©2004-2006 Dynojet Research, Inc. All Rights Reserved. Installation Guide For Model 200ip and 250ip Motorcycle PitDynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual is furnished under license and may only be used or copied in accordance with the terms of such license. This manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Dynojet.
TABLE OF CONTENTS Warnings Chapter 1 ................................................ v Specifications and Operating Requirements Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Your Dyno Room . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Carriage Plate and Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Installing the Carriage Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Installing the Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 Blower Mounts, Support Arm and Junction Box . . . . . . . . . . . . . . . . . . . 2-16 Mark and Drill Blower Mounts and Support Arm Mounting Holes . . . . . .
TA B L E O F C O N T E N T S High Pressure Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Installing the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 Attaching the Blower Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Appendix A Red Head Anchor Installation Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . .A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Appendix B Power Requirements Locations using 60Hz Power (North America & Japan) . . . . . . . . . . . . . .
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 outlets shall be installed near the equipment and 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 200iP/250iP Motorcycle Pit 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 Intake Air Fan—After building your dyno room, you will need to supply an intake air fan. The intake air fan supplies air to cool the bike’s engine while supplying fresh oxygen for you and your bike to breathe. It is a common misconception that you cannot tune a bike without a large fan simulating exact road conditions; however, a good cooling fan is the only requirement for consistent diagnostics and tuning. The installed fan should be 5200 CFM.
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 200iP/250iP 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 208.28 cm (82.00 in) 137.16 cm (54.00 in) PD017 45.72-46.67 cm (18.00-18.38 in) standard carriage: 304.80 cm (120.00 in) extended carriage: 355.60 cm (140.00 in) 179.07 cm (70.50 in) 105.03 cm (41.35 in) 76.20 cm (30.
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 GROUND HOOK REQUIREMENTS You may wish to install additional ground hooks (included with your dyno) for securing the motorcycle. The tie-down loops on the pit covers should work for most motorcycles. If you are running motorcycles that require a different tie-down location, mount the ground hooks accordingly. Note: Tie-down straps MUST pull the motorcycle forward.
SPECIFICATIONS AND OPERATING REQUIREMENTS Model 200iP/250iP Motorcycle Pit Dynamometer MODEL 200iP/250iP MOTORCYCLE PIT DYNAMOMETER ...................................
CHAPTER 1 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 refer to your WinPEP 7 User Guide (P/N 98128104).
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 Unpacking and Installing the Dyno UNPACKING AND INSTALLING THE 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 shipping company or Dynojet before proceeding with unpacking.
INSTALLATION Unpacking and Installing the Dyno VERIFYING THE PIT DIMENSIONS Before placing the dyno in the pit, take a moment to verify that the dimensions of the pit are correct. Refer to the pit dimensions (P/N 98229102) you received from your salesman for more detailed specifications. • pit depth: 45.00 cm (18.00 in) • pit length: 193.00 cm (76.00 in) • pit width: 121.00 cm (48.00 in) 121.00 cm (48.00 in) 45.00 cm (18.00 in) 193.00 cm (76.
CHAPTER 2 Unpacking and Installing the Dyno REMOVING THE DYNO FROM THE CRATE You will need to provide equipment capable of lifting a minimum of 1,043 kg. (2300 lb.) to lift the dyno (drum module) off the crate and into position in your dyno room. You will also need a pair of straps capable of supporting 1,043 kg. (2300 lb.) to attach to the dyno. Dynojet recommends using a single loop style strap. RECORD # Be sure you record the dynamometer number on the inside cover of this manual.
INSTALLATION Unpacking and Installing the Dyno 4 Place the drum module in the pit as shown. If you ordered an eddy current brake be sure to place the dyno in the appropriate side of the pit. 15.24 cm (6.00 in) 7.62 cm (3.00 in) Figure 2-4: Drum Module Placement in Pit—Left Side Retarder 15.24 cm (6.00 in) 7.62 cm (3.
