©2003-2006 Dynojet Research, Inc. All Rights Reserved.
Model 200i and 250i Motorcycle Dynamometer Installation Guide.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual, and the software described in it, is furnished
under license and may only be used or copied in accordance with the terms of such
license. 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: 98220104 Version 5 (5/06)
RECORD
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . .1-5
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Model 200i Motorcycle Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Model 250i Motorcycle Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Model 200i and 250i Motorcycle Dynamometer Installation Guide
i
TABLE OF CONTENTS
Chapter 2 Installation
Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unpacking and Inspecting Your Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Routing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Positioning and Securing the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Securing the Drum and Brake Module to the Floor . . . . . . . . . . . . . . . . . 2-19
Installing the Theta Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Support Arm and Monitor Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Installing the Support Arm and Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Routing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Routing the Pendant, RS232 Computer Cable, and Control Panel Cable .2-25
Routing the Eddy Current Brake Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . . 2-32
Tire Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Drum Side and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Ramp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
Ground Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
ii
Model 200i and 250i Motorcycle Dynamometer Installation Guide
Chapter 3 Accessories
Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Remove and Replace Dyno and Drum Covers . . . . . . . . . . . . . . . . . . . . . .3-3
Removing the Drum Top and Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the Center Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Routing the Air Brake Cable and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Air Pump and Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Installing the Filter and Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Cleaning the Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Pump Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Removing the Standard Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Installing the Extended Carriage Support Bracket . . . . . . . . . . . . . . . . . . .3-31
Installing the Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
High Pressure Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Installing the Blower Arm Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39
Installing the High Pressure Blower Assemblies . . . . . . . . . . . . . . . . . . . . .3-40
Connecting Power to the Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41
Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Removing the Hand Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43
Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-44
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . 3-49
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . .3-49
TAB LE OF CONT ENTS
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
iii
TABLE OF CONTENTS
Chapter 4 Control Panel Interface Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Basic Control Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . .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 Dyno Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
High Pressure Blower Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Replacing the Theta Controller Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Troubleshooting CPI Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Chapter 5 Basic Dyno Operation
Loading the Bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . .5-7
Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Appendix A Red Head Anchor Installation
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . .A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
iv
Model 200i and 250i Motorcycle Dynamometer Installation Guide
Appendix B Power Requirements
Locations Using 60Hz Power (North America & Japan) . . . . . . . . . . . . . . B-2
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Locations Using 50 Hz Power
(Locations Other than North America and Japan) . . . . . . . . . . . . . . . . . . . B-7
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
Appendix C Theta Controller
Power Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Accessing the Dip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
TAB LE OF CONT ENTS
Appendix D EEC Kit
EEC Finger Guards Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Removing the Drum Module Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5
Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Installing the Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6
Appendix E Standard and Extended Tire Carriage Installation—
Discontinued
Standard Tire Carriage—Discontinued . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Installing the Standard Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Extended Tire Carriage—Discontinued . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Installing the Extended Tire Carriage Support Bracket . . . . . . . . . . . . . . . . E-6
Installing the Extended Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-9
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
v
W
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 and instructions that must be followed for proper
operation. Power requirements and installation can be found in Appendix B. Failure to follow these
instructions could result in personal injury or damage to the dynamometer. 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.
Model 200i and 250i Motorcycle Dynamometer Installation Guide
vii
WARN INGS
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. Dynojet designs its
dyn amo me ter s t o be ver y t ole ran t o f st ati c sh oc ks 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 objects
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 difference of potential before the electronics
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 positive 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.
viii
Model 200i and 250i Motorcycle Dynamometer Installation Guide
WARNINGS
Other Potential Hazards
The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for
disconnect before service.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Always wear proper ear and eye protection when operating the dynamometer.
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.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured 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 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
ix
C HAPTER
S
PECIFICATIONS AND
Thank you for purchasing Dynojet’s Model 200i/250i Motorcycle Dynamometer.
Dynojet’s software and dynamometers will give you the power to get the maximum
performance out of vehicles you evaluate. Whether you are new to the benefits of a
chassis dynamometer or an experienced performance leader, the repeatability and
diagnostic tools of WinPEP 7 software and a Dynojet dynamometer will give you the
professional results you are looking for.
