, examine the exterior of the shipping container for any visible damage. If damage is detected at this stage, contact the shipper or Dynojet before proceeding with unpacking. Use the following steps to unload your dyno.
INSTALLATION Dyno Installation 4 Remove the six 1/4-inch screws securing the center panel on the dyno and remove the center panel. Note: Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to remove the 1/4-inch screws. For dynos with serial numbers lower than 2030152, Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap-On FA5E). A standard allen key may round off in the shallow screw head. 5 Remove the tire stop, tire lock, and hardware from the middle of the dyno.
CHAPTER 2 Dyno Installation 6 7 Remove the eight screws securing the top drum cover to the dyno and set aside. Remove the drum cover and set aside. Remove the two top screws securing each side drum cover to the dyno and set aside.
INSTALLATION Dyno Installation 8 Remove the remaining six side screws securing each side drum cover to the dyno and set aside. Remove the side drum covers and set aside. Note: For future reference, note the three access holes in the drum bulkhead. These access holes will be used to route cables when installing accessories once the top cover is back on. RECORD # Be sure you record the dynamometer number on the inside cover of this manual.
CHAPTER 2 Dyno Installation REMOVING THE DYNO FROM THE CRATE You will need to provide equipment capable of lifting a minimum of 1,133.98 kg (2,500 lbs.) to lift the dyno off the crate and into position in your dyno room. You will also need a pair of straps capable of supporting 1,133.98 kg (2,500 lbs.) to attach to the dyno. Dynojet recommends using a single loop style strap. 1 2 Remove the four lag bolts and washers securing the dyno to the crate base using a 9/16-inch socket, open or box end wrench.
INSTALLATION Dyno Installation 3 Route the single loop strap through the lifting eyes in front of the drum as shown in Figure 2-6. Note: The dyno should only be lifted using the lifting eyes. Verify no other part of the dyno is interfering with the strap. Do not place the strap around the cable routing bracket or any other part of the dyno.
CHAPTER 2 Dyno Installation ROUTING THE POWER CABLE 1 2 3 4 Locate the power cable inside the dyno. Slide the strain relief on the power cable through the opening in the dyno frame. Tighten the jam nut. Hand tighten the knurled nut.
INSTALLATION Dyno Installation POSITIONING AND SECURING THE DYNO 1 2 Gently lower the dyno into position. Be sure the location you have chosen for your dyno has enough room in front of the dyno for the maximum extension of the carriage. Refer to “Dynamometer Specifications and Requirements” on page 15 for more information. Secure the dyno to the floor in your dyno room. Note: Skip this step if you will be installing the eddy current brake.
CHAPTER 2 Battery BATTERY ................................... The model 200i/250i dyno is designed to carry a group 24 deep-cycle discharge series battery for operating the starter, optional power carriage, and optional wheel clamp. The typical dimensions for this series of batteries are 27 cm long by 17 cm wide by 23 cm tall (10.625-inches by 6.75-inches by 9.125-inches). The mounting is flexible so a battery that has dimensions close to this will work satisfactorily.
INSTALLATION Pickup Card PICKUP CARD ................................... The pickup card is an electronic circuit board that accurately senses each drum revolution. 1 2 3 4 Locate the pickup card bracket on the right side of the dyno just ahead of the drum. Install the pickup card to the bracket using two No. 8 screws. Do not tighten, the card must be aligned first.
CHAPTER 2 Eddy Current Brake EDDY CURRENT BRAKE ................................... The eddy current brake is an optional accessory. This section will walk you through removing the eddy current brake from the crate, and attaching the brake to your dyno. If you did not purchase the eddy current brake, skip this section and continue with “Installing the Support Arm and Tray” on page 2-21.
INSTALLATION Eddy Current Brake UNPACKING THE EDDY CURRENT BRAKE 1 2 3 Remove the sides of the crate. Remove the four screws securing the top cover and set aside. Remove the cover and set aside. Remove the hardware box and theta controller from the crate and verify the hardware box contents using the parts list. For more information on mounting the theta controller refer to page 2-20. RECORD # Be sure you record the eddy current brake number on the inside cover of this manual.
CHAPTER 2 Eddy Current Brake 4 5 Remove the four bolts securing the brake to the crate. Determine if the brake is to be mounted on the left or right side of your dyno. Make the following adjustments to the eddy current brake only if you want to mount the brake on the opposite side of the dyno that it is currently set up for. 5a 5b 5c Move the coupler and key to the other side of the brake.
INSTALLATION Eddy Current Brake 6 Remove the side drum cover, if not already removed, from the dyno. Refer to Figure 2-4 on page 2-5. 7 Place the nylon loop strap through the lifting eyes on either side of the brake. 8 Using a forklift, lift the eddy current brake from the crate and place the brake near the dyno making sure the panels on the brake and dyno are parallel. 9 Remove the eight bolts, washers, and nuts from the dyno frame where the connector plates will attach.
CHAPTER 2 Eddy Current Brake INSTALLING THE EDDY CURRENT BRAKE The eddy current brake comes with the coupler already installed on the brake shaft. The eddy current brake can be installed on either side of your dyno. The air brake is located on the right side of the dyno. It is not necessary to remove the air brake regardless of which side of the dyno you are installing the eddy current brake: right or left. Note: Safety requirements of your local country may require that both brakes are installed.
INSTALLATION Eddy Current Brake 3 4 5 6 7 8 Keeping the panels parallel, slide the eddy current brake towards the dyno. Slide the coupler over the key on the dyno shaft. You will need to support the coupler as you slide it onto the dyno shaft. Continue sliding the eddy current brake towards the dyno until the covers on the brake and dyno are flush. Secure the retarder connector plate to the dyno frame using the four bolts, washers, and nuts removed earlier.
CHAPTER 2 Eddy Current Brake 9 Secure the side panels on the eddy current brake to the panels on the dyno using a 1/4-20 bolt. Do this on each side. not visible from this view EB144 Figure 2-18: Secure the Side Panels to the Dyno 10 Replace the existing set screws on the coupler with the thread-lock set screws provided. 11 Tighten the coupler set screws.
INSTALLATION Eddy Current Brake SECURING THE DRUM AND BRAKE MODULE TO THE FLOOR Dynojet recommends you anchor the eddy current brake, along with the dyno, to the floor in your dyno room using concrete anchors. You will want to drill the holes and secure the dyno before placing the covers on your dyno. 1 2 3 Mark and drill the holes for the Red Head anchors. Install the Red Head anchors according to the instructions in Appendix A.
CHAPTER 2 Eddy Current Brake INSTALLING THE THETA CONTROLLER The theta controller is the interface between the eddy current brake and the dyno electronics. You will only install the theta controller if you ordered an eddy current brake. You will route the cables to it later. The theta controller is shipped in the eddy current brake crate. 1 2 Verify the theta controller dip switch settings. Refer to Appendix C for more information.
