©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
11 Replace the existing set screws on the coupler with the thread-lock set screws
provided.
12 Tighten the coupler set screws.
brake shaft
set screw
Figure 2-11: Tighten the Set Screws
dyno shaft
SECURING THE DRUM AND BRAKE MODULE TO THE PIT FLOOR
INSTALLATION
Eddy Current Brake
Dynojet recommends you secure your drum and brake modules to the pit floor in
your dyno room using concrete anchors. You will want to drill the holes and secure
the dyno before placing the covers on your dyno.
Note: You may wish to drill the holes for the carriage mounting plate, blower
mounts, and the support arm at this time. Refer to page 2-13 for carriage plate
instructions and page 2-16 for blower mounts and support arm instructions.
1 Drill the holes for Red Head Anchors.
2 Install the Red Head anchors according to the instructions in Appendix A.
drill holes
drill holes
drill holes
Figure 2-12: Secure the Drum and Brake Module to Pit Floor
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
drill hole (not visible) only when brake is mounted on right side
2-11
CHAPTER 2
Pickup Card
PICKUP CARD
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The pickup card is an electronic circuit board that accurately senses each drum
revolution.
1 Locate the pickup card bracket on the starter side of the dyno just ahead of the
drum.
2 Install the pickup card to the bracket using two No. 8 screws. Do not tighten, the
card must be aligned first.
Note: If your dyno is equipped with an air brake, you will need to attach
compressed air and power to your dyno before you can turn the drum.
3 Align the optical pickup card with the tab on the dyno drum axle. Be sure the tab
passes freely through the optical pickup. You may need to loosen the bracket to
help with alignment.
4 Once aligned, tighten the screws to secure the pickup card in place.
5 Refer to page page 2-34 for instructions on routing and connecting the pickup
card cable.
pickup card
bracket
The optical pickup is very delicate. Be careful not to damage the optical pickup
during alignment.
tab on dyno
optical pickup
pickup card
top view of pickup card, optical
pickup, and tab on dyno
tab on dyno
pickup card
Figure 2-13: Install the Pickup Card
2-12
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
Carriage Plate and Tire Carriage
CARRIAGE PLATE AND TIRE CARRIAGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The tire carriage is fastened to the bottom of the crate next to the dyno. Refer to page
2-2 for instructions on removing the tire carriage from the crate.
The following instructions are for the standard tire carriage. For more information on
the extended tire carriage refer to page 3-18.
INSTALLING THE CARRIAGE PLATE
INSTALLATION
1 Remove the four bearing plate screws and slide the carriage from the carriage
plate.
TC062
carriage plate
carriage screw
nut block
bearing plate
screws
Figure 2-14: Remove the Carriage From the Plate
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-13
CHAPTER 2
Carriage Plate and Tire Carriage
2 Use the carriage plate to mark and drill mounting holes as shown in Figure 2-15.
2a Using the carriage plate as a template, drill four 1/2-inch holes.
2b Install the Red Head anchors according to the instructions in Appendix A.
40.32 cm
(15.875 in)
66.04 cm
(26.0 in)
Figure 2-15: Carriage Plate Mounting Dimensions
3 Secure the carriage plate to the floor using four 3/8 x 1-inch bolts and
5/16-inch washers.
Figure 2-16: Install the Carriage Plate
2-14
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
TC053
INSTALLATION
Carriage Plate and Tire Carriage
INSTALLING THE TIRE CARRIAGE
1 Starting from the back of the dyno, slide the carriage under the carriage clamps.
2 Slide the carriage screw and the bearing bracket toward the nut block until the
carriage screw is touching the nut block.
3 Secure the bearing bracket to the carriage using four 1/4-20 x 1/2-inch
button-head flange bolts removed earlier.
carriage
carriage
clamp
nut block
carriage
screw
bearing bracket
Figure 2-17: Install the Tire Carriage
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-15
CHAPTER 2
Blower Mounts, Support Arm and Junction Box
BLOWER MOUNTS, SUPPORT ARM AND JUNCTION BOX
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before routing the cables, you must decide which side of the dyno to mount the
monitor support arm. The choice is based on personal preference and easy access to
your computer. For the following instructions, we will show the support arm and
control panel mounted on the right side of the dyno.