This document provides instructions for installing the Dynojet’s Model 200i/250i
Motorcycle Dynamometer (dyno). 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: 98220104
O
PERATING
R
EQUIREMENTS
1
Versio n 5
Last Updated: 4-13-06
This chapter is divided into the following categories:
•Introduction, page 1-2
• Dynamometer Specifications and Requirements, page 1-5
• Model 200i Dynamometer, page 1-9
• Model 250i Dynamometer, page 1-10
Model 200i and 250i Motorcycle Dynamometer Installation Guide
1-1
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.
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 all
locations.
THETA CONTROLLER
This appendix describes how to make power adjustments to the theta controller.
EEC KIT
This appendix describes the procedures for installing the EEC finger guards and door
safety switch.
STANDARD AND EXTENDED TIRE CARRIAGE INSTALLATION—DISCONTINUED
This appendix describes the procedures for installing the standard and extended tire
carriage without the easy removal bracket.
1-2
Model 200i and 250i Motorcycle Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
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. 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
RECORD
#
dynamometer and/or eddy current brake (retarder)
number on the inside cover of this manual.
Introduction
Bold
!
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, 3D visualizations, and press releases
about our latest product lines.
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
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.”
• 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.
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
1-3
CHAPTER 1
Introduction
Equalizer Box—If the air flow rate coming into the dyno room is greater than the air
flow rate leaving the dyno room, the room will become pressurized. A pressurized
dyno room will make measured power misleading. To compensate, you need an
equalizer box. The equalizer box is a baffled (to reduce noise) vent to the outside of
your dyno room. The size of the equalizer box is dependent on the size of your dyno
room and the size of your fans.
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. Plans for exhaust extraction (P/N 73429201) are available from Dynojet.
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 98129103).
Figure 1-1: Custom Dyno Room
1-4
Model 200i and 250i Motorcycle Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following specifications and requirements will help you set up your dyno area
and verify you have the requirements to operate your dyno safely.
BATTERY REQUIREMENTS
Your 200i/250i dyno is designed to carry a group 24 deep-cycle discharge series
battery for operating the starter, power carriage, and optional wheel clamp. The
typical dimensions for this series of batteries are 27 cm long by 17 cm wide by 23 cm
tall (10.625-inches by 6.75-inches by 9.125-inches). The mounting is flexible so a
battery that has dimensions close to this will work satisfactorily. 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 “Installing the Battery” on page 2-10.
CHASSIS SPECIFICATIONS
description specifications
Length
with standard carriage allow 271.78 cm (107.00 inches)
with extended carriage allow 322.58 cm (127.00 inches)
Height
to top of dyno cover 45.97 cm (18.10 inches)
Width
model 200i 106.68 cm (42.00 inches)
model 250i 179.60 cm (70.71 inches)
Weight
model 200i dyno/crated dyno 725 kg (1600 pounds)/771 kg (1700 pounds)
model 250i dyno/crated dyno 1,077.28 kg (2,375 pounds)/1,133.98 kg (2,500 pounds)
Drum
diameter 45.72 cm (18.00 inches)
width 50.80 cm (20.00 inches)
Frame structural steel channel and angle
Maximum Speed 322 KPH (200 MPH)
Maximum Motorcycle Length (front of
front wheel to center of rear wheel)
standard carriage 213 cm (84.00 inches)
extended carriage 256.54 cm (101.00 inches)
Remote Switches remote software control
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
1-5
CHAPTER 1
Dynamometer Specifications and Requirements
model 200i
carriage: allow 68.33 cm (26.9 in.)
extended carriage: allow
119.38 cm (47.0 in.)
45.97 cm (18.10 in.)
152.40 cm
(60.00 in.)
model 250i
179.60 cm
(70.71 in.)
106.68 cm
(42.00 in.)
127.74 cm
(50.29 in.)
72.92 cm
(28.71 in.)
202.77 cm
(79.83 in.)
carriage: allow 68.33 cm (26.9 in.)
extended carriage: allow
119.38 cm (47.0 in.)
45.97 cm (18.10 in.)
202.77 cm
(79.83 in.)