INSTALLATION Support Arm and Monitor Tray SUPPORT ARM AND MONITOR TRAY ................................... This articulated arm and platform supports the monitor, keyboard, and mouse in a convenient position for operation while seated on the motorcycle. The support arm can be mounted on either side of the dynamometer. PARTS LIST The following table lists all of the parts included in the Monitor Stand Installation kit.
CHAPTER 2 Support Arm and Monitor Tray poly washer second arm monitor tray poly washer first arm poly washer support arm MA017 Figure 2-22: Install the Support Arm and Monitor Tray 2-22 Model 200i and 250i Motorcycle Dynamometer Installation Guide
INSTALLATION Dyno Electronics DYNO ELECTRONICS ................................... The standard dyno electronics package is comprised of four interconnected modules: Atmospheric Sensing Module, RPM Module, Dynamometer Input/Output Module, and the CPU Module. For more information about their function refer to your WinPEP 7 User Guide (P/N 98128104).
CHAPTER 2 Dyno Electronics The standard dyno electronics is located inside the dyno electronics enclosure which is already mounted to the dyno chassis as shown in Figure 2-24. Cables which you will route in the next steps are prewired to the dyno electronics or to the CPI. You will connect the free ends of the cables to the appropriate devices.
INSTALLATION Routing Cables ROUTING CABLES ................................... For the following instructions, the support arm and control panel are shown mounted on the right side of the dyno. ROUTING THE PENDANT, RS232 COMPUTER CABLE, AND CONTROL PANEL CABLE 1 2 3 4 5 Remove the two screws securing the cable pass through cover (shown in Figure 2-25) closest to the monitor support and set it aside. The cables you will route will be coiled inside the chassis.
CHAPTER 2 Routing Cables 6 Locate the control panel and ready it to connect the control panel cable. The control panel ships in a separate container inside the dyno. 6a Remove the two nuts from the top of the cover and set aside. 6b Remove the screw on the top of the cover and set aside. 6c Remove the screw on the side of the cover and set aside. 6d Remove the four screws on the back of the cover and set aside. 6e Remove the control panel rear cover and set aside.
INSTALLATION Routing Cables 7 8 Route the control panel cable through the access hole on the side of the control panel box and through the cable tie. Attach the control panel cable to the Button board. access hole button board control panel cable with cable harness wrap cable tie Figure 2-27: Attach the Control Panel Cable to the Button Board 9 Secure the rear cover to the control panel. 9a Replace the four screws on the back of the cover removed earlier.
CHAPTER 2 Routing Cables 10 Secure the control panel to the monitor tray using two 8-32-inch screws. Note: If you did not order a monitor tray, install the control panel spindle to the back of your control panel using four 8-32 screws. Once installed, place the spindle on the control panel into the support arm where the monitor tray is shown in Figure 2-29.
INSTALLATION Routing Cables 11 Place the pendant in the slot provided on the control panel and route the cable bundle along the support arms with service loops to allow movement. 12 If you plan to route your cables through a zip tube refer to “Zip Tube” on page 244 and skip the following steps. 13 Attach the cable bundle with the cable clamps that are provided using 8-32-inch screws. Adjust the service loops to allow for easy movement of the monitor arms without pulling on the cables.
CHAPTER 2 Routing Cables ROUTING THE EDDY CURRENT BRAKE CABLES With the center panel off, now is a good time to connect and route the theta controller cables. You will only have a theta controller if you installed the optional eddy current brake accessory, see Figure 2-21 on page 2-20. 1 2 3 4 Attach the input power cable (P/N 66952004) to the top of the theta controller. Route the eddy current brake cable (P/N 66952003) from the eddy current brake to the bottom of the theta controller.
INSTALLATION Routing Cables WIRING THE BREAKOUT BOARD 1 Attach the temperature sensor cable to the Breakout board. The temperature sensor cable has five wires which connect to the wiring block labeled TEMP. This cable was routed to the Breakout board on page 2-30. • Green wire connects to G1 • White wire connects to W1 • Black wire connects to B1 • Red wire connects to R1 • Ground (shield) wire connects to S1 2 Attach the theta controller cable to the Breakout board, if it is not already connected.
CHAPTER 2 Routing Cables ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES The power carriage and wheel clamp are optional accessories. These cables will only be used if you ordered the accessories. For installation instructions refer to “Power Carriage” on page 3-42 and “Wheel Clamp” on page 3-47 for more information. 1 2 3 Remove the two screws securing the cable pass through cover on the front of the dyno and set aside. Locate the cables bundled inside the dyno.
INSTALLATION Routing Cables 4 5 6 Place a split snap bushing around the wheel clamp cable and secure into place in one hole on the cable pass through cover. Place a split snap bushing around the power carriage cable and secure into place in the other hole on the cable pass through cover. Secure the cable pass through cover to the dyno with the two screws removed earlier.
CHAPTER 2 Tire Carriage Installation .TIRE . . CARRIAGE . . . . . . INSTALLATION .......................... Be sure the location you have chosen for your dyno has enough room in front of the dyno for the maximum extension of the carriage. Refer to “Dynamometer Specifications and Requirements” on page 1-5 for more information. If you ordered the extended wheel carriage accessory, refer to “Installing the Extended Carriage Support Bracket” on page 3-31 and install it at this time.
INSTALLATION Tire Carriage Installation 4 5 Remove the four 1/4 x 20-inch button-head screws securing the bearing bracket. Remove the bearing bracket and the carriage screw.
CHAPTER 2 Tire Carriage Installation 6 7 Starting from the back of the dyno, slide the carriage under the carriage clamps. Slide the carriage screw and the bearing bracket toward the nut block until the carriage screw is touching the nut block. 8 Slide the hand crank onto the end of the carriage screw. 9 Secure the hand crank to the screw shaft by tightening the set screw using a 5/32-inch allen wrench. 10 Using the hand crank, screw the carriage through the nut block and into the screw support bracket.
INSTALLATION Tire Carriage Installation 12 Secure the tire stop to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts. Note: If you purchased the wheel clamp accessory, refer to “Wheel Clamp” on page 3-47 for installation instructions. 13 Secure the tire lock to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts.
CHAPTER 2 Drum Side and Top Covers DRUM SIDE AND TOP COVERS ................................... Before replacing the covers, be sure to install the battery, pickup card, eddy current brake, and any accessories you may have purchased with your dyno. Refer to Chapter 3 for accessory installation instructions. 1 Secure each side drum cover to the dyno using six of the screws you removed earlier.
INSTALLATION Drum Side and Top Covers 2 3 4 Secure the top of the side drum covers with the screws you removed earlier. Refer to Appendix D and install and adjust the finger guards if they are required in your location. Secure the top drum cover to the dyno using the eight screws removed earlier.
CHAPTER 2 Ramp Bracket RAMP BRACKET ................................... The ramp bracket allows you to attach your own ramp to the dyno. You will need to modify your ramp to secure it to the ramp bracket. 1 2 With the ramp upside down, center the ramp bracket under the lip at the top of the ramp. Using the larger holes on the bracket, mark and drill two 3/8-inch holes in the ramp.
