©2008 Dynojet Research, Inc. All Rights Reserved. Model 200iX/250iX Upgrade Installation Guide This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, as well as the software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license.
TABLE OF CONTENTS Warnings Chapter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Model 200iX/250iX Upgrade Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Chapter 2 Basic Dyno Operation Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . 2-5 Connecting The Primary Inductive Pickup .
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. Any dyno room design must incorporate sufficient exhaust extraction.
CHAPTER 1 MODEL 200IX/250IX UPGRADE Thank you for purchasing the 200iX/250iX upgrade for Dynojet’s Model 200i/250i Motorcycle Dynamometer. This upgrade will allow you to run a kart, ATV, or trike on your motorcycle dynamometer. Dynojet’s software and dynamometers will give you the power to get the maximum performance out of vehicles you evaluate.
CHAPTER 1 Introduction INTRODUCTION ................................... Before installing your 200iX/250iX upgrade, please take a moment to read this guide for installation instructions, dyno features, and other important information. CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. example of convention description The Caution icon indicates a potential hazard to the dynamometer equipment.
MODEL 200IX/250IX UPGRADE Model 200iX/250iX Upgrade Specifications MODEL 200IX/250IX UPGRADE SPECIFICATIONS ................................... The following specifications and requirements will help you set up your dyno area for the 200iX/250iX upgrade. Refer to the model 200i/250i installation guide for specifications and requirements for the bike dyno.
CHAPTER 1 Model 200iX/250iX Upgrade Specifications Figure 1-1: Model 250iX Dyno Dimensions 1-4 Model 200iX/250iX Upgrade Installation Guide
MODEL 200IX/250IX UPGRADE Model 200iX/250iX Upgrade Specifications Folding Ramp Option (Dyno) Eddy Current Brake Monitor Support and Tray High Pressure Blower Wheel Clamp Option Folding Ramp Option (iX Upgrade) Power Carriage Option Model 250i Dyno iX Drum Module iX Upgrade Trike Carriage Adapter Figure 1-2: Model 250iX Dyno with Accessories Version 1 Model 200iX/250iX Upgrade Installation Guide 1-5
CHAPTER 1 Dyno Preparation DYNO PREPARATION ................................... Use the following instructions to prepare the dyno for installing the upgrade kit. DISCONNECTING THE POWER Use the following steps to connect and disconnect power to the dyno. Always turn the power off when connecting and disconnecting cables. 1 Use the main breaker to turn power on and off to the dyno. The main breaker is located inside the CPI door.
MODEL 200IX/250IX UPGRADE Dyno Preparation REMOVING THE HIGH PRESSURE BLOWER ASSEMBLIES 1 2 3 Unplug each high pressure blower power cord from the dyno chassis. Remove the clamp lever securing the blower arm assembly to the dyno and discard. Do this for both blower assemblies. Lift the blower and arm assembly from the dyno and set aside. Do this for both blower assemblies. Note: Both blower assemblies must be removed in order to replace the lower blower arm.
CHAPTER 1 Dyno Preparation REMOVING THE MONITOR STAND 1 2 3 4 Disconnect all cables from the monitor stand. Remove the monitor arms and tray. Remove the four screws securing the monitor support and set aside. Remove the monitor support and set aside.
MODEL 200IX/250IX UPGRADE Dyno Preparation REMOVING THE DYNO PANELS 1 Push the wires, from the monitor stand, back through the cable pass through. Note: Perform this step only if the monitor stand was installed on the right side of the dyno. 2 Remove the five screws securing the top panel to the dyno and set aside. Remove the top panel and set aside. Disconnect the fan power cable from the power socket on the inside of the side panel.
CHAPTER 1 Drum Installation DRUM INSTALLATION ................................... When you receive your iX upgrade kit, 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 drum and items. You will need to provide equipment capable of lifting a minimum of 272 kg (600 lb.) to move the crated drum into position in your dyno room.