1-6
Model 200i and 250i Motorcycle Dynamometer Installation Guide
Figure 1-2: Model 200i and 250i Dimensions
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)
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
COMPUTER SPECIFICATIONS
You will need to provide a computer system to run the WinPEP software. WinPEP 7
includes complete documentation in online Help. From the WinPEP 7 menu bar,
choose Help
name and password). Refer to the section on Computer Specifications in the WinPEP
documentation, P/N 98118103, for the specific computer system requirements.
!
WinPEP 7 Help or visit www.winpep.com (accessible with a valid user
ELECTRICAL REQUIREMENTS
The Model 200i/250i dynamometers require a 240V - 30a single-phase electrical
circuit for reliable and precise operation. No other loads should be plugged into this
circuit and this circuit 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.
description specifications
Power Requirements 240v 30 amp single phase circuit
Frequency 50 or 60 Hz
Voltage
normal 240 VAC
min./max 215 VAC/245 VAC except Japan 195 VAC/245 VAC
Current 30 amps
Power Consumption 7200 watts
Power Cord P/N 76950401
length 3.048 m (10 ft.)
end twist-lock plug or three-pin IEC plug
wall receptacle (included with dyno) twist-lock four wire grounded 30A NEMA L14-30 or
three-pin IEC grounded 30A
Full Load Amperage (FLA) 30A
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
1-7
CHAPTER 1
Dynamometer Specifications and Requirements
ENVIRONMENTAL REQUIREMENTS
description specifications
Te mp e r at u r e
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 1,133.98 kg
(2,500 lbs.) to lift the dyno off the crate and into position in your dyno room. You will
also need a pair of straps capable of supporting 1,133.98 kg (2,500 lbs.) to attach to
the dyno. Dynojet recommends using 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 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.
Using the ground hooks as a pattern, install the Red Head anchors using the hardware
included with the ground hook kit. Install the Red Head anchors according to the
instructions in Appendix A.
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
downloading 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.
1-8
Model 200i and 250i Motorcycle Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Model 200i Motorcycle Dynamometer
MODEL 200i MOTORCYCLE DYNAMOMETER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire Carriage
Tie-down Loop
used to secure the
motorcycle to dyno
Drum
precision balanced
and knurled
Breaker
Breakout Board
Power Cord
Dyno Electronics Enclosure
houses the dyno electronics and
Air Connector
Figure 1-3: Model 200i Basic Dyno
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
power supply
Control Panel Interface
houses the Breakout board, main
power breaker, and battery disconnect
1-9
CHAPTER 1
Model 250i Motorcycle Dynamometer
MODEL 250i MOTORCYCLE DYNAMOMETER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Carriage
not shown
Wheel Clamp
not shown
Control Panel
not shown
Eddy Current
Brake Module
Monitor Tray
supports the monitor,
keyboard, and mouse
High Pressure Blower
cools the bike’s engine
Theta Controller
controls the eddy
current brake
1-10
Model 200i and 250i Motorcycle Dynamometer Installation Guide
Drum
precision balanced
and knurled
Figure 1-4: Model 250i With Optional Accessories
Tire Carriage
Tie-do wn Lo op
used to secure the
motorcycle to dyno
Air Brake
Air Pump
Assembly
C HAPTER
2
I
NSTALLATION
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:
• Dyno Installation, page 2-2
• Battery, page 2-10
• Pickup Card, page 2-11
• Eddy Current Brake, page 2-12
• Support Arm and Monitor Tray, page 2-21
• Dyno Electronics, “Dyno Electronics” on page 2-23
• Routing Cables, page 2-25
• Tire Carriage Installation, page 2-34
• Drum Side and Top Covers, page 2-38
• Ramp Bracket, page 2-40
• Ground Hooks, page 2-43
• Zip Tube, page 2-44
Model 200i and 250i Motorcycle Dynamometer Installation Guide
2-1
CHAPTER 2
Dyno Installation
DYNO INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following directions describe how to unpack, and install your dyno. Follow the
directions in the order that they are presented.
UNPACKING AND INSPECTING YOUR DYNO
When you receive your dyno, examine the exterior of the shipping container for any
visible damage. If damage is detected at this stage, contact the shipper or Dynojet
before proceeding with unpacking.
Use the following steps to unload your dyno. 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 “Dynamometer Specifications and
Requirements” on page 1-5 for more information.