INSTALLATION Ramp Bracket 3 Insert the 3/8-inch bolts from the top of the ramp and secure using 3/8-inch washers and nuts. Figure 2-42: Secure the Bolts to the Ramp 4 5 Remove the four 1/4-inch bolts from the rear of the drum cover. Secure the ramp bracket to the rear drum cover using the bolts you just removed.
CHAPTER 2 Ramp Bracket 6 Place the ramp on the ramp bracket slipping the bolts on the ramp through the large holes on the ramp bracket.
INSTALLATION Ground Hooks GROUND HOOKS ................................... You may wish to install additional ground hooks (included with your dyno) for securing the motorcycle. Use the following instructions as a guide in placing your ground hooks. 1 2 Locate each ground hook approximately 96.5 cm (38 inches) from the front of the dyno and approximately 20 cm (8 inches) from the side of the dyno (approximately 152.40 cm, 60 inches, apart).
CHAPTER 2 Zip Tube ZIP TUBE ................................... The zip tube encases the multiple cables running to the control panel. You will need to use the cable wrap tool (P/N 16510001) to insert the cables into the zip tube. 1 2 Rotate the cable holder to the open position. Insert the cable(s) into the cable holder.
CHAPTER 3 ACCESSORIES This chapter discusses the various optional accessories that are available for the Dynojet Motorcycle Dynamometer (dyno) to meet your individual needs. All of these options can be added at the factory at the time of original dyno purchase, or purchased separately and added at any time thereafter. For more information about these accessories, please contact Dynojet’s Product Specialist’s at 1-800-992-3525 for pricing and availability.
CHAPTER 3 Main Dyno Power MAIN DYNO POWER ................................... Many instructions in this guide will require you to connect or disconnect the power to the dyno as part of the installation process. Use the following steps to connect and disconnect power to the dyno. Note: Before you plug in your dyno, you or your electrician must refer to Appendix B for detailed power instructions. Always turn the power off when connecting and disconnecting cables.
ACCESSORIES Remove and Replace Dyno and Drum Covers REMOVE AND REPLACE DYNO AND DRUM COVERS ................................... You will need to remove and replace the drum top and side covers along with the dyno center panel to access many of the accessory areas. Refer to the following instructions. REMOVING THE DRUM TOP AND SIDE COVERS 1 2 3 Turn off the dyno and disconnect the AC power cord from its power source. Refer page 3-2.
CHAPTER 3 Remove and Replace Dyno and Drum Covers 4 Remove the remaining six screws securing each side drum cover to the dyno and set aside. Remove the side drum covers and set aside. Note: For clarity, only the removal of the right side drum cover is shown.
ACCESSORIES Remove and Replace Dyno and Drum Covers REMOVING THE CENTER PANEL 1 2 3 Remove the four 1/4-20 x 5/8-inch pan head screws securing the bearing bracket to the tire carriage and set aside. Using the hand crank, unscrew the bearing bracket and the carriage screw and set aside. Remove the tire carriage by sliding the carriage under the carriage clamps toward the back of the dyno and set aside.
CHAPTER 3 Remove and Replace Dyno and Drum Covers 4 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps and shims and set aside. 5 Remove the three carriage clamps and shims and set aside. 6 Remove the two 5/16-inch bolts and washers securing the nut block and shim and set aside. 7 Remove the nut block and shim and set aside. 8 Remove the six 1/4-20 x 5/8-inch pan head screws securing the center panel to the dyno carriage and set aside.
ACCESSORIES Air Brake AIR BRAKE ................................... The air brake comes installed and ready to use. You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the dynamometer. Once air pressure is connected and the air brake cable is routed, the air brake is ready to use.
CHAPTER 3 Air Brake ROUTING THE AIR BRAKE CABLE AND AIR HOSE 1 2 Open the CPI front panel to access the breakers and Breakout board. Route the air brake cable from the air brake solenoid to the CPI. Note: The CPI end of the air brake cable splits in two. 3 Connect the cable with the two black wires to the Breakout board wiring block labeled BRAKE. Attach the 4-pin connector to port P7 on the CPI board.
ACCESSORIES Air Brake 5 6 Route the air hose from the air brake through the access hole in the drum module upright, under the carriage frame brace, and connect to the bulkhead fitting at the front of the dyno. You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the dynamometer.
CHAPTER 3 Air Brake INSTALLING THE EMERGENCY STOP STICKER A properly installed air brake option adds an emergency stop function to the dyno shutdown button. With the air brake installed, activating the dyno shutdown button applies the brake and stops the drum. Installing the emergency stop sticker indicates the added functionality applied to the dyno shutdown button. 1 Remove the control panel rear cover. 1a Remove the two nuts from the top of the cover and set aside.
ACCESSORIES Air Brake 2 Remove the Button board. 2a Remove the four screws securing the Button board to the control panel and set aside. 2b Remove the Button board and set aside. button board screw Figure 3-10: Remove the Button Board 3 Unscrew the black switch body nut and remove the switch body. Set the nut and switch body aside.
CHAPTER 3 Air Brake 4 Place the emergency stop sticker over the dyno shutdown sticker.
ACCESSORIES Air Brake 5 Secure the switch body to the control panel using the switch body nut removed earlier. switch body switch body nut control panel Figure 3-13: Replace the Emergency Stop Button 6 Secure the Button board to the control panel using the four screws removed earlier.
CHAPTER 3 Air Brake 7 Secure the rear cover to the control panel. 7a Replace the four screws on the back of the cover removed earlier. 7b Replace the screw on the top of the cover removed earlier. 7c Replace the screw on the side of the cover removed earlier. 7d Replace the two nuts removed from the top of the cover removed earlier.
ACCESSORIES Air Brake CHANGING THE BRAKE PADS To prevent possible injury, open the CPI door and set the main breaker to the off position and unplug the dyno. Refer to Figure 3-1 for breaker location. 1 2 3 Remove the top and right side covers from the dyno. Refer to page 3-3. For safety, apply the brake and disconnect the air supply at the front of the dyno. Refer to Figure 3-6 on page 3-7. Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor.
CHAPTER 3 Air Brake 4 Using a 9/16-inch ratchet and wrench, remove the bolt, washer, and nut securing the spring to the brake assembly. The spring is located on the drum side of the brake assembly. Note: For clarity, the drum is not shown.
ACCESSORIES Air Brake 5 Remove the two bolts and two washers securing the brake caliper stop to the brake bracket and remove the brake caliper stop. Note: For clarity, the drum and parts of the dyno frame are not shown. brake bracket brake caliper stop Figure 3-18: Remove the Brake Caliper Stop 6 Remove the hairpin cotter from the bottom clevis pin located on the front of the air brake assembly.
CHAPTER 3 Air Brake 7 8 Push the bottom clevis pin towards the back of the assembly (drum side). You do not need to remove the pin completely. Remove the hairpin cotter from the top clevis pin located on the drum side of the air brake assembly. top hairpin cotter top clevis pin bottom clevis pin Figure 3-20: Remove the Bottom Pin and the Top Hairpin Cotter 9 Remove the top clevis pin.
