Dynojet 200iX, 250iX Installation Manual

©2010-2016 Dynojet Research, Inc. All Rights Reserved.
#
RECORD
Installation Guide For Above Ground Model 200iX and 250iX DynoWare RT Motorcycle Dynamometers.
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. Dynojet assumes no responsibility or liability for any error or inaccuracies that may appear in this manual. Except as permitted by such license, no part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Dynojet.
The Dynojet logo is a trademark of Dynojet Research, Inc.
Any trademarks, trade names, service marks, or service names owned or registered by any other company and used in this guide are the property of their respective companies.
Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA.
Printed in USA.
Part Number: 98200077 Version 2 (07/2016)
Dynamometer Number: ____________________________________________________
iX Dynamometer Number: _________________________________________________
iXW Dynamometer Number: _________________________________________________
Eddy Current Brake (Retarder) Number:_________________________________________________________
T
ABLE OF
C
ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Chapter 1 Specifications and Operating Requirements
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Your Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
DynoWare RT Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Main Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Chapter 2 Installation
Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Routing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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Secure the Dyno and Brake Module to the Floor . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Remove the Dyno Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
iX Drum Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Installing the iX Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
Installing the Bulkheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Identifying the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
Installing the DynoWare RT Main Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Routing the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . . . . . . . 2-38
Side and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
Installing the iX Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Fan Arm Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Trike Carriage Adapter and Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Installing the Trike Carriage Adapter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
Installing the Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Monitor Support and Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Control Panel and Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
High Pressure Blower Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Trike Carriage Adapter Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Ground Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Ramp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
Chapter 3 Accessories
Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Routing the Air Brake Cables and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
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Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Air Fuel Ratio Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Installing the Extension Support and Trike Carriage Adapter Assembly . . . . . . 3-18
Installing the Extended Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Removing the Hand Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
TABLE OF CONTENTS
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Chapter 4 Control Panel Interface Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Basic CPI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Using the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Understanding Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Using the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Using the Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Using the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Power Distribution Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Main Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
High Pressure Blower Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Maintaining and Troubleshooting the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . 4-10
Replacing the Eddy Current Brake Driver Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Troubleshooting CPI Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Chapter 5 Basic Dyno Operation
Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Connecting The Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Grounding the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Using the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
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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 and Installation
Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Power Requirements and Installation—Excluding North America and Japan B-5
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Appendix C EEC Kit Installation
EEC Finger Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Removing the Drum Module Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Installing the Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5
Appendix D Folding Ramp Installation
Ramp Installation—Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Removing the Ramp from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Installing the Ramp on the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
Ramp Installation—iX Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Appendix E Above Ground iXW Installation
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Dynamometer Specifications—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . E-2
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Above Ground iXW Upgrade Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5
Installing the Above Ground iXW Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . E-8
Installing the Bulkheads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11
Continue Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
Side and Top Covers—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . . . . . . . E-14
Installing the iXW Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-16
Continue Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-17
Ground Hook Installation—Above Ground iXW Dyno . . . . . . . . . . . . . . . . . . . . . E-18
TABLE OF CONTENTS
Appendix F Torque Values
Standard Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3
Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Grade 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Grade 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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W
CAUTION
ARNINGS
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.
Dynojet is not responsible for false operation due to unexpected dynamometer operation such as may be caused by static, software bugs, hardware failure, etc.
Dynojet is not responsible for damage resulting from improper installation of the dynamometer or from improper service rendered to the dynamometer. Dynojet is not responsible for damage incurred due to alteration of the dynamometer or components, use of unapproved parts, or abuse to the dynamometer.
Do not connect or disconnect cables or components on the dynamometer with the power on. Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when using
and servicing the dynamometer.
Equipment Power Requirements
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect voltage will void the dynamometer warranty. Installation may require a licensed electrician.
Potentially Lethal Voltages
Components attached to and within the dynamometer operate with potentially lethal voltages. To provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power source before servicing electrical components or wiring. Disconnect all power cords before servicing electrical components for the greatest assurance of safety.
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
viii
WARN ING S
Electrostatic Discharge Precautions
CAUTION
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. Dynojet designs its dynamometers to be very tolerant of static shocks by the users, but the electronics are vulnerable when the electronics are exposed. ESD occurs as a result of a difference of potential between two o bjects when the two objects touch. Damage occurs as a result of the energy released when the discharge (touch) occurs. The difference of potential can accumulate by as simple an action as a user moving across carpet or a seat. If that person’s energy is discharged directly to the electronics, the electronics can be damaged .
Precautions
To protect against ESD damage, you must eliminate the di ffer ence of pote nt ial befo re the el ect r oni cs are handled. Touch the chassis of the dynamometer before touching any of the electronics. By touching the chassis, you discharge any static shocks to the chassis instead of to the electronics.
If you are holding a circuit board or dynamometer component in your hand when you approach the machine, touch the chassis of the dynamometer with your hand before installing the circuit board or component.
When handling a circuit board or component to someone, touch that person with your hand first, then hand them the component.
Always carry circuit boards in anti-static bags when the boards are exposed (removed from the dynamometer).
Battery Fire and Explosion Hazards
There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Discard used batteries according to the manufacturer’s instructions.
Automotive Batteries
In operation, batteries generate and release flammable hydrogen gas. They must always be assumed to contain this gas which, if ignited by burning cigarette, naked flame or spark, may cause battery explosion with dispersion of casing fragments and corrosive liquid electrolyte. Carefully follow manufacturer's instructions for installation and service. Keep away all sources of gas ignition and do not allow metallic articles to simultaneously contact the negative and positive terminals of a battery.
Do not allow the positive and negative terminals to short-circuit. The dynamometer chassis is tied to the negative side of the battery. Do not short between the positive battery terminal or the starter connections to the chassis. In addition, make sure metal tools such as screw drivers, wrenches, and torque wrenches do not come in contact with the negative and positi ve terminals of the battery. Short circuiting the terminals of the battery can cause burn injuries, damage to the dynamometer, or trigger explosions.
Charging
Batteries being charged will generate and release flammable hydrogen gas. Charging space should be ventilated. Keep battery vent caps in position. Prohibit smoking and avoid creation of flames and sparks nearby.
Wear protective clothing, eye and face protection, when charging or handling batteries.
WARN ING S
CAUTION
Grounding Requirements
Always ground the vehicle to the dynamometer. Never operate the dynamometer without properly grounding the vehicle to the dyno.
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. Always wear proper ear and eye protection when operating the dynamometer. Never operate the dynamometer with the covers removed. Never stand behind the dynamometer when in operation. Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems
before proceeding. Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken. Verify brake operation before beginning any dynamometer testing. Verify the vehicle is properly secured to the dynamometer. Verify the vehicle is properly grounded to the dynamometer. Never operate the blowers without the guards installed. Exercise care with any dynamometer testing; portions of the dynamometer and vehicle may become
hot. As with any equipment using electricity and having moving parts, there are potential hazards. To use
this dynamometer safely, the operator should become familiar with the instructions for operation of the dynamometer and always exercise care when using it.
Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically recommended in published user-repair instructions that you understand and have the skills to carry out.
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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CHAPTER 1
S
PECIFICATIONS AND
O
PERATING
R
EQUIREMENTS
Thank you for purchasing Dynojet’s Above Ground Model 200iX/250iX 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 Power Core software and a Dynojet dynamometer will give you the professional results you are looking for.
This document provides instructions for installing the above ground motorcycle dynamometer (dyno) along with the kart upgrade. This document will walk you through operating requirements, installation, accessories, and basic dyno operation. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
Document Part Number: 98200077 Version 2 Last Updated: 07-25-2016
This chapter is divided into the following categories:
• Introduction, page 1-2
• Dynamometer Specifications and Requirements, page 1-5
• DynoWare RT Electronics, page 1-11
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-1
CHAPTER 1