CHAPTER 2 Eddy Current Brake EDDY CURRENT BRAKE ................................... This section will walk you through removing the eddy current brake (or retarder) from the crate and attaching the brake to your dyno. To route and wire the temperature sensor cable and the theta controller to the Breakout board refer to “Routing the Eddy Current Brake, Battery, and Dyno Power Cables” on page 2-32 and “Wiring the Breakout Board” on page 2-36.
INSTALLATION Eddy Current Brake UNPACKING THE EDDY CURRENT BRAKE 1 2 3 Remove the four bolts securing the brake to the crate. Remove the retarder connector plates, if present. 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. • Move the coupler and key to the other side of the brake.
CHAPTER 2 Eddy Current Brake apply force using hammer and punch shaft key apply force using hammer and punch Figure 2-7: Removing the Key 4 5 6 Place the ends of a nylon loop strap through the lifting eyes on either side of the brake and hook onto the shaft. Using a forklift, lift the eddy current brake from the crate and place the brake in the pit near the drum module making sure not to hit the coupler. Be sure you record the eddy current brake number on the inside cover of this manual.
INSTALLATION Eddy Current Brake INSTALLING THE EDDY CURRENT BRAKE It is not necessary to remove the optional air brake if you are installing the eddy current brake on the right side. If you mount the eddy current brake on the right side you will need to change the retarder cover, refer to page 2-39. Note: Safety requirements of your local country may require that both brakes are installed. Be sure to follow the safety requirements specific to your country.
CHAPTER 2 Eddy Current Brake 6 Continue sliding the eddy current brake towards the dyno until the uprights on the brake and dyno are flush. Loosely secure the retarder connector plates to the dyno frame using the eight bolts, washers, and six nuts removed earlier. Note: Do not tighten the bolts. 7 8 Verify the uprights on the drum and eddy current brake modules are flush with the top of the pit floor before you tighten the connector plates. 8a Loosen all upright bolts.
INSTALLATION Eddy Current Brake 11 Replace the existing set screws on the coupler with the thread-lock set screws provided. 12 Tighten the coupler set screws. dyno shaft brake shaft set screw Figure 2-11: Tighten the Set Screws SECURING THE DRUM AND BRAKE MODULE TO THE PIT FLOOR Dynojet recommends you secure your drum and brake modules to the pit 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.
CHAPTER 2 Pickup Card PICKUP CARD ................................... The pickup card is an electronic circuit board that accurately senses each drum revolution. 1 2 3 4 5 Locate the pickup card bracket on the starter 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.
INSTALLATION Carriage Plate and Tire Carriage CARRIAGE PLATE AND TIRE CARRIAGE ................................... The tire carriage is fastened to the bottom of the crate next to the dyno. Refer to page 2-2 for instructions on removing the tire carriage from the crate. The following instructions are for the standard tire carriage. For more information on the extended tire carriage refer to page 3-18.
CHAPTER 2 Carriage Plate and Tire Carriage 2 Use the carriage plate to mark and drill mounting holes as shown in Figure 2-15. 2a Using the carriage plate as a template, drill four 1/2-inch holes. 2b Install the Red Head anchors according to the instructions in Appendix A. 40.32 cm (15.875 in) 66.04 cm (26.0 in) Figure 2-15: Carriage Plate Mounting Dimensions 3 Secure the carriage plate to the floor using four 3/8 x 1-inch bolts and 5/16-inch washers.
INSTALLATION Carriage Plate and Tire Carriage INSTALLING THE TIRE CARRIAGE 1 2 3 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. Secure the bearing bracket to the carriage using four 1/4-20 x 1/2-inch button-head flange bolts removed earlier.
CHAPTER 2 Blower Mounts, Support Arm and Junction Box BLOWER MOUNTS, SUPPORT ARM AND JUNCTION BOX ................................... Before routing the cables, you must decide which side of the dyno to mount the monitor support arm. The choice is based on personal preference and easy access to your computer. For the following instructions, we will show the support arm and control panel mounted on the right side of the dyno.