MODEL 200IX/250IX UPGRADE Drum Installation part description lower blower arm (2) P/N 21600015 washer, 1.5 x .38 ID x .187 THK (2) P/N 26215220 part description trike carriage adapter assembly P/N 71300002 bolt kit P/N 79100000 washer, 1.87 x 1.25 ID x .25 THK (2) P/N 26215521 4 5 Version 1 Remove the crate braces that support the top portion of the crate. Remove the four lag bolts and washers securing the drum to the crate base using a 9/16-inch socket, open or box end wrench.
CHAPTER 1 Drum Installation INSTALLING THE IX DRUM MODULE You will need the following parts: • 26152030 Spacer • 36561045 Screw, 1/4-20 x 5/8", PH, Torx (2) • 37620622 Woodruff Key (2) • 62240070 Retarder Driveline Assembly • 63200001 iX Drum Module 1 Remove the drum safety cover from the iX drum module. 2 Remove the six screws securing the iX drum cover and set aside. Remove the cover and set aside. 3 Place the nylon loop strap around the shaft on either side of the drum module.
MODEL 200IX/250IX UPGRADE Drum Installation 12 Place the air pump spacer (P/N 26152030) as shown in Figure 1-8. Note: For clarity, the iX drum module is not shown.
CHAPTER 1 Drum Installation 13 Secure the connector plate on either side of the drum module to the dyno frame using the screws removed earlier. 14 Verify the panels on the drum module and the dyno line up. These covers must be flush and parallel. If these covers are not flush, place shims between the floor and the drum module or the dyno until they are flush. 15 Once aligned, tighten all screws. 16 Secure the side panels on the drum module to the panels on the dyno using one 1/4-20 x 5/8-inch screw.
MODEL 200IX/250IX UPGRADE Bulkheads and Covers BULKHEADS AND COVERS ................................... You will need the following parts: • • • • • • • 21200022 21200024 21600012 36468100 36561045 61300007 76950053 Middle Bulkhead Front Bulkhead Toe Kick Bracket Nut, 1/4-20, Nylock (5) Screw, 1/4-20 x 5/8", PH, Torx (16) Monitor Support Brace Cable, Fan Power Extension INSTALLING THE BULKHEADS 1 2 3 4 Place the monitor support brace on the five studs on the front bulkhead.
CHAPTER 1 Bulkheads and Covers 5 6 7 8 Remove the existing 3/8-inch screw from the drum module and secure the toe kick bracket to the drum module. Attach the blower extension cable to the existing blower cable, disconnected earlier, by matching up the colors. Route the cables removed from the monitor stand over to the left side of the dyno. Route any monitor arm cables through the cable pass through.
MODEL 200IX/250IX UPGRADE Bulkheads and Covers INSTALLING THE PANELS AND COVERS 1 Secure the drum top cover to the drum module using the six 1/4-20 x 5/8-inch button-head screws removed earlier. Note: Extra 1/4-20 x 5/8-inch button-head screws are included, should they be requuired. drum top cover Figure 1-12: Securing the Drum Module Top Cover 2 Secure the center panel to the bulkheads using six 1/4-20 x 5/8-inch button-head screws.
CHAPTER 1 Bulkheads and Covers 3 4 Attach the blower extension cable to the fan socket. • Connect the brown wire to N • Connect the blue wire to L • Connect the green/yellow wire to ground Secure the dyno side panel to the bulkheads using the eleven screws removed earlier.
MODEL 200IX/250IX UPGRADE Bulkheads and Covers 5 6 Secure the dyno top side panel to the bulkheads using the five screws removed earlier. Secure the drum side cover to the drum module using the eight 1/4-20 x 5/8-inch button-head screws removed earlier. dyno top side panel drum side cover Figure 1-15: Securing the Dyno Top Side Panel and Drum Side Cover 7 Place the drum safety cover over the drum. This cover has two pins to keep it in place. Risk of injury.