MARK AND DRILL BLOWER MOUNTS AND SUPPORT ARM MOUNTING HOLES
1 Using the carriage mounting plate and the dyno frame as reference, position the
support arm and optional blower mounts as shown.
Note: The high pressure blowers are an optional accessory. If you did not order
high pressure blowers, you will not need to install the blower mounts.
2 Using the mounting plates as a template, mark and drill 1/2-inch holes.
3 Install the Red Head anchors according to the instructions in Appendix A.
‘mark and drill
(four places)
111.76 cm
(44.0 in)
24.13 cm
(9.5 in)
24.13 cm
(9.5 in)
mark and drill
(four places)
111.76 cm
(44.0 in)
Figure 2-18: Blower Mounts and Support Arm Placement
2-16
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLATION
Blower Mounts, Support Arm and Junction Box
INSTALLING THE BLOWER MOUNTING PLATE, SUPPORT ARM, AND JUNCTION BOX
The high pressure blowers are an optional accessory. If you did not order high
pressure blowers, you will not need to install the blower mounting plates. Refer page
3-24 to for high pressure blower installation instructions.
1 Secure the blower mounting plate to the pit floor using four 3/8 x 1-inch bolts
and 5/16-inch washers.
Note: The right blower mounting plate is secured under the support arm.
2 Secure the support arm and junction box to the pit floor using four 3/8 x 1-inch
bolts and 5/16-inch washers.
Note: The support arm can be mounted on either side of the dyno.
blower mount
PD039
support arm
blower mount
junction box
Figure 2-19: Install the Blower Mounting Plates, Support Arm, and Junction Box
(under support arm)
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-17
CHAPTER 2
Blower Mounts, Support Arm and Junction Box
INSTALLING THE ARMS AND MONITOR TRAY
1 Insert a plastic cap in both ends of each arm.
2 Place a poly washer around the pin of the first arm and insert the pin into the
support arm.
3 Place a poly washer around the pin of the second arm and insert the pin into the
first arm.
4 Place a poly washer around the pin of the tray and insert the pin into the second
arm.
Note: The monitor tray is an optional accessory. If you did not order a monitor
tray, skip this step.
5 Check for clearance between the monitor arm and motorcycle, walls, ceiling, etc.
Note: Dynojet does not recommend placing the computer CPU on the
monitor/keyboard tray since vibration can cause damage to the computer.
monitor tray
poly washer
second arm
poly washer
first arm
poly washer
support arm
Figure 2-20: Install the Monitor Tray
2-18
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ROUTING CABLES
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following instructions show the support arm and control panel mounted on the
right side of the dyno with the Control Panel Interface (CPI) and dyno electronics on
the left side of the dyno.
The CPI and dyno electronics must be placed near the conduits in the pit.
Be sure to keep the power and communications cables in different pit conduits. For
the following instructions, we will designate the pit conduits as shown in Figure 2-21.
INSTALLATION
Routing Cables
dyno
electronics
control panel
interface
(CPI)
route communications cables
in designated conduit
junction box
monitor support and tray
control panel
route power cables
in designated conduit
Figure 2-21: Pit Dyno Room Layout
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
PD026A
2-19
CHAPTER 2
Routing Cables
BATTERY REQUIREMENTS
The model 200i/250i dyno is designed to carry a group 24 deep cycle discharge series
battery for operating the starter, optional power carriage, and optional wheel clamp.
The typical dimensions for this series of batteries are 10 5/8-inches long by 6 3/4inches wide by 9 1/8-inches tall. The mounting is flexible so a battery that has
dimensions close to this will work satisfactorily. The built in battery cables are
configured for top post batteries. This battery is not included with your dyno. You will
need to provide this battery.