INSTALLATION Blower Mounts, Support Arm and Junction Box INSTALLING THE BLOWER MOUNTING PLATE, SUPPORT ARM, AND JUNCTION BOX The high pressure blowers are an optional accessory. If you did not order high pressure blowers, you will not need to install the blower mounting plates. Refer page 3-24 to for high pressure blower installation instructions. 1 Secure the blower mounting plate to the pit floor using four 3/8 x 1-inch bolts and 5/16-inch washers.
CHAPTER 2 Blower Mounts, Support Arm and Junction Box INSTALLING THE ARMS AND MONITOR TRAY 1 2 3 4 5 Insert a plastic cap in both ends of each arm. Place a poly washer around the pin of the first arm and insert the pin into the support arm. Place a poly washer around the pin of the second arm and insert the pin into the first arm. Place a poly washer around the pin of the tray and insert the pin into the second arm. Note: The monitor tray is an optional accessory.
INSTALLATION Routing Cables ROUTING CABLES ................................... The following instructions show the support arm and control panel mounted on the right side of the dyno with the Control Panel Interface (CPI) and dyno electronics on the left side of the dyno. The CPI and dyno electronics must be placed near the conduits in the pit. Be sure to keep the power and communications cables in different pit conduits.
CHAPTER 2 Routing Cables BATTERY REQUIREMENTS 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 10 5/8-inches long by 6 3/4inches wide by 9 1/8-inches tall. The mounting is flexible so a battery that has dimensions close to this will work satisfactorily. The built in battery cables are configured for top post batteries.
INSTALLATION Routing Cables INSTALLING THE BATTERY 1 2 Secure the battery to the tray with the battery hold-down. Refer to page 2-32 for instructions on routing and connecting the battery cable.
CHAPTER 2 Routing Cables ACCESSING THE CPI The CPI comes wired and ready to install. Should you need to re-route the cables so they come out a different side of the box, use the following instructions to access the CPI box. 1 2 3 4 Turn off the power to the dyno. Refer to “Main Dyno Power” on page 3-2 for more information. Remove the eight button-head screws securing the cover and set aside. Remove the cover and set aside. Open the front panel to access the breakers and Breakout board.
INSTALLATION Routing Cables ROUTING THE CONTROL PANEL, PENDANT CABLES, AND RPM CABLE 1 2 Route the control panel cable (P/N 76951502) from the CPI through the designated communications pit conduit, through the pit, and out of the pit as shown. Route the pendant cable from the dyno electronics input/output module through the same conduit and along the same path as the control panel cable. Refer to “Dyno Electronics” on page 1-10.
CHAPTER 2 Routing Cables 5 Remove the control panel rear cover. 5a Remove the two nuts from the top of the cover and set aside. 5b Remove the screw on the top of the cover and set aside. 5c Remove the screw on the side of the cover and set aside. 5d Remove the four screws on the back of the cover and set aside. 5e Remove the control panel rear cover and set aside.
INSTALLATION Routing Cables 6 7 8 Route the control panel cable and RPM 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. Secure the panel mount connector on the RPM cable to the control panel using two #4-40 pan-head phillips screws. Note: Routing the RPM cable is optional.
CHAPTER 2 Routing Cables 12 Secure the control panel to the monitor tray using two 8-32-inch screws. Note: If you did not order a monitor tray, you will need to install the control pod spindle on the bottom of your control panel using four 8-32 screws as shown in the detail in Figure 2-28. Once installed, place the pin on the control panel into the support arm where the monitor tray is. 13 Place the pendant in the slot on the control panel.
INSTALLATION Routing Cables ROUTING THE HIGH PRESSURE BLOWER CABLES The high pressure blowers are an optional accessory. If you did not order the high pressure blowers it is still necessary to route the blower cables to the junction box. To route the cables from the junction box to the blowers refer to “Attaching the Blower Cables” on page 3-25. 1 Route each blower cable (P/N 76950315) from the CPI through the designated power pit conduit, through the pit, and out of the pit as shown.
CHAPTER 2 Routing Cables ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES The wheel clamp is an optional accessory. If you did not order this accessory, it is still necessary to route the cables to the junction box. After you install the wheel clamp you can finish routing the cables, refer to “Wheel Clamp” on page 3-26 for installation instructions.