Introduction

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-2
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.
INSTALLATION
This chapter describes the procedures for installing the dyno.
ACCESSORIES
This chapter lists each dyno accessory alphabetically and describes the procedures for installing and using the accessory.
CONTROL PANEL INTERFACE OPERATION
This chapter describes the Control Panel Interface (CPI) operating procedures.
BASIC DYNO OPERATION
This chapter describes basic dyno operating procedures.
RED HEAD INSTALLATION
This appendix describes the procedures for installing the Red Head anchors.
POWER REQUIREMENTS
This appendix describes the power requirements and installation instructions for the dyno.
EEC FINGER GUARD & DOOR SAFETY SWITCH KIT
This appendix describes the procedures for installing the EEC finger guards and door safety switch.
FOLDING RAMP INSTALLATION
This appendix describes the procedures for installing the folding ramp assemblies for the dyno and iX upgrade.
ABOVE GROUND IXW INSTALLATION
This appendix describes the procedures for installing the above ground iXW upgrade kit.
TORQUE VALUES
This appendix describes standard and metric torque values.
SPECIFICATIONS AND OPERATING REQUIREMENTS
Introduction

CONVENTIONS USED IN THIS MANUAL

CAUTION
#
RECORD
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. 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.
The Record # icon reminds you to record your dynamometer and/or eddy current brake (retarder) number on the inside cover of this manual.
Bold Highlights items you can select on in the software
interface, including buttons and menus. The arrow indicates a menu choice. For example,
“select
File Open means “select the File menu,
then select the
Open choice on the File menu.”

