Dynojet 250iP Installation Guide
©2004-2006 Dynojet Research, Inc. All Rights Reserved.
Installation Guide For Model 200ip and 250ip Motorcycle PitDynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual is furnished under license and may only be used
or copied in accordance with the terms of such license. This manual is furnished for
informational use only, is subject to change without notice, and should not be construed
as a commitment by Dynojet. 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: 98229103 Version 2 (03/06)
RECORD
Dynamometer Number: ____________________________________________________
Eddy Current Brake
(Retarder) Number:_________________________________________________________
#
T
ABLE OF
C
ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Model 200iP/250iP Motorcycle Pit Dynamometer . . . . . . . . . . . . . . . . . .1-9
Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Chapter 2 Installation
Unpacking and Installing the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Uncrate the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Verifying the Pit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Securing the Drum and Brake Module to the Pit Floor . . . . . . . . . . . . . . .2-11
Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
i
TABLE OF CONTENTS
Carriage Plate and Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Installing the Carriage Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Installing the Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Blower Mounts, Support Arm and Junction Box . . . . . . . . . . . . . . . . . . .2-16
Mark and Drill Blower Mounts and Support Arm Mounting Holes . . . . . . 2-16
Installing the Blower Mounting Plate, Support Arm, and Junction Box . . .2-17
Installing the Arms and Monitor Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Routing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Accessing the CPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Routing the Control Panel, Pendant Cables, and RPM Cable . . . . . . . . . .2-23
Routing the High Pressure Blower Cables . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . . 2-28
Routing the Eddy Current Brake, Battery, and Dyno Power Cables . . . . . .2-32
Routing the Pickup Card and Dyno Electronics Cables . . . . . . . . . . . . . . . 2-34
Routing the Air Pump Power, Air Fuel Sensor,
and Dyno Electronics Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . .2-38
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . .2-38
Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
Changing the Retarder Cover for Right Side Installations . . . . . . . . . . . . .2-39
Installing the Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-40
Junction Box Cover, Cable Cover, and End Cap . . . . . . . . . . . . . . . . . . .2-44
Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Chapter 3 Accessories
Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Routing the Air Brake Cable and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
ii
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Air Pump and Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Installing the Extended Carriage Plate . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Installing the Extended Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
High Pressure Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Installing the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Attaching the Blower Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Installing the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . .3-27
Chapter 4 Control Panel Interface Operation
Basic CPI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . .4-4
Using the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Understanding Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Using the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Using the Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Using the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Power Distribution Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Main Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
High Pressure Blower Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Maintaining and Troubleshooting the Wheel Clamp . . . . . . . . . . . . . . . . . 4-9
Replacing the Theta Controller Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Troubleshooting CPI Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
TAB LE OF CON T ENTS
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
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
iii
TABLE OF CONTENTS
Appendix A Red Head Anchor Installation
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . .A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Appendix B Power Requirements
Locations using 60Hz Power (North America & Japan) . . . . . . . . . . . . . . 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)
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
. . . . . . . . . . . . . . . . . . .B-7
Appendix C EEC Finger Guard and
Door Safety Switch Installation
EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Installing the Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Appendix D Theta Controller
Power Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Accessing the Dip Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
iv
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
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 Requires Proper Grounding
Various dynamometer components are equipped with a three-pronged plug (grounded) to guard
against shock hazards. The plug should be plugged directly into a properly grounded three-prong
receptacle. In locations where a two-prong wall receptacle is installed, it must be replaced with a
properly grounded three-prong dedicated outlet in accordance with the U.S. National Electric Code,
or equivalent, and local codes and ordinances. The work should be performed by a qualified
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 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
v
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 to be v er y to ler an t of sta ti c sh ock s 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 energy 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.
vi
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
WARNINGS
Other Potential Hazards
The AC power outlets shall be installed near the equipment and shall be easily accessible to allow for
disconnect before service.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Always wear proper ear and eye protection when operating the dynamometer.
Always wear protective clothing (pants and closed toed shoes) 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 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
vii
C HAPTER
S
PECIFICATIONS AND
Thank you for purchasing Dynojet’s Model 200iP/250iP Motorcycle Pit Dynamometer.
Dynojet’s software and dynamometers will give you the power to get the maximum
performance out of vehicles you evaluate. Whether you are new to the benefits of a
chassis dynamometer or an experienced performance leader, the repeatability and
diagnostic tools of WinPEP 7 software and a Dynojet dynamometer will give you the
professional results you are looking for.