INSTALLATION Routing Cables 8 9 Secure the cable track bracket to the junction box using two 8-32 screws. Secure the cable track bracket to the wheel clamp using a 1/4-20 screw. Note: If you do not have the wheel clamp, you will need to install the adapter bracket to the tire stop using the tire stop hardware.
CHAPTER 2 Routing Cables 10 Remove the four screws securing the power carriage cover and set aside. 11 Bring the power carriage cable (two-pin connector) from the cable track over to the motor mount. 12 Secure the strain relief to the side of the power carriage motor mount.
INSTALLATION Routing Cables 13 Place the power carriage motor assembly near the motor mount and plug the motor connector into the power carriage cable. 14 Secure the power carriage cover using the four screws removed earlier. 15 Connect the wheel clamp cable to the wheel clamp. Refer to page 3-27 for instructions on installing the wheel clamp. Note: If you do not have a wheel clamp, the wheel clamp cable will hang from the cable track.
CHAPTER 2 Routing Cables ROUTING THE EDDY CURRENT BRAKE, BATTERY, AND DYNO POWER CABLES 1 Route the eddy current brake cable (P/N 66952005) from the eddy current brake through the designated power pit conduit and to the theta controller. Route the battery cable (P/N 76950312) from the CPI through the same conduit and over to the battery. Refer to the steps and Figure 2-35 on page 2-33 for instructions on connecting the battery and starter cables.
INSTALLATION Routing Cables 5 Connect the battery and starter cables. 5a Attach the brown cable to the positive (+) battery post. 5b Attach the red battery cable to the positive (+) battery post and to the large stud on the starter solenoid. 5c Attach the blue and yellow cable to the negative (-) battery post. 5d Attach the black battery cable to the negative (-) battery post and to the grounding location on the starter brace. 5e Attach the blue cable to the starter solenoid.
CHAPTER 2 Routing Cables ROUTING THE PICKUP CARD AND DYNO ELECTRONICS CABLES 1 Route the pickup card cable (P/N 66953002) from the CPI through the designated pit conduit and over to the pickup card. Attach the cable to the pickup card. Note: Be sure to keep the power and communications cables in different pit conduits. 2 Route the 25-pin cable (P/N 42924251) from the dyno electronics input/output module to the Breakout board. Refer to Figure 2-38 for Breakout board location.
INSTALLATION Routing Cables ROUTING THE AIR PUMP POWER, AIR FUEL SENSOR, AND DYNO ELECTRONICS POWER CABLES 1 2 3 Route the air pump power cable (P/N 76950318) from the CPI to the air pump. Route the air fuel sensor cable (P/N 76950701) from the dyno electronics to the air pump. Route the dyno electronics power cable to your power source. Refer to “Dyno Electronics” on page 1-10 for the dyno electronics power cable location.
CHAPTER 2 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 2-32. • 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.
INSTALLATION 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 you plug in your dyno, you or your electrician must refer to Appendix B for detailed power information. Always turn the power off when connecting and disconnecting cables.
CHAPTER 2 Final Adjustments and Tests POWER CARRIAGE FINAL ADJUSTMENTS AND TESTS The power carriage allows you to easily adjust for various wheel bases distances with the press of a button. Refer to “Using the Power Carriage” on page 4-5 for more information on using the power carriage. To route the power carriage cables refer to “Routing the Power Carriage and Wheel Clamp Cables” on page 2-28. Using the Control Panel, press the carriage forward and backward buttons and verify that the motor does turn.
INSTALLATION Pit Covers PIT COVERS ................................... Before installing the covers, be sure to install the battery, pickup card, eddy current brake, air brake, EEC Kit, and any accessories you may have purchased with your dyno. This section describes how to install the pit covers and drum guards. CHANGING THE RETARDER COVER FOR RIGHT SIDE INSTALLATIONS Note: If you ordered an eddy current brake (retarder) and plan to mount it on the right side, you will need to change the retarder cover.