TECHNICAL SUPPORT

For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product lines.
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CHAPTER 1
Introduction
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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YOUR DYNO ROOM

This section is not meant to imply that a dyno room is essential to repeatable results on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan, exhaust extraction, and noise reduction capabilities can add a new dimension to your shop.
A proper dyno room design will help to ensure repeatable, accurate runs. A good dyno room should do the following:
• minimize noise
• provide a controlled environment for testing
• provide a view window (safety glass) for customers
• be designed with safety in mind
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.
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.
Exhaust Extraction—An exhaust fan is needed to remove exhaust gasses, especially carbon monoxide, from the dyno room. Carbon monoxide is potentially lethal to people if not removed from the room and will affect engine power when mixed with fresh air.
Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death. Operate machine in well ventilated area.
Fire Suppression—Always have adequate fire suppression or fire extinguishers in your dyno room.
Industrial Noise Control, Inc—Industrial Noise Control, Inc. offers a zinc-coated steel room custom built to your specifications. This room meets all dyno room requirements. The dyno room must be clean and dry with a comfortable room air temperature above 32 degrees Fahrenheit (0 degrees Celsius), and have some system of exhaust extraction. For more information on a dyno room, refer to your Pre-Installation Guide For Model 200i, 250i, 200iP, and 250iP Motorcycle Dynamometers (P/N 98200081).
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 200iX/250iX dyno is designed to carry a group 24 deep-cycle discharge series battery for operating the starter, power carriage, and optional wheel clamp. The typical dimensions for this seri es 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. The built-in battery cables are configured for top-post batteries. This battery is not included with your dyno. You will need to provide this battery. For more information on installing the battery, refer to “Battery” on page 2-13.

CHASSIS SPECIFICATIONS

description specifications
Length
with standard carriage allow 271.78 cm (107.00 in.) with extended carriage allow 322.58 cm (127.00 in.) with ramp 370.84 cm (146.00 in.)
Height
to top of dyno cover 45.97 cm (18.00 in.)
Width
model 200iX 200.69 cm (79.00 in.) model 250iX 274.32 cm (108.00 in.)
Weight
model 200i dyno/crated dyno 725 kg (1600 pounds)/771 kg (1700 pounds) model 250i retarder module/crated 953 kg (2100 pounds)/1,089 kg (2400 pounds) 200iX/250iX drum module/crated 136 kg (300 pounds)/363 kg (800 pounds)
Drum
diameter 45.72 cm (18.00 in.) width 50.80 cm (20.00 in.) diameter, 200iX/250iX 45.72 cm (18.00 in.)
width, 200iX/250iX 55.88 cm (22.00 in.) Frame structural steel Maximum Speed 322 KPH (200 MPH) Maximum Motorcycle Length (front of front
wheel to center of rear wheel)
standard carriage 213.00 cm (84.00 in.)
extended carriage 256.54 cm (101.00 in.) Remote Switches remote software control
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CHAPTER 1
Dynamometer Specifications and Requirements
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-6
Figure 1-1: Model 250iX Dyno Dimensions
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
iX Drum Module
Eddy Current
Brake
High Pressure
Blower
Wheel Clamp
Option
Power Carriage
Option
Monitor Support
and Tray
Model 250i Dyno
Air Brake Option
(not shown)
Air Pump Option
(not shown)
Control Panel
Trike Adapter
Assembly
Folding Ramp Option
(Dyno Module)
Folding Ramp Option
(iX Module)
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
Figure 1-2: Model 250iX Dyno with Accessories
1-7
CHAPTER 1
Dynamometer Specifications and Requirements
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-8