This document provides instructions for installing the Dynojet 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: 98229103
O
PERATING
R
EQUIREMENTS
1
Versio n 2
Last Updated: 3-16-06
This chapter is divided into the following categories:
•Introduction, page 1-2
• Dynamometer Specifications and Requirements, page 1-5
• Model 200iP/250iP Motorcycle Pit Dynamometer, page 1-9
Model 200iP/250iP Motorcycle Pit 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.
EEC FINGER GUARD & DOOR SAFETY SWITCH KIT
This appendix describes the procedures for installing the EEC finger guards and door
safety switch.
POWER REQUIREMENTS
This appendix describes the power requirements and installation instructions for all
locations excluding North America.
THETA CONTROLLER
This appendix describes how to make power adjustments to the theta controller.
1-2
Model 200iP/250iP Motorcycle Pit 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
• be designed with safety in mind
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.”
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
1-3
CHAPTER 1
Introduction
Intake Air Fan—After building your dyno room, you will need to supply an intake air
fan. The intake air fan supplies air to cool the bike’s engine while supplying fresh
oxygen for you and your bike to breathe. It is a common misconception that you
cannot tune a bike without a large fan simulating exact road conditions; however, a
good cooling fan is the only requirement for consistent diagnostics and tuning. The
installed fan should be 5200 CFM.
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 200iP/250iP Motorcycle Pit 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 200iP/250iP dyno is designed to carry a group 24 deep-cycle discharge series
battery for operating the starter, power carriage, and optional wheel clamp. 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 2-21.
CHASSIS SPECIFICATIONS
description specifications
Length
with standard carriage allow 304.80 cm (120.00 in)
with extended carriage allow 355.60 cm (140.00 in)
Height
from bottom of dyno to top of dyno 45.72-46.67 cm (18.00-18.38 in)
from top of pit to drum guard 5.40 cm (2.13 in)
from top of pit to top of tire carriage 50.64 cm (16.00 in)
Width
from pit cover to pit cover
model 200iP/250iP
Weight
model 200iP drum module/crated dyno 725 kg (1600 pounds)/817 kg (1800 pounds)
model 250iP retarder module/crated dyno 953 kg (2100 pounds)/1,043 kg (2300 pounds)
Drum
diameter 45.72 cm (18.00 in)
width 50.80 cm (20.00 in)
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 213.00 cm (84.00 in)
extended carriage 256.54 cm (101.00 in)
208.28 cm (82.00 in)
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
1-5
CHAPTER 1
Dynamometer Specifications and Requirements
137.16 cm
(54.00 in)
208.28 cm
(82.00 in)
45.72-46.67 cm
(18.00-18.38 in)
179.07 cm
(70.50 in)
105.03 cm
(41.35 in)
PD017
standard carriage: 304.80 cm (120.00 in)
extended carriage: 355.60 cm (140.00 in)
76.20 cm
(30.00 in)
Figure 1-2: Model 200iP/250iP Dimensions
1-6
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
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 200iP/250iP 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
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 1,043 kg.
(2300 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 1,043 kg. (2300 lb.) to attach to the
dyno. Dynojet recommends using single loop style straps.
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
1-7
CHAPTER 1
Dynamometer Specifications and Requirements
GROUND HOOK REQUIREMENTS
You may wish to install additional ground hooks (included with your dyno) for
securing the motorcycle. The tie-down loops on the pit covers should work for most
motorcycles. If you are running motorcycles that require a different tie-down location,
mount the ground hooks accordingly.
Note: Tie-down straps MUST pull the motorcycle forward.
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
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 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Model 200iP/250iP Motorcycle Pit Dynamometer
MODEL 200iP/250iP MOTORCYCLE PIT DYNAMOMETER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel
Interface
not shown
houses all electronics
Eddy Current
Brake Module
with Theta Controller
in CPI box
model 250iP only
High Pressure Blowers
cools the bike’s engine
(optional)
Tire Carr iage
with Power Carriage
Monitor Tray
supports the monitor,
keyboard, and mouse
Air Pump
Assembly
not shown
(optional)
Control Panel
Junction Box
Cable Cover
Drum
precision balanced
and knurled
Figure 1-3: Model 200iP/250iP With Optional Accessories
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
Air Brake
(optional)
Tie-down Loop
used to secure the
motorcycle to dyno
1-9
CHAPTER 1
Dyno Electronics
DYNO ELECTRONICS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The standard dyno electronics package is comprised of four interconnected modules:
Atmospheric Sensing Module, RPM Module, Dynamometer Input/Output Module, and
the CPU Module. For more information refer to your WinPEP 7 User Guide
(P/N 98128104).