CHAPTER 2 Pit Covers 2 3 Remove the four No. 6-32 pan head screws securing the heat shield and insulation and set aside. Move the heat shield and insulation to other side of the cover as shown in Figure 2-40 and secure with the four No. 6-32 pan head screws removed earlier.
INSTALLATION Pit Covers Note: If this is a European dyno, you will need to install the EEC finger guards. Refer to Appendix B for EEC finger guard installation instructions. 3 Loosely attach the drum guard bracket to the left side drum cover using four 1/4-20 x 1/2-inch button-head flange screws. Note: Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to secure the 1/4-inch screws.
CHAPTER 2 Pit Covers 6 7 Place the right side drum cover over the drum module. Loosely secure the right side drum cover using four 3/8-16 x 1/2-inch button-head flange screws. Do not tighten. 8 Loosely secure the right side drum cover to the drum guard bracket using four 1/4-20 x 1/2-inch button-head flange screws. 9 Align the pit covers so the drum guard is centered on the drum both front to back and side to side. 10 Tighten all pit cover screws.
INSTALLATION Pit Covers 11 Install the drum guards using two 1/4-20 x 1/2-inch button-head flange screws and two 1/4-20-inch crush nuts. Note: If you installed the EEC finger guards, you will need to adjust them now. Refer to page C-3 for adjusting instructions.
CHAPTER 2 Junction Box Cover, Cable Cover, and End Cap JUNCTION BOX COVER, CABLE COVER, AND END CAP ................................... Before installing the junction box cover, cable cover, and end cap be sure to route all of your cables. If you ordered any additional accessories refer to Chapter 3 for installation instructions. 1 Secure the blower connector cover to the junction box using two 4-40 screws. This cover attaches opposite the blower connectors.
INSTALLATION Junction Box Cover, Cable Cover, and End Cap 3 4 5 Loosely attach the end cap to the pit cover using two 1/4-20 button-head screws. Leave these screws loose. Secure the cable cover to the end cap and junction box using two 8-32 screws. Tighten the end cap screws.
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 Specialists 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. 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 Air Brake AIR BRAKE ................................... The optional 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 to 60 ps i clean dry air Route the air brake air hose through the access hole in the drum module upright and through the pit conduit. Connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the air hose.
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 3-5: Removing 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 3-8: Replacing 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, disconnect the battery and unplug the dyno. 1 2 3 4 5 6 Open the CPI’s front panel access and turn off the main breaker. Unplug the dyno power cable. Refer to page 3-2. Remove the eight button-head screws securing the right drum cover and set aside. Remove the right drum cover and set aside. For safety, apply the brake and disconnect the air supply. Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor.
CHAPTER 3 Air Brake 7 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.
ACCESSORIES Air Brake 8 Remove the two bolts and two washers securing the brake caliper stop to the brake bracket and remove the brake caliper stop. brake bracket brake caliper stop Figure 3-13: Remove the Brake Caliper Stop 9 Remove the hairpin cotter from the bottom clevis pin located on the front of the air brake assembly.
CHAPTER 3 Air Brake 10 Push the bottom clevis pin towards the back of the assembly (drum side). You do not need to remove the pin completely. 11 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 3-15: Remove Bottom Pin and Top Hairpin Cotter 12 Remove the top clevis pin.
ACCESSORIES Air Brake 13 Lift the air brake assembly up and away from the dyno. air brake assembly Figure 3-17: Remove the Brake Assembly 14 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). 15 Install the new brake pads and secure the pads with new springs. 16 Place the air brake assembly back on the brake bracket. Refer to Figure 3-17.
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 3-18.
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 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. The extended carriage comes with a 58-inch cable carrier, instead of the standard 40-inch cable carrier. For cable routing instructions refer to “Routing the Power Carriage and Wheel Clamp Cables” on page 2-28.
ACCESSORIES Extended Carriage INSTALLING THE EXTENDED CARRIAGE PLATE 1 Remove the four bearing plate screws and slide the extended carriage from the extended carriage plate.