COMPRESSED AIR REQUIREMENTS

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.
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)
The following requirements are needed for the on-dyno compressed air pump assembly:
• Clean and dry air, 100 psi or greater, 5 CFM or better flow
• Fittings to hook your air system to a 3/8-inch inside diameter hose (if no air brake is present)
• 1/4-inch NPT pipe thread compressed air connector
• optional air regulator
description minimum specifications recommended specifications
Operating System Windows 7 or later Windows 7 or later Processor Dual Core Processor,
Memory 4GB System Ram 8GB System Ram or more Hard Drive 100GB or larger
Monitor/Graphics Card 1280x1024 (SXGA) resolution or
Network Adapter 1 free 10/100 Mbps
External Media CD Rom Drive CD Rom Drive Printer Printer, if prints or needed Color printer, if prints are needed

COMPUTER SPECIFICATIONS

You will need to provide a computer system to run the Power Core software. Refer to
www.dynojet.com for the latest computer requirements.
2GHz or faster
(54MB required for program)
higher
RJ45 Ethernet Port
Intel Core i5 2.8GHz or faster
500GB or larger (54 MB required for program)
1600x900 (WSXGA) resolution or higher
1 free 10/100Mbps RJ45 Port on IP Router, Wireless, or Wired and Internet Access
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements

DRILL AND DRILL BIT REQUIREMENTS

You will need to provide a drill and drill bit capabl e of dril ling holes in concrete. Refer to Appendix A for more information on installing Red Head Anchors.
• drill bit size: 1/2-inch
• minimum hole depth: 1 5/8-inch (41.2 mm)

ELECTRICAL REQUIREMENTS

The Model 200iX/250iX dynamometers require a 240V - 30a single-phase electrical circuit for reliable and precise operation. No other loads should be plugged into these circuits and these circuits should be independent of the lighting in the dyno room. Before you plug in your dyno, you or your electrician must refer to Appendix B for detailed information.

ENVIRONMENTAL REQUIREMENTS

description specifications
Temperature
operating min./max 10°C/50°C (50°F/122°F) storage min./max 0°C/60°C (32°F/140°F)
Humidity 0 to 95% non condensing

FORKLIFT REQUIREMENTS

You will need to provide equipment capable of lifting a minimum of 2268 kg. (5000 lb.) 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 2268 kg. (5000 lb.) to attach to the dyno. Dynojet recommends using single loop style straps.

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 dyno 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.
Using the ground hooks as a pattern, use the hardware included with the ground hook kit to install the Red Head anchors according to the instructions in Appendix A.
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CHAPTER 1
Dynamometer Specifications and Requirements
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-10

GROUNDING REQUIREMENTS

CAUTION
You will need to ground the vehicle to the dynamometer before every run using the vehicle grounding kit P/N 76100015. Never operate the dynamometer without first grounding the vehicle to the dynamometer. Refer to “Grounding the Vehicle” on page 5-8.
Always ground the vehicle to the dynamometer. Never operate the dynamometer without properly grounding the vehicle to the dyno.

PHONE AND INTERNET ACCESS

Dynojet recommends you have a phone close to the dyno to call for assistance in an emergency. You may also wish to contact Dynojet to troubleshoot your dyno.
Internet access on your computer is desirable for contacting Dynojet and downl oading new information and updates.

TIE-DOWN STRAPS

Dynojet recommends using motorcycle tie-down straps for securing the bike on the dyno. You will need to provide the tie-down straps.
SPECIFICATIONS AND OPERATING REQUIREMENTS

DynoWare RT Electronics

DYNOWARE RT ELECTRONICS
air fuel ratio
module
eddy current
brake driver
DynoWare RT
main module
speed pickup
The DynoWare RT electronics consists of a main module and a speed pickup. Optional modules include the Air Fuel Ratio (AFR) module and the Eddy Current Brake (ECB) driver. Use this section to identify the modules and connections. More detailed information for configuring the DynoWare RT electronics can be found in the Power Core Help.
Figure 1-3: DynoWare RT Electronics
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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CHAPTER 1
DynoWare RT Electronics
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-12