The battery provides the necessary energy to run the starter, optional power carriage,
and optional wheel clamp. The CPI has a built in battery charging circuit to keep the
battery charged. Each time the starter, power carriage, or wheel clamp is used, this
built in charging circuit will recharge the battery. The charging rate is sufficient to
keep up with loading a bike, operating the wheel clamp, and adjusting the power
carriage every five minutes. Recharging from use of the built in dyno starter will take
longer. Do not add any external battery chargers to the car battery.
Note: If you do not install the battery make sure the positive battery cable is
insulated from the chassis as the charging circuit is always providing charging
current whenever the dyno main power breaker is turned on.
The battery charging circuit is active anytime the main power on the dyno is turned
on. If the main breaker is turned off then the battery will not be charged. Frequent use
of the starter will quickly deplete the battery and it may need several hours of the
internal charging to bring the battery back to a full charge.
For more information on installing the battery, refer to page 2-10.
Note: If you do not wish to use the wheel clamp and the power carriage or
operate the built-in starter then it is not necessary to install the battery.
USING A BATTERY CHARGER
In order to utilize the starter on dynos that do not have the Control Panel, you will
need to provide an on board battery charger. A small trickle charger or battery minder
is sufficient in the charging range of 1A. Verify the battery charger does not overcharge
the battery when left attached.
Note: Dynojet recommends using a ring connector style charger.
• Using the bolts from the battery terminals, secure the ring connectors from the
charger to the battery terminals.
• Secure the charger in a safe location in the dyno.
• Route the power cable out of the dyno. Make sure the cable cannot be
damaged.
These small chargers should be available from your normal distribution supply chain
or other sources such as NAPA, JC Whitney, or Northern Tools.
There is danger of explosion if the battery is incorrectly replaced. Wear
protective clothing, eye, and face protection when charging or handling
batteries. Refer to Warnings for more information.
2-20
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLING THE BATTERY
9
1 Secure the battery to the tray with the battery hold-down.
2 Refer to page 2-32 for instructions on routing and connecting the battery cable.
INSTALLATION
Routing Cables
battery
PD08
Figure 2-22: Installing the Battery
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-21
CHAPTER 2
Routing Cables
ACCESSING THE CPI
The CPI comes wired and ready to install. Should you need to re-route the cables so
they come out a different side of the box, use the following instructions to access the
CPI box.
1 Turn off the power to the dyno. Refer to “Main Dyno Power” on page 3-2 for more
information.
2 Remove the eight button-head screws securing the cover and set aside.
3 Remove the cover and set aside.
4 Open the front panel to access the breakers and Breakout board.
cover
front panel access
PD027
Figure 2-23: Accessing the CPI
2-22
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ROUTING THE CONTROL PANEL, PENDANT CABLES, AND RPM CABLE
1 Route the control panel cable (P/N 76951502) from the CPI through the
designated communications pit conduit, through the pit, and out of the pit as
shown.
2 Route the pendant cable from the dyno electronics input/output module through
the same conduit and along the same path as the control panel cable. Refer to
“Dyno Electronics” on page 1-10.
Note: Be sure to keep the power and communications cables in different pit
conduits.
3 Route the RPM induction connection cable from the dyno electronics RPM
module through the same conduit and along the same path as the control panel
cable.
Note: Routing the RPM cable is optional.
4 From the pit, route the cables through the junction box.
INSTALLATION
Routing Cables
dyno
electronics
CPI
route power cables
in designated conduit
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
route communications cables
in designated conduit
PD028A
Figure 2-24: Route the Control Panel, Pendant Cables, and RPM Cables
2-23
CHAPTER 2
0
Routing Cables
top nuts
5 Remove the control panel rear cover.
5a Remove the two nuts from the top of the cover and set aside.
5b Remove the screw on the top of the cover and set aside.
5c Remove the screw on the side of the cover and set aside.
5d Remove the four screws on the back of the cover and set aside.