9-pin hand
system expansion
connector
held pendant
25-pin socket
RPM inductive
pickup socket
atmospheric
sensing module
RPM module
input/output module
CPU module
power
9-pin RS-232 socket
3-pin power plug
Figure 1-4: The Dyno Electronics
1-10
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
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:
• Unpacking and Installing the Dyno, page 2-2
• Eddy Current Brake, page 2-6
• Pickup Card, page 2-12
• Carriage Plate and Tire Carriage, page 2-13
• Blower Mounts, Support Arm, and Junction Box, page 2-16
• Routing Cables, page 2-19
• Final Adjustments and Tests, page 2-37
• Pit Covers, page 2-39
• Junction Box Cover, Cable Cover, and End Cap, page 2-44
• Zip Tube, page 2-46
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-1
CHAPTER 2
Unpacking and Installing the Dyno
UNPACKING AND INSTALLING THE DYNO
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When you receive your dyno, examine the exterior of the shipping container for any
visible damage. If damage is detected at this stage, contact the shipping company or
Dynojet before proceeding with unpacking.
Since this manual ships inside the packing crate, you must have already cut the bands
around the crate, removed the “remove by customer only” boards, and lifted the
pallet containing the pit covers from the top of the crate and set it aside in order to
remove the top of the crate.
It is important to follow the remaining steps carefully.
UNCRATE THE DYNO
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 and support arm and set aside. The tire carriage and
support arm are fastened to the bottom of the crate.
3 Remove any hardware boxes, the control panel interface, and accessories from
the crate and set aside.
tire carriage
support arm
Figure 2-1: Uncrate the Dyno
2-2
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
45.00 cm
(18.00 in)
INSTALLATION
Unpacking and Installing the Dyno
VERIFYING THE PIT DIMENSIONS
Before placing the dyno in the pit, take a moment to verify that the dimensions of the
pit are correct.
Refer to the pit dimensions (P/N 98229102) you received from your salesman for
more detailed specifications.
• pit depth: 45.00 cm (18.00 in)
• pit length: 193.00 cm (76.00 in)
• pit width: 121.00 cm (48.00 in)
121.00 cm
(48.00 in)
193.00 cm
(76.00 in)
Figure 2-2: Verify the Pit Dimensions
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-3
CHAPTER 2
Unpacking and Installing the Dyno
REMOVING THE DYNO FROM THE CRATE
You will need to provide equipment capable of lifting a minimum of 1,043 kg.
(2300 lb.) to lift the dyno (drum module) off the crate and into position in your dyno
room. You will also need a pair of straps capable of supporting 1,043 kg. (2300 lb.) to
attach to the dyno. Dynojet recommends using a single loop style strap.
dyno number
stamped on frame
(not visible)
RECORD
Be sure you record the dynamometer number on the inside cover of this
manual.
1 Remove the four lag bolts and washers securing the drum module to the crate
base using a 9/16-inch socket, open or box end wrench.
2 Wrap the single loop straps around the drum module shaft.
3 Lift the drum module off the crate and move into position in your pit.
#
Figure 2-3: Remove the Dyno From the Crate Base
2-4
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLATION
Unpacking and Installing the Dyno
4 Place the drum module in the pit as shown. If you ordered an eddy current brake
be sure to place the dyno in the appropriate side of the pit.
15.24 cm
(6.00 in)
7.62 cm
(3.00 in)
15.24 cm
(6.00 in)
Figure 2-4: Drum Module Placement in Pit—Left Side Retarder
7.62 cm
(3.00 in)
Figure 2-5: Drum Module Placement in Pit—Right Side Retarder
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-5
CHAPTER 2
Eddy Current Brake
EDDY CURRENT BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section will walk you through removing the eddy current brake (or retarder)
from the crate and attaching the brake to your dyno. To route and wire the
temperature sensor cable and the theta controller to the Breakout board refer to
“Routing the Eddy Current Brake, Battery, and Dyno Power Cables” on page 2-32 and
“Wiring the Breakout Board” on page 2-36.
You will need to provide equipment capable of lifting the eddy current brake off the
crate and into position in your dyno room. You will also need a pair of straps. Dynojet
recommends using continuous nylon loop style straps.
To prevent possible injury, unplug all power cords and disconnect the battery.