ACCESSORIES Air Brake 10 Lift the air brake assembly up and away from the dyno. Figure 3-22: Remove the Brake Assembly 11 Remove the brake pad retaining springs and slide the pads out. Note: You will need to use pliers to remove the spring securing the outside pad (closest to the castle nut). 12 Install the new brake pads and secure the pads with new springs. 13 Place the air brake assembly back on the brake bracket. Refer to Figure 3-22.
CHAPTER 3 Air Brake ADJUSTING THE BRAKE PAD CLEARANCE There should be equal pad clearance on both sides of the rotor. If the pads touch the rotor during a run, the information provided by the dyno will be inaccurate. Use the following steps to adjust the clearance. 1 2 3 4 5 6 Loosen the brake caliper stop bolts. Insert the brake adjusting shim between the inboard brake pad and the brake rotor. Refer to Figure 3-23.
ACCESSORIES Air Pump and Filter Assembly AIR PUMP AND FILTER ASSEMBLY ................................... Refer to the Air Fuel Ratio Module Installation and User Guide (P/N 98295110) for proper operating and maintenance procedures. Refer to the Flow Meter User Guide (P/N 98129104) to test your air pump for accuracy. Failure to follow proper procedures may result in inaccurate data or damage to the equipment. These manuals can be found on your WinPEP CD or at www.dynojet.com.
CHAPTER 3 Air Pump and Filter Assembly PARTS LIST The following table lists all of the parts included in the Air Pump and Filter Assembly (P/N 64193009 Domestic or P/N 64193010 European) 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.
ACCESSORIES Air Pump and Filter Assembly 4 Install the filter assembly with the four 1/4-inch screws removed in step two. filter assembly Figure 3-25: Install the Filter Assembly 5 Install the pump assembly and exhaust bottle bracket using the two 3/8-inch bolts removed in step 3.
CHAPTER 3 Air Pump and Filter Assembly 6 Connect the 1/4-inch inlet hose and the 1/8-inch inlet hose. 1/8-inch inlet hose 1/4-inch inlet hose Figure 3-27: Connect the Inlet Hoses 7 8 Install two grommets and the outlet hoses as shown in Figure 3-28. Install the exhaust bottles and insert the outlet hoses into the bottles.
ACCESSORIES Air Pump and Filter Assembly 9 Attach the sensor to the sensor block. 10 Attach the sensor cable to the corresponding cable from the inside back panel of the dyno. sensor cable sensor back view of filter assembly Figure 3-29: Install the Sensor 11 Locate the wiring harness coming from the switch at the bottom of the filter assembly. This wiring harness has two connectors. One connector attaches to the pump while the other attaches to the dyno.
CHAPTER 3 Air Pump and Filter Assembly PUMP HEAD MAINTENANCE Depending on usage, the pump will need periodic maintenance. Use the following instructions to remove the pump from the dyno. Once removed, refer to the Air Fuel Ratio Module Installation and User Guide for detailed pump head maintenance procedures. To prevent possible injury, open the CPI door and set the main breaker to the off position and unplug the dyno. Refer to Figure 3-1 for breaker location.
ACCESSORIES Air Pump and Filter Assembly 4 5 Remove the two 3/8-inch bolts securing the bracket to the pump assembly and set the bolts and bracket aside. Remove the pump assembly. bottle bracket pump assembly Figure 3-32: Remove the Pump Assembly 6 7 Remove the four screws securing the pump to the bracket and set aside. Remove the pump from the bracket.
CHAPTER 3 Extended Carriage EXTENDED CARRIAGE ................................... The extended carriage option increases the maximum wheel base (measured from the front of the front wheel to the center of the rear wheel) from 84 inches to 101 inches for testing raked cruisers and drag bikes. If you do not have the extended tire carriage with the bearing bracket, refer to Appendix D for instructions on installing the extended tire carriage—discontinued.
ACCESSORIES Extended Carriage REMOVING THE STANDARD TIRE CARRIAGE If you have already installed the standard tire carriage, use the following steps to remove it. 1 2 3 Remove the four 1/4-20 x 5/8-inch pan head screws securing the bearing bracket to the tire carriage and set aside. Using the hand crank, unscrew the bearing bracket and the carriage screw and set aside. Remove the tire carriage by sliding the carriage under the carriage clamps toward the back of the dyno and set aside.
CHAPTER 3 Extended Carriage 4 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps and shims and set aside. 5 6 Remove the three carriage clamps and shims and set aside. Remove the two 5/16-inch bolts and washers securing the nut block and shim and set aside. Remove the nut block and shim and set aside.
ACCESSORIES Extended Carriage INSTALLING THE EXTENDED CARRIAGE SUPPORT BRACKET 1 2 3 Loosely attach the extended carriage support bracket to the front of the dyno using six 3/8-16 x 1/2-inch button-head flange allen bolts. Using a straight edge, line the top of the support bracket with the top of the dyno chassis. Tighten all six screws.
CHAPTER 3 Extended Carriage 4 Secure the extended carriage strap to the dyno using two 5/16 x 1-inch bolts and two 5/16-inch lock washers. Note: If your support bracket does not have holes, use the strap as a template to drill them. bolt lock washer strap Figure 3-37: Secure the Strap to the Dyno 5 Secure the strap to the support bracket using two 5/16 x 1-inch bolts, two 5/16-inch lock washers, two 5/16-inch flat washers, and two 5/16-inch nuts.
ACCESSORIES Extended Carriage 6 7 Using the original shim and the large shim included with the kit, attach the nut block to the front of the extended carriage support bracket using two 5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock washers, and two 5/16-inch nuts.
CHAPTER 3 Extended Carriage INSTALLING THE EXTENDED CARRIAGE 1 2 Remove the four 1/4 x 20-inch button-head screws securing the bearing bracket to the carriage. Remove the bearing bracket and the carriage screw.
ACCESSORIES Extended Carriage 3 4 5 6 7 8 Starting from the back of the dyno, slide the carriage under the front carriage clamp and the nut block. Slide the hand crank onto the end of the carriage screw. Secure the hand crank to the screw shaft by tightening the set screw using a 5/32-inch allen wrench. Screw the carriage screw into the nut block until it is halfway through the nut block. Secure the bearing bracket to the carriage using four 1/4-20 x 1/2-inch button-head flange bolts.
CHAPTER 3 Extended Carriage 9 Using the hand crank, move the carriage forward until the holes for the rear carriage clamps are accessible. 10 Attach the two rear carriage clamps to the dyno using the shims, washers, and bolts removed earlier.
ACCESSORIES Extended Carriage 11 Secure the tire stop to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts. Note: If you purchased the wheel clamp accessory, refer to “Wheel Clamp” on page 3-47 for installation instructions. 12 Secure the tire lock to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts.