5e Remove the control panel rear cover and set aside.
top screw
side screw
CP01
rear screws
Figure 2-25: Remove the Control Panel Rear Cover
2-24
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
6 Route the control panel cable and RPM cable through the access hole on the side
A
of the control panel box and through the cable tie.
7 Attach the control panel cable to the Button board.
8 Secure the panel mount connector on the RPM cable to the control panel using
two #4-40 pan-head phillips screws.
Note: Routing the RPM cable is optional.
control panel cable with
cable harness wrap
RPM cable
cable tie
INSTALLATION
Routing Cables
access hole
button board
panel mount
connector
Figure 2-26: Attach the Control Panel Cable to the Button Board
9 Tighten the cable tie.
10 If you purchased the optional air brake, install the Emergency Stop Sticker at this
time. Refer to page 3-6 for directions.
11 Secure the rear cover to the control panel.
11a Replace the four screws on the back of the cover removed earlier.
11b Replace the screw on the top of the cover removed earlier.
11c Replace the screw on the side of the cover removed earlier.
11d Replace the two nuts removed from the top of the cover removed earlier.
CP007
Figure 2-27: Replace the Control Panel Rear Cover
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-25
CHAPTER 2
Routing Cables
12 Secure the control panel to the monitor tray using two 8-32-inch screws.
Note: If you did not order a monitor tray, you will need to install the control pod
spindle on the bottom of your control panel using four 8-32 screws as shown in
the detail in Figure 2-28. Once installed, place the pin on the control panel into
the support arm where the monitor tray is.
13 Place the pendant in the slot on the control panel.
Note: If you plan on routing your cables through a zip tube refer to “Zip Tube” on
page 2-46 and skip the following steps.
14 Route the cable bundle along the support arms with service loops to allow
movement as shown below.
15 Using the provided cable clamps and 8-32-inch screws, attach the cable bundle to
the arms and the support arm. Adjust the service loops to allow for easy
movement of the monitor arms without pulling on the cables.
place
pendant
here
dyno
electronics
CPI
install control pod
spindle if you did not
purchase the monitor
tray
control
panel
Figure 2-28: Install the Control Panel
2-26
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
PD031A
ROUTING THE HIGH PRESSURE BLOWER CABLES
The high pressure blowers are an optional accessory. If you did not order the high
pressure blowers it is still necessary to route the blower cables to the junction box. To
route the cables from the junction box to the blowers refer to “Attaching the Blower
Cables” on page 3-25.
1 Route each blower cable (P/N 76950315) from the CPI through the designated
power pit conduit, through the pit, and out of the pit as shown.
Note: Be sure to keep the power and communications cables in different pit
conduits.
2 From the pit, route both cables into the junction box.
INSTALLATION
Routing Cables
dyno
electronics
CPI
route power cables
in designated conduit
PD032B
Figure 2-29: Route the Blower Cables
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-27
CHAPTER 2
B
A
Routing Cables
ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES
The wheel clamp is an optional accessory. If you did not order this accessory, it is still
necessary to route the cables to the junction box. After you install the wheel clamp
you can finish routing the cables, refer to “Wheel Clamp” on page 3-26 for installation
instructions.
1 Route the power carriage cable (P/N 76950314) from the CPI through the
designated power pit conduit, through the pit, and out of the pit as shown in
Figure 2-33.
2 Route the wheel clamp cable (P/N 76950313) from the CPI through the same
conduit and along the same path as the power carriage cable.
Note: Be sure to keep the power and communications cables in different pit
conduits.
3 From the pit, route both cables through the junction box as shown in Figure 2-33.
4 Press each cable into the cable track.
Note: The cable must be pressed into the cable track before installing the cable
track ends and brackets.
5 Snap the cable track ends onto the cable track as shown below.
6 Secure the junction box cable track bracket to the cable track end using two 4-40
screws and nuts.