PARTS LIST
The following table lists all of the parts included in the Eddy Current Brake
Installation kit. Check your kit against the parts listed to make sure you have received
all of the parts. If any part is missing, contact Dynojet Technical Support.
part number description quantity
21227107 Retarder Connector Plate (already installed) 2
21629403 Bar, Load Cell 1
36582034 Screw, 3/8"-16 x 1 1/4", BH-FLNG 8
37620622 Woodruff Key, 3/8" x 1 3/8" 1
49950030 Temperature Sensor 1
61228400 Hood, Top, Retarder Module 1
63223700 Retarder Module 1
66411002
or
66411003
Theta-2 Controller 120V
or
Theta-2 Controller 240V
1
2-6
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
UNPACKING THE EDDY CURRENT BRAKE
1 Remove the four bolts securing the brake to the crate.
2 Remove the retarder connector plates, if present.
3 Determine if the brake is to be mounted on the left or right side of your dyno.
Make the following adjustments to the eddy current brake only if you want to
mount the brake on the opposite side of the dyno that it is currently set up for.
• Move the coupler and key to the other side of the brake.
To remove the key, use a punch and a hammer to apply pressure in the
direction of the arrows shown in Figure 2-7.
• The retarder connector plates (removed in step 2) will need to be moved to
the other side of the brake once the brake is installed in the pit.
• Move the temperature sensor to the other side of the brake.
INSTALLATION
Eddy Current Brake
connector plate
temperature sensor
coupler
connector plate
eddy current brake set up for left side installation
connector plate
temperature
sensor
coupler
connector plate
eddy current brake set up for right side installation
Figure 2-6: Left or Right Side Brake Set Up
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-7
CHAPTER 2
Eddy Current Brake
shaft
4 Place the ends of a nylon loop strap through the lifting eyes on either side of the
5 Using a forklift, lift the eddy current brake from the crate and place the brake in the
6 Be sure you record the eddy current brake number on the inside cover of
apply force using
hammer and punch
key
Figure 2-7: Removing the Key
brake and hook onto the shaft.
pit near the drum module making sure not to hit the coupler.
this manual.
apply force using
hammer and punch
RECORD
#
lifting eye
eddy current brake number
Figure 2-8: Record Eddy Current Brake Number
2-8
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLING THE EDDY CURRENT BRAKE
It is not necessary to remove the optional air brake if you are installing the eddy
current brake on the right side. If you mount the eddy current brake on the right side
you will need to change the retarder cover, refer to page 2-39.
Note: Safety requirements of your local country may require that both brakes are
installed. Be sure to follow the safety requirements specific to your country.
1 Insert the key into the keyway on the drum module shaft.
2 Use a c-clamp to press the key in.
INSTALLATION
Eddy Current Brake
key
key way on dyno shaft
Figure 2-9: Install the Key
3 Remove the eight bolts, washers, and six nuts from the dyno frame where the
connector plates will attach (where the connector plate attaches to the starter
brace, there are only two nuts). Refer to Figure 2-10.
4 Remove the starter brace and set aside. Only remove the starter brace when
installing the eddy current brake on the left (starter) side of the dyno.
5 Keeping the panels parallel, slide the eddy current brake towards the dyno. Slide
the coupler over the key on the dyno shaft. You will need to support the coupler
as you slide it onto the dyno shaft.
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-9
CHAPTER 2
Eddy Current Brake
6 Continue sliding the eddy current brake towards the dyno until the uprights on
7 Loosely secure the retarder connector plates to the dyno frame using the eight
8 Verify the uprights on the drum and eddy current brake modules are flush with
9 Secure the starter brace to the starter using the washer and nut removed earlier.
10 Remove the straight edges.
the brake and dyno are flush.
bolts, washers, and six nuts removed earlier.
Note: Do not tighten the bolts.
the top of the pit floor before you tighten the connector plates.
8a Loosen all upright bolts.
8b Place two straight edges across the drum module uprights as shown.
8c With the upright tight against the straight edges, tighten the connector plate
bolts and nuts on the drum module.
Note: You can use c-clamps to attach the upright to the straight edges to make
this quicker. Tighten the c-clamps until the uprights are flush with the pit floor.
8d Tighten the upright bolts and nuts on the drum module.
8e Repeat this for the eddy current brake module uprights.
c-clamp
straight edge
loosen bolts
securing
uprights
loosen bolts
connector
plate bolts
loosen bolts
securing
uprights
securing
uprights
drum module
loosen bolts
securing uprights
(not visible)
Figure 2-10: Secure the Uprights
upright
starter brace
connector plate bolts
eddy current brake
module upright
loosen bolts
securing uprights
(not visible)
PD009A
2-10
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
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