CHAPTER 3 High Pressure Blower HIGH PRESSURE BLOWER ................................... The high pressure blower supplies air to cool the bike’s engine. This section will walk you through the blower installation procedures. To prevent possible injury, open the CPI door and set the main breaker to the off position and unplug the dyno. Refer to Figure 3-1 for breaker location. PARTS LIST The following table lists all of the parts included in the High Pressure Blower Installation kit (P/N 76722003).
ACCESSORIES High Pressure Blower INSTALLING THE BLOWER ARM ASSEMBLIES Repeat the following steps for each blower arm assembly. 1 2 3 Place a 1/4-inch thick poly washer around the pin on the blower arm assembly. Insert the pin on the blower arm assembly into the dyno. Secure the clamp lever to the dyno.
CHAPTER 3 High Pressure Blower INSTALLING THE HIGH PRESSURE BLOWER ASSEMBLIES Repeat the following steps for each blower assembly. Note: Make sure the motor on each blower is facing out (away from the dyno) and that the intake is facing in. 1 2 Place a 1/8-inch thick poly washer around the pin on the blower assembly. Insert the pin on the blower assembly into the blower arm.
ACCESSORIES High Pressure Blower CONNECTING POWER TO THE BLOWERS Each blower has its own power cord and will plug directly into the dyno chassis. 1 2 Plug the power cord from the blower into the power source located on the dyno chassis. Activate the blower using the switch on the blower motor. The blowers are independent of one another; each blower can be turned on and off individually. Risk of injury. Eye protection required. Be aware of debris from blowers.
CHAPTER 3 Power Carriage POWER CARRIAGE ................................... The power carriage replaces the standard hand crank with an electrically powered tire carriage allowing you to easily adjust for various wheel base distances with the press of a button. This option is ideal for dynos that are recessed where the hand crank is difficult to access. The power carriage will also reduce the time spent making adjustments for various length motorcycles.
ACCESSORIES Power Carriage REMOVING THE HAND CRANK 1 2 Loosen the set screw on the hand crank and remove the hand crank. Using a 7/16-inch wrench, remove the two bolts securing the flange bearing.
CHAPTER 3 Power Carriage INSTALLING THE POWER CARRIAGE 1 2 3 Insert the coupler jaw on the carriage screw making sure the inside of the coupler jaw is flush with the end of the carriage screw. Secure the coupler jaw with the set screw. Secure the motor mount to the carriage using two 1/4-20 x 1-inch bolts and two 1/4-inch lock washers. The motor mount is installed in front of the flange bearing. If the motor mount is already installed, skip this step and continue.
ACCESSORIES Power Carriage 4 5 6 Bring the power carriage cable (two-pin connector) from the front of the dyno over to the motor mount. The routing for this cable was shown on page 2-32. Secure the power carriage cable strain relief to the side of the motor assembly cover. Insert the plastic coupler spider on the carriage screw half of the coupler.
CHAPTER 3 Power Carriage 7 8 9 Place the power carriage motor assembly near the motor mount and plug the motor connector into the power carriage cable. Turn the carriage screw to align the coupler jaws with each other and slide the coupler jaws together until the motor assembly cover is flush with the motor mount. Secure the motor assembly cover to the motor mount with four 1/4-20 x 1/2-inch button-head screws.
ACCESSORIES Wheel Clamp WHEEL CLAMP ................................... For more information on using the wheel clamp, refer to page 4-7. 1 Remove the six 1/4-20 x 1-inch screws securing the wheel clamp cover. Remove the cover and set the cover and screws aside. cover Figure 3-51: Remove the Wheel Clamp Cover 2 3 Place the wheel clamp on the carriage. Align the four holes on the wheel clamp with the holes on the carriage.
CHAPTER 3 Wheel Clamp 4 5 6 Bring the wheel clamp cable (three-pin connector) from the front of the dyno over to the wheel clamp. This cable was routed on page 2-32. Install the wheel clamp cable strain relief to the side of the wheel clamp. Plug the wheel clamp cable into the connector on the wheel clamp motor. strain relief wheel clamp cable WC005A Figure 3-53: Install Wheel Clamp Strain Relief 7 Replace the wheel clamp cover.
ACCESSORIES Final Adjustments and Tests FINAL ADJUSTMENTS AND TESTS ................................... After you have installed all of your additional accessories and routed all necessary cables, perform the following procedures to ensure the safe and effective operation of your dyno. Note: Before replacing the top cover, if your country requires you install the safety switch, please refer to the instructions in Appendix B.
CHAPTER 4 CONTROL PANEL INTERFACE OPERATION This chapter will walk you through the basic operating procedures and how to maintain and troubleshoot the components associated with the control panel interface (CPI). To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 4 Introduction INTRODUCTION ................................... The control panel interface (CPI) consists of a main control board which is mounted internal to the 200i/250i motorcycle dyno or in an external box for a pit dyno or retrofit. This board provides switching and control of many functions within the dyno. The front panel of this board is accessible through the side door on the dyno or door on the external box.
CONTROL PANEL INTERFACE OPERATION Basic Control Panel Operation BASIC CONTROL PANEL OPERATION ................................... The control panel may be mounted to either side of the tray for easy access by the dyno user while seated on the bike. The graphics on the control panel are grouped together according to function and color coded for ease of identification.
CHAPTER 4 Basic Control Panel Operation control panel feature Air Fuel Ratio Air Pump Emergency Stop/Dyno Shutdown High Pressure Blowers (Blowers) Power Carriage Starter Status Indicator Wheel Clamp description This optional accessory allows control of the internal air pump of the air fuel ratio sampling system. Refer to page 4-4 for more information. Deactivates the dyno outputs whenever the button is pressed or the external E-Stop circuit is opened. Refer to page 4-5 for more information.
CONTROL PANEL INTERFACE OPERATION Basic Control Panel Operation USING THE EMERGENCY STOP/DYNO SHUTDOWN The emergency stop/dyno shutdown button is designed to deactivate the dyno outputs whenever the button is pressed or the external E-Stop circuit is opened. When E-Stop is activated the blowers will be turned off, the power carriage will stop, and the wheel clamp will stop. The starter will be deactivated as well as the AFR air pump and the retarder will be de-activated.
CHAPTER 4 Basic Control Panel Operation USING THE POWER CARRIAGE This optional accessory requires the CPI and battery to operate. Use the control panel to activate the power carriage allowing you to center the bike’s rear tire on the dyno drum. The power carriage and wheel clamp cannot be activated at the same time. Note: When operating the power carriage with a bike on the dyno, make sure the bike is in neutral. Note: Always loosen or remove the bike tie-down straps before moving the carriage.
CONTROL PANEL INTERFACE OPERATION Basic Control Panel Operation USING THE STATUS INDICATOR The status indicator provides information on the status of the CPI control and the various inputs to the CPI. • Status: Off—indicates the CPI may not be receiving power due to the dyno being turned off or lack of power being applied to the dyno. • Status: Steady On—indicates all inputs into the CPI are okay for normal dyno operation and the CPI is receiving power.