7 Secure the wheel clamp cable track bracket to the cable track end using two 4-40
screws and nuts.
cable track end
cable track end
junction box cable
track bracket
A
PD050
Figure 2-30: A. Install the Cable Track Ends B. Install the Cable Track Brackets
wheel clamp cable
track bracket
B
PD050
2-28
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
tire stop
INSTALLATION
Routing Cables
8 Secure the cable track bracket to the junction box using two 8-32 screws.
9 Secure the cable track bracket to the wheel clamp using a 1/4-20 screw.
Note: If you do not have the wheel clamp, you will need to install the adapter
bracket to the tire stop using the tire stop hardware.
cable track bracket
junction box
adapter bracket
wheel clamp
cable track bracket
Figure 2-31: Install the Cable Track
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-29
CHAPTER 2
Routing Cables
10 Remove the four screws securing the power carriage cover and set aside.
11 Bring the power carriage cable (two-pin connector) from the cable track over to
the motor mount.
12 Secure the strain relief to the side of the power carriage motor mount.
power carriage
cable
strain relief
Figure 2-32: Secure the Strain Relief and Cable
2-30
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLATION
Routing Cables
13 Place the power carriage motor assembly near the motor mount and plug the
motor connector into the power carriage cable.
14 Secure the power carriage cover using the four screws removed earlier.
15 Connect the wheel clamp cable to the wheel clamp. Refer to page 3-27 for
instructions on installing the wheel clamp.
Note: If you do not have a wheel clamp, the wheel clamp cable will hang from the
cable track.
cable track
power carriage
wheel clamp
dyno
electronics
CPI
route power cables
in designated conduit
PD033A
Figure 2-33: Route the Power Carriage and Wheel Clamp Cables
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-31
CHAPTER 2
C
Routing Cables
ROUTING THE EDDY CURRENT BRAKE, BATTERY, AND DYNO POWER CABLES
1 Route the eddy current brake cable (P/N 66952005) from the eddy current brake
through the designated power pit conduit and to the theta controller.
2 Route the battery cable (P/N 76950312) from the CPI through the same conduit
and over to the battery. Refer to the steps and Figure 2-35 on page 2-33 for
instructions on connecting the battery and starter cables.
Note: Be sure to keep the power and communications cables in different pit
conduits.
3 Route the temperature sensor cable from the eddy current brake through the
designated pit conduit and to the break-out board, see Figure 2-38.
4 Route the dyno power cable from the CPI to your power source, but do not plug
it in yet.
dyno power cable
dyno
electronics
CPI
eddy current
brake cable
theta
controller
route power cables
in designated conduit
temperature
sensor cable
Figure 2-34: Route the Eddy Current Brake, Battery, and Power Cables
battery cable
starter cable
battery
starter
PD034
2-32
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLATION
Routing Cables
5 Connect the battery and starter cables.
5a Attach the brown cable to the positive (+) battery post.
5b Attach the red battery cable to the positive (+) battery post and to the large
stud on the starter solenoid.
5c Attach the blue and yellow cable to the negative (-) battery post.
5d Attach the black battery cable to the negative (-) battery post and to the
grounding location on the starter brace.
5e Attach the blue cable to the starter solenoid.
battery cable
blue cable
blue/yellow cable
Figure 2-35: Connect the Battery and Starter Cables
black cable
starter solenoidstarter brace
brown cable
battery
red cable
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-33
CHAPTER 2
Routing Cables
ROUTING THE PICKUP CARD AND DYNO ELECTRONICS CABLES
1 Route the pickup card cable (P/N 66953002) from the CPI through the designated
pit conduit and over to the pickup card. Attach the cable to the pickup card.
Note: Be sure to keep the power and communications cables in different pit
conduits.
2 Route the 25-pin cable (P/N 42924251) from the dyno electronics input/output
module to the Breakout board. Refer to Figure 2-38 for Breakout board location.
Refer to “Dyno Electronics” on page 1-10 for the 25-pin cable location.