MAIN MODULE CONNECTIONS

1
2
1
2
12
Linx
!
C
Dynojet Research, Inc.
2191 Mendenhall Drive
N. Las Vegas, NV 89081
100-240 VAC
50-60 Hz
1.0 A
1
2
1234
Analog
Status
B
A
A
B
!
C
A description of the main module symbols and connections follows.
use this port to use this port to
RPM Inputs Connect inductive and optical
RPM inputs.
Auxiliary Temperature
Connect to an auxiliary input for an infrared temperature sensor.
Communication I/O Connect to auxiliary Dynojet
Communication I/O Connect to auxiliary dyno
Communication I/O Connect to internal dyno
Drum Connect to the drum 1 and
products such as the Power Commander, Wideband 2, Power Vision, etc.
electronics such as the pendant, atmospheric module, AFR module, etc.
electronics and controllers such as the ECB controller.
drum 2 speed inputs and digital brake outputs.
Auxiliary Switch Connect to the brake air
pressure switch on 248 and older 224 dynos.
Emergency Stop Connects the dyno electronics
to the emergency stop input on the 200i/250i dynos.
Network Connection
Connects the dyno electronics to your computer or computer network.
Refer to Instructions
Do not press this button unless instructed to do so by a Dynojet Technician. This button may need to be pressed to update the device.
SPECIFICATIONS AND OPERATING REQUIREMENTS
DynoWare RT Electronics

NETWORK CONNECTIONS

wireless network
internet and router
direct connection
point to point
The Dynojet DynoWare RT dyno electronics connects to your computer directly or over a Local Area Network. If you have an existing network, connect t he DynoWare RT main module to a router or a network switch on your network. If you don't have an existing network, you can create a network for the DynoWare RT by connecting the main module to a router.
There are some advantages to connecting the DynoWare RT to a network, particularly a wireless network. With DynoWare RT on a network, you don't have to have one dedicated computer for the dyno. Any computer on the network can connect and operate the dyno. A wireless connection allows you to control the dyno from inside the vehicle without a cable running to the DynoWare RT main module.
Note: Only one computer at a time can connect.
When the DynoWare RT main module is on a network connected to the internet, automatic updates for both the box and software are possible.
connection method auto updates
Wireless Network Internet
Wireless Network Router
Direct Connection Point to Point
Yes Yes Yes
multi-computer connection wireless connection
Yes Yes
Figure 1-4: DynoWare RT Network Connections
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
1-13
CHAPTER 2
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.
This chapter is divided into the following categories:
• Unpacking and Inspecting the Dyno, page 2-2
• Dyno Installation, page 2-10
• Battery, page 2-13
• Pickup Card, page 2-14
• Eddy Current Brake, page 2-15
• Secure the Drum and Brake Module to the Floor, page 2-23
• Remove the Dyno Covers, page 2-24
• iX Drum Module Installation, page 2-25
I
NSTALLATION
• Cable Routing, page 2-32
• Side and Top Covers, page 2-40
• Fan Arm Mounts, page 2-44
• Trike Carriage Adapter and Carriage Assembly, page 2-45
• Monitor Support and Tray, page 2-49
• Control Panel and Cable, page 2-50
• Final Adjustments and Tests, page 2-53
• Zip Tube, page 2-55
• Ground Hooks, page 2-56
• Ramp Bracket, page 2-57
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
2-1
CHAPTER 2

Unpacking and Inspecting the Dyno

Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
2-2
UNPACKING AND INSPECTING THE DYNO
D036
C
tire carriage
support arm
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. You will need to provide equipment capable of lifting a minimum of 1,133.98 kg (2,500 lbs.) to move the crated dyno into position in your dyno room. Refer to “Forklift Requirements” on page 1-9 for more information.
1 Move the crated dyno to a clear area near your dyno room. 2 Using a pry bar, or a large flat screwdriver, and a hammer, remove the top and
sides of the crate.
3 Inspect the exterior of the dyno for any indications of damage. Report any damage
immediately. 4 Remove the tire carriage. The tire carriage is fastened to the bottom of the crate. 5 Remove the support arm. The support arm is fastened to the bottom of the crate.
Refer to“Monitor Support and Tray” on page 2-49 for more information.
Figure 2-1: Remove the Tire Carriage and Support Arm from the Crate
INSTALLATION
Unpacking and Inspecting the Dyno
6 Remove the six 1/4-inch screws securing the center panel on the dyno and remove
D037
C
center panel
tire stop and tire lock
in middle
the center panel.
Note: Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to
remove the 1/4-inch screws. 7 Remove the tire stop, tire lock, and hardware from the middle of the dyno.
Figure 2-2: Remove the Center Panel
Version 2 Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
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CHAPTER 2
Unpacking and Inspecting the Dyno
Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide
2-4
8 Remove the eight screws securing the top drum cover to the dyno and set aside.
D 038
C
top drum cover
side drum cover
side drum cover
Remove the drum cover and set aside. 9 Remove the two top screws securing each side drum cover to the dyno and set
aside.
Figure 2-3: Remove the Top Drum Cover
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