CHAPTER 4 Basic Control Panel Operation CLOSING THE WHEEL CLAMP Do not run into the edges of the wheel clamp pads with the bike tire. Make sure the wheel clamp is sufficiently open before loading the motorcycle. 1 Once the bike's front tire is fully seated in the clamp, press and hold the close button (left hand yellow square button). As you hold the button, the wheel clamp mechanism will close on the bike’s wheel and tire. The wheel clamp status light will blink as the clamp is closing.
CONTROL PANEL INTERFACE OPERATION Power Distribution Assembly POWER DISTRIBUTION ASSEMBLY ................................... The Power Distribution Assembly, inside the CPI, has three circuit breakers to protect the internal dyno circuits, the main dyno circuit breaker and two blower circuit breakers. MAIN DYNO CIRCUIT BREAKER The main dyno circuit breaker is rated for 240VAC at 30A and all of the power into the dyno passes through this breaker.
CHAPTER 4 Maintenance and Troubleshooting MAINTENANCE AND TROUBLESHOOTING ................................... This section contains basic maintenance and troubleshooting information for the wheel clamp, theta controller fuses and CPI fuses. WHEEL CLAMP • Make sure the bike tire and wheel are clean to reduce the possibility of scratching the rim. • Keep the wheel clamp pads clean using Isopropyl Alcohol.
CONTROL PANEL INTERFACE OPERATION Maintenance and Troubleshooting REPLACING THE THETA CONTROLLER FUSES The theta controller has two fuses. For more information on routing the theta controller cable refer to page 2-30. Hazardous voltage. To prevent possible injury, open the CPI door and set the main breaker to the off position and unplug the dyno. Refer to Figure 1-3 for breaker location. 1 Open the Control Panel Interface (CPI) cover and set aside. Refer to Figure 2-24 on page 2 24.
CHAPTER 4 Maintenance and Troubleshooting TROUBLESHOOTING CPI FUSES Fuses F3 and F4 fuse the 240VAC as it enters the CPI board. One fuse for each leg of the 240VAC. If either of these fuses are blown there will be no power to the CPI board or any of the accessories. The Status Light on the board as well as the button panel will be off. Replace with a 5x20 mm 3A fast blow fuse. Fuse F5 provides protection for the DC power that is produced by the on board power supply and routed to the CPI board.
CHAPTER 5 BASIC DYNO OPERATION This chapter includes instructions for basic dyno operation. For more detailed instructions, refer to the WinPEP 7 User Guide. This manual can be found on your WinPEP CD or at www.dynojet.com.
CHAPTER 5 Loading the Bike LOADING THE BIKE ................................... Use the following steps to load a motorcycle on the dyno. Keep the motorcycle balanced while driving on and off the dyno. Risk of injury. Always wear proper eye and ear protection when operating the dyno. 1 2 3 Load the bike on the dyno. Place the bike on the dyno so the front tire is in the tire stop. Strap the front wheel to the tire stop and tighten or use the control panel to run the wheel clamp closed.
BASIC DYNO OPERATION Loading the Bike 6 7 Attach the tie-down straps from a solid place on the bike to the tie-downs on the dyno or the ground hook locations (refer to page 2-43). Position the straps to allow proper clearance for the brake pedal, the shift lever and the exhaust pipes. For best results, hook the straps at the rear of the bike so they pull down and forward. Sit on the bike with your feet on the pegs. Remove the slack from the straps.
CHAPTER 5 Connecting the RPM Pickup CONNECTING THE RPM PICKUP ................................... Your Dynojet dynamometer includes a primary wire inductive pickup and two secondary wire inductive pickups. These small “clothespin like” inductive pickups are used to sense RPM. An RPM pickup is required if you want to view torque graphs. Generally you will use one secondary wire inductive pickup on a spark plug wire. Vehicles with wasted spark ignition systems may require two secondary inductive pickups.
BASIC DYNO OPERATION Connecting the RPM Pickup CONNECTING THE PRIMARY INDUCTIVE PICKUP The primary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray RF interference may result. The inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration. Do not drop the inductive pickup or snap the pickup closed. Use extreme care in handling and placement of the pickups.
CHAPTER 5 Connecting the RPM Pickup Depending on accessibility, the user can make a primary wire hookup from the coil or the ignition module. Ignition modules can be found usually under the seats or side covers. Refer to the following table to determine the wire color when hooking up the inductive tack lead to the primary side of the ignition.
BASIC DYNO OPERATION Connecting the RPM Pickup CONNECTING THE SECONDARY INDUCTIVE PICKUP If the primary wire is not accessible connect a secondary inductive pickup to an available spark plug wire. The secondary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray RF interference may result. The inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration.
CHAPTER 5 Connecting the RPM Pickup Erratic tachometer operation can be caused by Electro Magnetic Interference (EMI). The following are some steps that the user can take to clean up the signal if an EMI situation occurs. • Ground the computer case to a good earth ground, like the receptacle box. • Keep the computer as far away from the dyno as possible. • Try attaching one secondary inductive cable to one wire and attach a second inductive cable to the first in a piggy back fashion.
BASIC DYNO OPERATION Pre-run Inspection PRE-RUN INSPECTION ................................... Perform a vehicle inspection before making a run. Check the following: • Check the radiator coolant (if applicable) and oil levels. • Check the fuel source. • Rotate the drum and check for rocks caught in the tire tread that could fly out. • For motorcycles, check the chain and the chain master link. Make sure it is lubricated and adjusted to the proper tension. • Check the tire pressure and tire speed rating.
CHAPTER 5 Pre-run Inspection BEFORE STARTING THE ENGINE Connect an exhaust hose or hoses (if dual exhaust) on the vehicle, make sure the hose fits over the tail pipe, is not plugged or kinked and the hose is vented correctly out of the dyno room. Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death. Operate machine in well ventilated area. ENGINE WARM UP Warm the vehicle’s engine and drivetrain before beginning testing.
BASIC DYNO OPERATION Making a Test Run MAKING A TEST RUN ................................... Dyno runs provide safe, reliable road testing right in the shop. The dyno allows you to measure, record, and diagnose performance problems quickly. The dyno combined with WinPEP 7 produces consistent, easily interpretable power graphs. Use the following instructions to ensure repeatable and accurate measurements. 1 2 3 4 5 Verify the vehicle is secured properly.
CHAPTER 5 Preventative Maintenance PREVENTATIVE MAINTENANCE ................................... This section contains basic preventative maintenance and troubleshooting information for the wheel clamp and CPI fuses. To maintain proper dynamometer operation, Dynojet recommends you make routine checks of the dyno. • Drum—keep the drum clean and keep all objects clear of the drum. • Brake Pads—check the brake pad clearance regularly. Change the brake pads when they are worn to less than 0.060 inch thick.
APPENDIX A RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi-Set™II Anchors. The anchors will be used to secure the dyno to concrete. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Be sure to read and understand the warnings included in this appendix. WARNINGS Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors.
APPENDIXA Installation INSTALLATION ................................... Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number. catalog number Carbon Steel RM-38/RL-38 (9.5 mm) drill bit size 1/2-inch minimum hole depth 1 5/8-inch (41.2 mm) setting tool catalog number RT-138 Use the following instructions to install the Red Head anchors.