3 Route the 9-pin serial cable (P/N 42967090) from the dyno electronics CPU
Module to your computer. Refer to “Dyno Electronics” on page 1-10 for the
9-pin serial cable location.
pickup card
9-pin cable to
computer
25-pin
cable to
breakout
board
electronics
25-pin cable to
breakout board
dyno
CPI
pickup card cable
route communications cables
in designated conduit
PD035
Figure 2-36: Route the Pickup Card and Dyno Electronics Cables
2-34
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ROUTING THE AIR PUMP POWER, AIR FUEL SENSOR, AND DYNO ELECTRONICS POWER CABLES
1 Route the air pump power cable (P/N 76950318) from the CPI to the air pump.
2 Route the air fuel sensor cable (P/N 76950701) from the dyno electronics to the
air pump.
3 Route the dyno electronics power cable to your power source. Refer to “Dyno
Electronics” on page 1-10 for the dyno electronics power cable location.
dyno electronics
power cable
INSTALLATION
Routing Cables
dyno
electronics
CPI
air fuel
sensor cable
air pump
power cable
PD036A
air pump
Figure 2-37: Route the Air Pump Power, Air Fuel Sensor, and Dyno Electronics Power Cables
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-35
CHAPTER 2
Routing Cables
WIRING THE BREAKOUT BOARD
1 Attach the temperature sensor cable to the Breakout board. The temperature
sensor cable has five wires which connect to the wiring block labeled TEMP. This
cable was routed to the Breakout board on page 2-32.
• Green wire connects to G1 • White wire connects to W1
• Black wire connects to B1 • Red wire connects to R1
• Ground (shield) wire connects to S1
2 Attach the theta controller cable to the Breakout board, if it is not already
connected. The theta controller cable has five wires which connect to the wiring
block labeled LOAD CONTROL.
• Black wire connects to V- • Red wire connects to V+
• White wire connects to O+ • Green wire connects to O-
• Ground (shield) wire connects to SH
3 Attach the pickup; card cable to the Breakout board. The pickup card cable has
four wires which connect to the wiring block labeled DRUM 1.
temp
load control
• Red wire connects to R1 • Black wire connects to B1
• White wire connects to W1 • Ground (shield) wire connects to S1
4 Verify jumpers J1 and J2 are set either for the eddy current brake and air brake or
for the air brake only as shown in Figure 2-38.
If you have an eddy current brake and air brake, the air brake will only be
activated when the dyno electronics power is turned off, the E-stop button is
pressed, or the optional door interlock is installed and activated.
5 Close the CPI front access panel. Refer to page 2-22.
J2 J1
eddy current brake only or
eddy current brake and air
brake with control panel
pick-up card
J1J2
air brake
only
Figure 2-38: Wire the Breakout Board
2-36
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
FINAL ADJUSTMENTS AND TESTS
5
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After you have installed all of your additional accessories and routed all necessary cables,
perform the following procedures to ensure the safe and effective operation of your dyno.
Note: Before you plug in your dyno, you or your electrician must refer to Appendix B
for detailed power information.
Always turn the power off when connecting and disconnecting cables.
INSTALLATION
Final Adjustments and Tests
TURNING ON THE DYNO POWER
1 Replace the CPI cover if it was removed. Refer to page 2-22 for more information.
2 Plug the power plug into the power outlet.
3 Turn on the main breaker inside the CPI door.
Note: Use the main breaker to turn power on and off to the dyno.
power plug
PD02
main breaker
Figure 2-39: Turn on the Dyno Power
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-37
CHAPTER 2
Final Adjustments and Tests
POWER CARRIAGE FINAL ADJUSTMENTS AND TESTS
The power carriage allows you to easily adjust for various wheel bases distances with
the press of a button. Refer to “Using the Power Carriage” on page 4-5 for more
information on using the power carriage. To route the power carriage cables refer to
“Routing the Power Carriage and Wheel Clamp Cables” on page 2-28.
Using the Control Panel, press the carriage forward and backward buttons and verify
that the motor does turn.