CHAPTER 3 Extended Carriage 2 Use the extended carriage plate to mark and drill mounting holes as shown in Figure 3-20. 2a Using the extended carriage plate as a template, drill four 1/2-inch holes. 2b Install the Red Head anchors according to the instructions in Appendix A. 40.32 cm (15.875 in) Figure 3-20: Extended Carriage Plate Mounting Dimensions 3-20 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide 66.04 cm (26.
ACCESSORIES Extended Carriage 3 Secure the extended carriage plate to the floor using four 3/8 x 1-inch bolts and 5/16-inch washers.
CHAPTER 3 Extended Carriage INSTALLING THE EXTENDED TIRE CARRIAGE 1 2 3 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. Secure the bearing bracket to the carriage using the four 1/4-20 x 1/2-inch button-head flange bolts removed earlier.
ACCESSORIES 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. PARTS LIST The following table lists all of the parts included in the High Pressure Blower Assembly (P/N 76722003). 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.
CHAPTER 3 High Pressure Blower INSTALLING THE HIGH PRESSURE BLOWERS Refer to page 2-16 for blower mount installation instructions. Repeat the following steps for each blower assembly. blower assembly 1 Place two 1/4-inch thick poly washers around the pin on the blower mount. Note: Only use one 1/4-inch thick poly washer with the blower mount installed with the support arm. 2 3 4 5 6 7 8 Place the lower blower arm over the blower mount pin.
ACCESSORIES High Pressure Blower ATTACHING THE BLOWER CABLES The blower cables were routed from the CPI to the junction box on page 2-27. Refer to “Routing the High Pressure Blower Cables” on page 2-27 for more information. 1 Attach the two blower connectors to the junction box using 4-40 screws. Note: The blower connectors are attached to the blower cables. 2 Connect the cables from each blower to the connectors on the junction box.
CHAPTER 3 Wheel Clamp WHEEL CLAMP ................................... The wheel clamp allows you to easily adjust for various wheel thicknesses with the press of a button. Refer to “Using the Wheel Clamp” on page 4-6 for more information on using the wheel clamp. INSTALLING THE WHEEL CLAMP 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.
ACCESSORIES Wheel Clamp 4 5 6 7 Bring the wheel clamp cable (three-pin connector) from the cable track over to the wheel clamp. This cable was routed on page 2-28. 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. Replace the wheel clamp cover.
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 Basic CPI Operation BASIC CPI 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.
CONTROL PANEL INTERFACE OPERATION Basic CPI 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 4-3 for more information. Deactivates the dyno outputs whenever the button is pressed or the external E-Stop circuit is opened.
CHAPTER 4 Basic CPI 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.
CONTROL PANEL INTERFACE OPERATION Basic CPI Operation USING THE POWER CARRIAGE This 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.
CHAPTER 4 Basic CPI 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.
CONTROL PANEL INTERFACE OPERATION Basic CPI 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.
CHAPTER 4 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 CIRCUIT BREAKER The main circuit breaker is rated for 240VAC at 30A and all of the power into the dyno passes through this breaker. In the event of a major overload or failure this breaker will trip.
CONTROL PANEL INTERFACE OPERATION Maintenance and Troubleshooting MAINTENANCE AND TROUBLESHOOTING ................................... This section contains basic maintenance and troubleshooting information for the wheel clamp, theta controller fuses and CPI fuses. MAINTAINING AND TROUBLESHOOTING THE 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.
CHAPTER 4 Maintenance and Troubleshooting REPLACING THE THETA CONTROLLER FUSES Hazardous voltage. To avoid risk of electrical shock, disconnect the battery and unplug the dyno. 1 Remove the Control Panel Interface (CPI) cover and set aside. Refer to “Accessing the CPI” on page 2-22. 2 Gently push the fuse holder slightly inward and rotate counterclockwise. Remove the fuse holder. 3 Replace the fuse with a fuse type listed below. 4 Replace the CPI cover using the eight button-head screws removed earlier.
CONTROL PANEL INTERFACE OPERATION Maintenance and Troubleshooting TROUBLESHOOTING CPI FUSES Fuses F3 and F4 fuse the 240VAC as it enters the CPI board. One fuse is used 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.