RED HEAD ANCHOR INSTALLATION Installation 3 Using a hammer, drive the anchor flush with the surface of the concrete, or below the surface if the hole depth exceeds minimum embedment. Figure A-3: Red Head Anchor—Drive the Anchor Flush 4 Using a hammer, expand the anchor with the setting tool. The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor. Note: Use only Ramset/Red Head setting tools to insure proper installtion.
APPENDIX B POWER REQUIREMENTS Different countries have different standards for delivery of AC (alternating current) electricity to homes and buildings. The frequency (number of cycles per second) in Hertz (Hz) varies from country to country. North America typically uses 60 Hz power. Western Japan including the Osaka, Kyoto, Nagoya, Hiroshima regions also uses 60Hz power. Eastern Japan including the Tokyo, Kawasaki, Sapporo, Yokohama, and Sendai regions uses 50Hz power.
APPENDIXB Locations Using 60Hz Power (North America & Japan) LOCATIONS USING 60HZ POWER (NORTH AMERICA & JAPAN) ................................... The following power requirements and instructions are for North America, much of Japan, and other locations using 60 Hz power. All other locations should refer to the instructions found in “Locations Using 50 Hz Power (Locations Other than North America and Japan)” on page B-7.
POWER REQUIREMENTS Locations Using 60Hz Power (North America & Japan) INSTALLING THE WALL RECEPTACLE The wall receptacle is included with your dyno and is shipped in a box in the center of your dyno or may be shipped in advance in a separate package. Refer to page 2-2 for more information on removing the hardware shipped with the dyno. The wall receptacle is a single phase 240 volt 30A dedicated circuit with a neutral connection and a ground.
APPENDIXB Locations Using 60Hz Power (North America & Japan) TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet. If the voltage readings do not match the following table, DO NOT connect the dyno. You must have a licensed electrician correct the power connection. Connecting the dyno to the incorrect voltage can result in damage to the dyno and will void the dyno warranty. Contact Dynojet with any questions.
POWER REQUIREMENTS Locations Using 60Hz Power (North America & Japan) REPLACING THE POWER PLUG Use the following instructions to replace the four wire plug and socket. The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of four conductors. The power cord that attaches to the dyno has four conductors internally and their colors are brown, blue, black, and green/yellow. 1 2 3 4 Connect 240VAC single phase power between the brown and the blue wire connection points.
APPENDIXB Locations Using 60Hz Power (North America & Japan) CONNECTING THE DYNO 1 2 3 4 5 6 7 Turn off the main circuit breaker on the dyno. The main breaker is located in the CPI door. Refer to page 3-2 for breaker location. Off is the down position. Once you verify the voltages on the receptacle, connect the dyno to the receptacle. Connect the high pressure blowers to the dyno. For more information on connecting the blowers, refer to “Connecting Power to the Blowers” on page 341.
POWER REQUIREMENTS Locations Using 50 Hz Power (Locations Other than North America and Japan) LOCATIONS USING 50 HZ POWER (LOCATIONS OTHER THAN NORTH AMERICA AND JAPAN) ................................... The next section of this appendix contains the power requirements and instructions for dyno installations excluding North America and 60 Hz areas of Japan. Note: Refer to page B-2 for power requirements and instructions for North America and Japan.
APPENDIXB Locations Using 50 Hz Power (Locations Other than North America and Japan) INSTALLING THE WALL RECEPTACLE The wall receptacle is a single 240 volt 30A dedicated circuit with a ground. The cable carrying the power to this receptacle should be 4.0 mm2 (ten gauge) or larger. Check with local building codes for the correct size. 1 2 3 Connect one of the 240V legs to the N terminal (white). Connect the other 240V leg to the L terminal (no color). Connect the ground conductor to the green terminal.
POWER REQUIREMENTS Locations Using 50 Hz Power (Locations Other than North America and Japan) TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet. Using a voltmeter that is capable of measuring AC voltage, measure between the points listed below and verify that the correct voltages are present.
APPENDIXB Locations Using 50 Hz Power (Locations Other than North America and Japan) REPLACING THE POWER PLUG Use the following instructions to replace the plug and socket. The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of three conductors. The power cord that attaches to the dyno has four conductors internally and their colors are brown, blue, black, and green/yellow.
POWER REQUIREMENTS Locations Using 50 Hz Power (Locations Other than North America and Japan) CONNECTING THE DYNO 1 2 3 4 5 6 7 Version 5 Turn off the main circuit breaker on the dyno. The main breaker is located in the CPI door. Refer to page 3-2 for breaker location. Off is the down position. Once you verify the voltages on the receptacle, connect the dyno to the receptacle. Connect the high pressure blowers to the dyno.
APPENDIX C THETA CONTROLLER This appendix describes how to make power adjustments on the theta controller. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIXC Power Adjustment POWER ADJUSTMENT ................................... The 240 VAC theta controller is calibrated for a nominal 230 to 240 VAC line voltage; in certain countries, line voltages of 210 to 220 VAC may be encountered and the dip switch can be set to provide full output current of 10 amps even with the reduced line voltage. Note: This controller cannot be converted to operate on 120 VAC line voltage. Hazardous voltage.
THETA CONTROLLER Power Adjustment Power Line Frequency Adjustment—The theta controller is shipped with the dip switch set for 60 Hz. In some cases, the dip switch is set based on the country it is shipping to. However, you will need to determine the correct line frequency and set the switch accordingly. 60 Hz Power Line Frequency Adjustment—For all of North America, this switch should be set to the 60 Hz position.
APPENDIX D EEC KIT This appendix provides instructions for installing the European Economic Community (EEC) Kit to the model 200i/250i motorcycle dyno. This appendix will walk you through installing the EEC finger guards and door safety switch. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIXD EEC Finger Guards Installation EEC FINGER GUARDS INSTALLATION ................................... The EEC finger guards are secured to the drum module hood and provide extra protection from the drum by regulating the distance between the drum and the chassis. The placement of the finger guards can be manually adjusted. REMOVING THE DRUM MODULE HOOD Before installing the EEC finger guards, the drum module hood must be removed. Never operate the dynamometer with the drum module hood removed.
EEC KIT EEC Finger Guards Installation INSTALLING THE EEC FINGER GUARDS 1 Secure each EEC finger guard to the drum module hood using two 1/4-20 x 5/8-inch pan head screws.
APPENDIXD EEC Finger Guards Installation 2 Secure the drum module hood with the EEC finger guards to the dyno using the eight 1/4-20 x 5/8-inch pan head screws removed earlier. Note: For clarity, the eddy current brake and dyno carriage are not shown. Do not operate the dynamometer without the EEC finger guards properly installed. The gap between the finger guards and the drum must be less than 0.64 centimeters. Refer to page D-5 for instructions on adjusting the gap.