WHEEL CLAMP FINAL ADJUSTMENTS AND TESTS
The wheel clamp is an optional accessory. To install the wheel clamp refer to “Wheel
Clamp” on page 3-26. To route the wheel clamp cables refer to “Routing the Power
Carriage and Wheel Clamp Cables” on page 2-28.
1 Place a stack of catalogs into the wheel clamp.
2 Using the Control Panel, press the close button and observe that the wheel clamp
does close. Hold the button until the motor turns off and the status light is on
steady.
3 Press and hold the right hand wheel clamp button then press the left hand button
to open the clamp.
Refer to “Using the Wheel Clamp” on page 4-6 for more information on using the
Control Panel.
2-38
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
PIT COVERS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before installing the covers, be sure to install the battery, pickup card, eddy
current brake, air brake, EEC Kit, and any accessories you may have purchased
with your dyno.
This section describes how to install the pit covers and drum guards.
CHANGING THE RETARDER COVER FOR RIGHT SIDE INSTALLATIONS
INSTALLATION
Pit Covers
Note: If you ordered an eddy current brake (retarder) and plan to mount it on the
right side, you will need to change the retarder cover.
left side installation
looking from the bottom
Figure 2-40: Retarder Cover for Left and Right Side Installations
1 Remove the six 1/4-20-inch button-head screws, 1/4-inch flat washers, and
1/4-20-inch lock nuts securing the two angle supports to the bottom of the
retarder cover and set aside.
right side installation
looking from the bottom
screw
angle support
washer
nut
Figure 2-41: Right Side Retarder Cover—Angle Supports
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-39
CHAPTER 2
Pit Covers
2 Remove the four No. 6-32 pan head screws securing the heat shield and insulation
and set aside.
3 Move the heat shield and insulation to other side of the cover as shown in Figure
2-40 and secure with the four No. 6-32 pan head screws removed earlier.
heat shield
screw
Figure 2-42: Right Side Retarder Cover—Heat Shield and Insulation
4 Move the two angle supports to the other side of the cover as shown in
Figure 2-40 and secure with the six 1/4-20-inch button-head screws, 1/4-inch flat
washers, and 1/4-20-inch lock nuts removed earlier.
5 Continue with the instructions for installing the pit covers.
INSTALLING THE PIT COVERS
1 Place the retarder cover over the retarder module.
Note: If your retarder is mounted on the right side, you will need to change the
retarder cover. Refer to page 2-39.
2 Loosely secure the retarder cover using four 3/8-16 x 1/2-inch button-head flange
screws. Do not tighten.
Figure 2-43: Retarder Cover
2-40
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLATION
Pit Covers
Note: If this is a European dyno, you will need to install the EEC finger guards.
Refer to Appendix B for EEC finger guard installation instructions.
3 Loosely attach the drum guard bracket to the left side drum cover using four
1/4-20 x 1/2-inch button-head flange screws.
Note: Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to
secure the 1/4-inch screws. For dynos with serial numbers lower than 2030152,
Dynojet recommends using a hardened 5/32-inch hex driver (such as
Snap-On Fa5E) to attach the 1/4-inch screws. A standard allen key may round off
in the shallow screw head.
drum guard bracket
Figure 2-44: Drum Guard Bracket
4 Place the left side drum cover over the drum module.
5 Loosely secure the left side drum cover using four 3/8-16 x 1/2-inch button-head
flange screws. Do not tighten.
Figure 2-45: Left Side Drum Cover
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-41
CHAPTER 2
Pit Covers
6 Place the right side drum cover over the drum module.
7 Loosely secure the right side drum cover using four 3/8-16 x 1/2-inch button-head
flange screws. Do not tighten.
8 Loosely secure the right side drum cover to the drum guard bracket using four
1/4-20 x 1/2-inch button-head flange screws.
9 Align the pit covers so the drum guard is centered on the drum both front to back
and side to side.
10 Tighten all pit cover screws.
Note: If this is a European dyno, you will need to adjust the EEC finger guards.
Refer to Appendix C for EEC finger guard installation instructions.