CHAPTER 1 Trike Carriage Adapter Installation TRIKE CARRIAGE ADAPTER INSTALLATION ................................... Use the following instructions to remove the carriage assembly, install the trike carriage adapter (P/N 71300002), and replace the carriage assembly.
MODEL 200IX/250IX UPGRADE Trike Carriage Adapter Installation REMOVING THE CARRIAGE SCREW AND CARRIAGE The monitor stand and high pressure blowers are not shown for clarity. If the carriage is not installed, skip to “Installing the Trike Carriage Adapter Assembly” on page 1-23. 1 2 3 Remove the four 1/4-20 x 1/2-inch button-head screws securing the bearing bracket and set aside.
CHAPTER 1 Trike Carriage Adapter Installation REMOVING THE CARRIAGE CLAMPS, SHIMS, AND NUT BLOCK If the carriage is not installed, skip to “Installing the Trike Carriage Adapter Assembly” on page 1-23. 1 2 3 4 Remove the two 5/16 x 1-inch bolts and two 5/16-inch lock washers securing each carriage clamp and shim and discard. This hardware will not be used. Remove the three carriage clamps and shims and discard. These will not be used.
MODEL 200IX/250IX UPGRADE Trike Carriage Adapter Installation INSTALLING THE TRIKE CARRIAGE ADAPTER ASSEMBLY 1 2 Secure the trike carriage adapter assembly to the dyno using six 5/16 x 1-inch button-head bolts where the carriage assembly was installed and two 3/8 x 1-inch button-head bolts as shown in Figure 1-19. Lube the tracks with the included lube or use grease.
CHAPTER 1 Trike Carriage Adapter Installation INSTALLING THE CARRIAGE ASSEMBLY 1 2 3 4 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. Using the hand crank, or the control panel to run the power carriage, run the carriage screw through the nut block and into the screw support bracket on the carriage assembly.
MODEL 200IX/250IX UPGRADE Tie-Down Installation TIE-DOWN INSTALLATION ................................... You will need the following parts: 1 2 • 36582034 Bolt, 3/8-16 x 1.25", Button-head, Flange (8) • 61300009 Tie-Down (2) Install the tie-downs on the right side of the dyno using four 3/8-16 x 1.25-inch button-head flange screws. Place the tie-down on the left side of the dyno, but do not secure. Note: Do not secure the tie-down used with the monitor arm until the monitor arm is in place.
CHAPTER 1 Monitor Stand and Blowers Installation MONITOR STAND AND BLOWERS INSTALLATION ................................... You will need the following parts: 1 2 • 21600015 Lower Blower Arm (2) • 26215220 Washer 1.5 x .38 ID x .187 THK (2) • 26215521 Washer 1.87 x 1.25 ID x .25 THK (2) • 35712991 Clamp Lever, 3/8-16 x 3/4" (2) • 76950317 Blower Extension Cord Secure the monitor support to the dyno using the four screws removed earlier.
MODEL 200IX/250IX UPGRADE Monitor Stand and Blowers Installation 3 4 5 6 7 8 9 10 11 12 13 Place a 1/4-inch thick poly washer around the pin on the tie-down with the monitor arm. Place two 1/4-inch thick poly washers around the pin on the tie-down without the monitor arm. Replace the existing lower blower arms with the new lower blower arms as shown in Figure 1-23. Place the new lower blower arm over the pin. Place an aluminum washer between the clamp lever and the lower bower arm.
CHAPTER 1 Ground Hook Installation GROUND HOOK INSTALLATION ................................... Use the following instructions to install the ground hooks. You will need the following parts: 1 2 3 4 • 10111 Ground Hook/D-Ring (4) • 10112 D-Ring Bracket (4) • 36932100 Washer, 3/8”, Splitlock, Steel (8) • 37513200 Anchor, Redhead, 3/8" (8) • DM150-002-007 Washer, 5/16", Flat (8) • DM150-019-012 Bolt, 3/8-16 x 1”, Hex (8) Mark the ground hook placement as shown in Figure 1-24.