EEC KIT EEC Finger Guards Installation ADJUSTING THE EEC FINGER GUARDS Once the drum module hood is installed, the EEC finger guards will need to be adjusted. 1 2 Loosen the 1/4-20-inch pan head screws and adjust the EEC finger guards so they are 0.16 cm to 0.64 cm (.0625 in. to .25 in.) from the drum. Tighten the screws. Check the EEC finger guards regularly to verify the clearance has not changed. Note: For clarity, the eddy current brake and dyno carriage are not shown.
APPENDIXD Door Safety Switch DOOR SAFETY SWITCH ................................... Safety requirements of your local country may require that a door safety switch is installed. Be sure to follow the safety requirements specific to your country. The door safety switch requires the air brake to work. This switch is located on the dyno room door and is triggered when the pressure applied to it is released causing the air brake to lock. This prevents the dyno from being used when the door is open.
EEC KIT Door Safety Switch 6 Loosen the screws that hold the jumper wires in place and remove the wire. 7 Route the black and yellow wire from the safety switch through the dyno. Make sure the switch will not get caught in any moving components or chafed on any edges. 8 9 Attach the yellow wire to the 1A position on the J2 connector. Attach the black wire to the 6B position on the J4 connector.
APPENDIX E STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED This appendix contains instructions for installing the standard and extended tire carriage that do not have a bearing bracket. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIXE Standard Tire Carriage—Discontinued STANDARD TIRE CARRIAGE—DISCONTINUED ................................... If your tire carriage does not have the bearing bracket, you will need to use the following directions. INSTALLING THE STANDARD TIRE CARRIAGE 1 2 Install the three carriage clamps and shims using two 5/16-inch bolts and washers each. Install the nut block and shim using two 5/16-inch bolts and washers.
STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED Standard Tire Carriage—Discontinued 3 Using a 5/32-inch allen wrench, remove the two 1/4 x 1/2-inch button-head screws securing the screw support bracket. Remove the bracket and set the screws and bracket aside. screw support bracket carriage screw Figure E-2: Remove the Screw Support Bracket 4 5 6 Slide the carriage under the carriage clamps and the nut block until the carriage screw is touching the nut block.
APPENDIXE Standard Tire Carriage—Discontinued 7 8 Using the hand crank, screw the carriage through the nut block. Install the screw support bracket. 8a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure E-4. 8b Place the screw support bracket in front of the carriage screw. The two threaded holes in the bracket should face the two matching holes in the carriage.
STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED Standard Tire Carriage—Discontinued 10 Secure the tire stop to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts. 11 Secure the tire lock to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts.
APPENDIXE Extended Tire Carriage—Discontinued EXTENDED TIRE CARRIAGE—DISCONTINUED ................................... If your tire carriage does not have the bearing bracket, you will need to use the following directions. Refer to page 3-29 for instructions on removing the standard tire carriage. INSTALLING THE EXTENDED TIRE CARRIAGE SUPPORT BRACKET 1 2 3 Loosely attach the extended carriage support bracket to the front of the dyno using six 3/8-16 x 1/2-inch button-head flange allen bolts.
STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED Extended Tire Carriage—Discontinued 4 5 Secure the extended carriage strap to the dyno using two 5/16 x 1-inch bolts and two 5/16-inch lock washers. Using the holes on the strap as a guide, drill two 3/8-inch holes in the extended carriage support bracket. Note: If your support bracket already has the required holes, skip this step.
APPENDIXE Extended Tire Carriage—Discontinued 7 8 Using the original shim and the large shim included with the kit, attach the nut block to the front of the extended carriage support bracket using two 5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock washers, and two 5/16-inch nuts.
STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED Extended Tire Carriage—Discontinued INSTALLING THE EXTENDED TIRE CARRIAGE 1 2 3 4 Slide the extended carriage under the nut block and clamps until the carriage screw contacts the nut block. Be sure the slide plate is under the rear carriage clamps. Slide the hand crank onto the end of the carriage screw. Secure the hand crank to the screw shaft by tightening the set screw using a 5/32-inch allen wrench.
APPENDIXE Extended Tire Carriage—Discontinued 5 Install the screw support bracket. 5a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure E-11. 5b Place the screw support bracket in front of the carriage screw. The two threaded holes in the bracket should face the two matching holes in the carriage. Loosely install the two 1/4 x 1/2-inch button-head screws.
STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED Extended Tire Carriage—Discontinued 6 7 Secure the tire stop to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts. Secure the tire lock to the carriage using four 3/8-16 x 1/2-inch button-head flange bolts.
INDEX wiring jumpers 2-31 wiring theta controller 2-31 50 Hz power B-7 60 Hz power B-2 A accessories 3-1 air brake 3-7 air pump and filter assembly 3-21 eddy current brake 2-12 extended carriage 3-28 high pressure blower 3-38, 3-41 monitor tray 2-21 power carriage 3-42 air brake 3-7 adjustments and tests 3-14 brake pads 3-15 emergency stop sticker 3-10 parts list 3-7 routing cables 3-8 air fuel ratio, using air pump 4-4 air pump and filter assembly 3-21 cleaning the filter 3-25 installation 3-22 parts l
INDEX D dimensions 1-6 dip switches C-2 disclaimers -vii document part number 1-1 drum covers removing and replacing 3-3 drum guards, adjusting ce D-5 dyno installation 2-1 operation 5-1 positioning 2-9 power, main 3-2 requirements 1-5 securing 2-9 specifications 1-5 unpacking 2-2 dyno electronics 2-23 dyno room 1-3 equalizer box 1-4 exhaust extraction 1-4 fire suppression 1-4 noise control 1-4 dyno shutdown 4-5 dyno shutdown sticker 3-12 E eddy current brake 2-12 cables 2-30 coupler 2-17 installation 2
P PDA, see power distribution assembly pendant, routing cables 2-25 pickup card 2-11 wiring to breakout board 2-31 power 50 Hz B-7 60 Hz B-2 connecting the dyno, 50 Hz B-11 connecting the dyno, 60 Hz B-6 hard wiring 60 Hz B-5 hard wiring, 50 Hz B-10 installation 50 Hz B-7 installation 60 Hz B-2 installing receptacle 60 Hz B-3 installing receptacle, 50 Hz B-8 main dyno 3-2 replacing power plug 50 Hz B-10 replacing power plug 60 Hz B-5 requirements 50 Hz B-7 routing cable 2-8 testing voltages 50 Hz B-9 testi
INDEX T technical support 1-3 temperature sensor 2-31 temperature sensor cable 2-30 wiring to breakout board 2-31 testing the dyno 5-11 testing voltages 50 Hz B-9 testing voltages 60 Hz B-4 theta controller dip switches C-2 installation 2-20 power adjustment C-2 power line frequency C-3 power line voltage C-3 replace fuses 4-11 route control cable 2-20 wiring to breakout board 2-31 tie down straps 1-8 attaching 5-3 tire carriage 5-2 belleville washers E-4 hand crank 2-36, E-3 installation 2-34, E-2 nut bl