CHAPTER 5 BASIC DYNO OPERATION This chapter includes instructions for basic dyno operation. For more detailed instructions, refer to your 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.
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. 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 installation.
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, Yokohoma, 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 crate with 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’s CPI box has four conductors internally and their colors are brown, blue, black, and green/yellow.
APPENDIXB Locations using 60Hz Power (North America & Japan) CONNECTING THE DYNO 1 2 3 4 5 6 Turn off the main circuit breaker on the dyno. The main breaker is located inside the CPI door. When the handle is in the down position all power into the dyno is turned off. Refer to page 3-2 for breaker location. Once you verify the voltages on the receptacle, connect the dyno to the receptacle. Check that the high pressure blowers are connected to the dyno.
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’s CPI box 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 Version 2 Turn off the main circuit breaker on the dyno. The main breaker is located inside the CPI door. When the handle is in the down position all power into the dyno is turned off. Refer to page 3-2 for breaker location. Once you verify the voltages on the receptacle, connect the dyno to the receptacle. Check that the high pressure blowers are connected to the dyno.
APPENDIX C EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION This appendix contains instructions for installing the EEC Kit to the model 200iP/250iP motorcycle pit dynamometers. This appendix will walk you through installing the EEC finger guards and door safety switch. The finger guards and door safety switch are required only for European dynamometers. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIXC EEC Finger Guards EEC FINGER GUARDS ................................... The European model 200iP/250iP dynamometers require guards mounted on the front and back of the drum guard bracket. The EEC finger guards 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. Do not operate the dynamometer without the EEC finger guards properly installed.
EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION EEC Finger Guards ADJUSTING THE EEC FINGER GUARDS Once the pit cover plates are installed and adjusted, the EEC finger guards will need to be adjusted. 1 2 Loosen the 1/4-20 x 5/8-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.
APPENDIXC 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 FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION Door Safety Switch 5 Loosen the screws that hold the jumper wires in place and remove the wire. 6 Route the black and yellow wire from the door safety switch through the dyno. Make sure the switch will not get caught in any moving components or chafed on any edges. 7 8 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 D 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.
APPENDIXD 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.
INDEX 25-pin cable 2-34 50Hz power B-7–B-11 60Hz power B-2–B-6 9-pin cable 2-34 A accessories air brake 3-3–3-16 air pump and filter assembly 3-17 eddy current brake 2-6 extended carriage 3-18–3-22 high pressure blowers 3-23–3-25 monitor tray 2-18 wheel clamp 3-26–3-27 air brake 3-3–3-16 adjustments and tests 3-10, 3-16 brake pads 3-11–3-15, 3-16 emergency stop sticker 3-6 parts list 3-3 routing cables 3-4 air fuel sensor cable 2-35 air pump and filter assembly 3-17 air pump power cable 2-35 air pump, us
INDEX control panel 4-2 air pump 4-3 blowers 4-3, 4-4 dyno shutdown 4-3, 4-4 emergency stop 4-3, 4-4 features 4-2–4-3 installing 2-26 power carriage 4-3, 4-5 routing cables 2-23–2-26 starter 4-3, 4-5 status indicator 4-3 wheel clamp 4-3, 4-6 control panel interface basic operation 4-2–4-7 battery charger 2-20 removing the cover 2-22 conventions 1-3 coupler 2-9 set screws 2-11 CPI removing the cover 2-22 routing cables 2-23 CPU module 2-34 crate remove dyno 2-4 remove tire carriage 2-2 unpacking dyno 2-2–2-
I Industrial Noise Control, Inc.
INDEX S secondary inductive pickup 5-7 setting tool A-3 specifications 1-5–1-8 starter routing cable 2-33 using 4-5 starter brace 2-9, 2-10 status indicator 4-3, 4-6 support arm anchor placement 2-16 installing 2-17 remove from crate 2-2 T technical support 1-3 temperature sensor cable routing wiring to breakout board 2-36 testing voltages B-4, B-9 theta controller dip switches D-2 power adjustment D-2 power line frequency D-3 power line voltage D-3 replace fuses 4-10 wiring to breakout board 2-36 tie-d