1 Remove the crate braces and sides.
Note: At this point, you will want to inspect the exterior of the dyno for any
indications of damage. Report any damage immediately.
2 Remove the tire carriage. The tire carriage is fastened to the bottom of the crate.
3 Remove the support arm. The support arm is fastened to the bottom of the crate.
For more information on the support arm and monitor tray refer to page 2-21.
support arm
Figure 2-1: Remove the Tire Carriage and Support Arm from the Crate
2-2
Model 200i and 250i Motorcycle Dynamometer Installation Guide
tire carriage
INSTALLATION
Dyno Installation
4 Remove the six 1/4-inch screws securing the center panel on the dyno and remove
the center panel.
Note: Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to
remove the 1/4-inch screws. For dynos with serial numbers lower than 2030152,
Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap-On
FA5E). A standard allen key may round off in the shallow screw head.
5 Remove the tire stop, tire lock, and hardware from the middle of the dyno.
center panel
tire stop and tire lock
in middle
Figure 2-2: Remove the Center Panel
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
2-3
CHAPTER 2
Dyno Installation
6 Remove the eight screws securing the top drum cover to the dyno and set aside.
Remove the drum cover and set aside.
7 Remove the two top screws securing each side drum cover to the dyno and set
aside.
top drum cover
side drum cover
side drum cover
Figure 2-3: Remove the Top Drum Cover
2-4
Model 200i and 250i Motorcycle Dynamometer Installation Guide
INSTALLATION
Dyno Installation
8 Remove the remaining six side screws securing each side drum cover to the dyno
and set aside. Remove the side drum covers and set aside.
Note: For future reference, note the three access holes in the drum bulkhead.
These access holes will be used to route cables when installing accessories once
the top cover is back on.
RECORD
Be sure you record the dynamometer number on the inside cover of this
manual.
#
side drum cover
dyno number stamped
on frame
side drum cover
access holes in drum
bulkhead (only two
visible from this view)
Figure 2-4: Remove the Side Drum Covers
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
2-5
CHAPTER 2
Dyno Installation
REMOVING THE DYNO FROM THE CRATE
You will need to provide equipment capable of lifting a minimum of 1,133.98 kg
(2,500 lbs.) to lift the dyno off the crate and into position in your dyno room. You will
also need a pair of straps capable of supporting 1,133.98 kg (2,500 lbs.) to attach to
the dyno. Dynojet recommends using a single loop style strap.
1 Remove the four lag bolts and washers securing the dyno to the crate base using a
9/16-inch socket, open or box end wrench.
2 The pickup card may be taped to the lifting eye. Remove the pickup card and set it
aside.
bolt and washer
lifting eye
bolt and washer not
visible from this view
Figure 2-5: Remove the Dyno from the Crate Base
2-6
Model 200i and 250i Motorcycle Dynamometer Installation Guide
bolt and washer
lifting eye
bolt and washer
INSTALLATION
Dyno Installation
3 Route the single loop strap through the lifting eyes in front of the drum as shown
in Figure 2-6.
Note: The dyno should only be lifted using the lifting eyes. Verify no other part of
the dyno is interfering with the strap. Do not place the strap around the cable
routing bracket or any other part of the dyno.
lifting eye
cable routing
bracket
lifting eye
Figure 2-6: Loop Strap Placement
4 Carefully lift the dyno off the crate and move into position in your dyno room.
Note: While the dyno is supported by the forklift and before it is placed in your
dyno room, the power cable must be routed through the front of the dyno.
loop strap
Figure 2-7: Lift the Dyno off the Crate
Version 5 Model 200i and 250i Motorcycle Dynamometer Installation Guide
2-7
CHAPTER 2
Dyno Installation
ROUTING THE POWER CABLE
1 Locate the power cable inside the dyno.
2 Slide the strain relief on the power cable through the opening in the dyno frame.
3 Tighten the jam nut.
4 Hand tighten the knurled nut.
opening in
dyno frame
strain relief around
power cord
Figure 2-8: Route the Power Cable
jam nut
inside dyno
cut away view from
inside dyno
knurled nut
outside dyno
2-8
Model 200i and 250i Motorcycle Dynamometer Installation Guide
Loading...