CHAPTER 2 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 2 Loading the Vehicle LOADING THE VEHICLE ................................... Use the following steps to load a vehicle on the dyno. For detailed information on loading a motorcycle on the dyno, refer to your motorcycle dyno installation guide. Risk of injury. Always wear proper eye and ear protection when operating the dyno. 1 2 3 4 5 6 Verify your computer is running. Set the dyno brake on by pressing the red button on the hand held pendant. For ATVs, slide the carriage to the center position.
BASIC DYNO OPERATION Loading the Vehicle 7 8 9 When the vehicle is positioned properly on the dyno, shut the engine off. • If the vehicle has an automatic transmission, place it in park. • If the vehicle has a manual transmission, place it in gear. Attach two tie-down straps from the anchor points on the ramp, or the ground hooks, to the rear of the vehicle. Attach two tie-down straps from the anchor points on the dyno to the vehicle chassis.
CHAPTER 2 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 SECONDARY INDUCTIVE PICKUP 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. Do not drop the inductive pickup or snap the pickup closed. Use extreme care in handling and placement of the pickups.
CHAPTER 2 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.
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 2 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 2 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.
APPENDIX A 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 RAMP KIT INSTALLATION This appendix contains instructions for installing the 200iX/250iX ramp kit. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIX B Ramp Installation RAMP INSTALLATION ................................... Verify the dyno ramp is in place and secured to the dyno before beginning with the iX upgrade ramp installation. You will need the following parts: 1 2 3 4 • 21200029 Tie-Down Hook Plate • 21200039 Ramp Top Cover • 21200047 Ramp Panel • 36561045 Screw, 1/4-20 x 5/8”, PH, Torx (8) • 61300011 Folding Ramp Option • DM150-020-005 Nut, Crush, 1/4-20 (8) Remove the two existing 3/8-16 x 1.
RAMP KIT INSTALLATION Ramp Installation 5 6 Secure the ramp panel to the iX ramp using four 1/4-20 x 5/8-inch pan-head torx screws and four 1/4-20 nuts. Secure the ramp panel to the dyno ramp using four 1/4-20 x 5/8-inch pan-head torx screws and four 1/4-20 nuts. Note: If the dyno ramp does not have the holes, drill four 1/4-inch holes.
APPENDIX B Ramp Installation 7 Remove the four existing 1/4-20 x 5/8-inch screws from the dyno ramp as shown in Figure B-3. 8 Remove the two existing 1/4-20 x 5/8-inch screws from the iX ramp as shown in Figure B-3. 9 Secure the ramp tie-down to the dyno ramp using the four screws removed earlier. 10 Secure the ramp tie-down to the iX ramp using the two screws removed earlier. 11 Place the ramp cover as shown in Figure B-3. Note: The ramp cover provides easy access to the air pump filter assembly.
INDEX A accessories 1-5 air pump spacer 1-13 B battery hazards iv blower extension cable 1-16, 1-18 blowers installing 1-27 removing 1-7 brake pads 2-10 brake pressure 2-10 bulkheads blower extension cable 1-16 front 1-15 installing 1-15 middle 1-15 monitor support brace 1-15 toe kick bracket 1-16 C carriage installing 1-24 removing 1-21 carriage clamps 1-22 center panel 1-17 chassis specifications 1-3 connector plate 1-14 conventions 1-2 crate, removing parts 1-10 D dimensions 1-4 disclaimers iii d
INDEX H hazards v height 1-3 I inspection 2-7 L length 1-3 loading the vehicle 2-2 S secondary inductive pickup 2-5 setting tool A-3 shims 1-22 side panel 1-18 spacer, air pump 1-13 specifications chassis 1-3 length, height, width, weight 1-3 T maintenance 2-10 making a run 2-9 middle bulkhead 1-15 monitor stand installing 1-26 removing 1-8 monitor support brace 1-15 technical support 1-2 testing the dyno 2-9 tie-down straps 2-3 tie-downs, installing 1-25 toe kick bracket 1-16 top side panel 1-19