Figure 2-46: Right Side Drum Cover
2-42
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLATION
Pit Covers
11 Install the drum guards using two 1/4-20 x 1/2-inch button-head flange screws
and two 1/4-20-inch crush nuts.
Note: If you installed the EEC finger guards, you will need to adjust them now.
Refer to page C-3 for adjusting instructions.
screw
drum guard
Figure 2-47: Install the Drum Guards
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-43
CHAPTER 2
Junction Box Cover, Cable Cover, and End Cap
JUNCTION BOX COVER, CABLE COVER, AND END CAP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before installing the junction box cover, cable cover, and end cap be sure to route all
of your cables. If you ordered any additional accessories refer to Chapter 3 for
installation instructions.
1 Secure the blower connector cover to the junction box using two 4-40 screws.
This cover attaches opposite the blower connectors.
blower connector
junction box
blower connector
cover
Figure 2-48: Install the Blower Connector Cover
2 Secure the junction box cover to the junction box using two 8-32 screws.
junction box cover
Figure 2-49: Install the Junction Box Cover
2-44
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
INSTALLATION
Junction Box Cover, Cable Cover, and End Cap
3 Loosely attach the end cap to the pit cover using two 1/4-20 button-head screws.
Leave these screws loose.
4 Secure the cable cover to the end cap and junction box using two 8-32 screws.
5 Tighten the end cap screws.
end cap
cable cover
PD042
Figure 2-50: Secure the End Cap and Cable Cover
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
2-45
CHAPTER 2
Zip Tube
ZIP TUBE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The zip tube encases the multiple cables running to the control panel. You will need
to use the cable wrap tool (P/N 16510001) to insert the cables into the zip tube.
1 Rotate the cable holder to the open position.
2 Insert the cable(s) into the cable holder.
•Pendant Cable
•Control Panel Cable
•RPM cable(s)
• Additional cables, if desired
cable(s)
cable holder
guide body
end of cables
Figure 2-51: Insert Cable(s) Into Cable Holder
3 Rotate the cable holder closed.
4 Insert the guide body into the zip tube.
Note: Make sure you start the cable wrap tool close to the end of the cables. This
will make it easier to pull the tool along the length of the cables.
5 Pull the cable wrap tool through the zip tube along the length of the cables.
guide body
zip tube
cable wrap tool
Figure 2-52: Securing Cable(s) Into the Zip Tube
2-46
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
end of cables
C HAPTER
3
A
CCESSORIES
This chapter discusses the various optional accessories that are available for the
Dynojet Motorcycle Dynamometer (dyno) to meet your individual needs. All of these
options can be added at the factory at the time of original dyno purchase, or
purchased separately and added at any time thereafter. For more information about
these accessories, please contact Dynojet’s Product Specialists at 1-800-992-3525 for
pricing and availability.
Installation instructions for some of these options can be found in this chapter.
Complete installation instruction manuals may also be found by browsing the
Manuals folder on your WinPEP installation CD.
This chapter is divided into the following categories:
• Main Dyno Power, page 3-2
•Air Brake, page 3-3
• Air Pump and Filter Assembly, page 3-17
• Extended Carriage, page 3-18
• High Pressure Blower, page 3-23
• Wheel Clamp, page 3-26
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-1
CHAPTER 3
5
Main Dyno Power
MAIN DYNO POWER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Many instructions in this guide will require you to connect or disconnect the power to
the dyno as part of the installation process. Use the following steps to connect and
disconnect power to the dyno.
Before you plug in your dyno, you or your electrician must refer to Appendix B for
detailed power instructions.
Always turn the power off when connecting and disconnecting cables.
1 Use the main breaker to turn power on and off to the dyno.
The main breaker is located inside the CPI door. When the handle is in the down
position all power into the dyno is turned off.
2 Disconnect the power plug to ensure all power has been removed from the dyno
before performing certain installation procedures.
power plug
PD02
main breaker
breakout board
Figure 3-1: Main Dyno Power
3-2
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
AIR BRAKE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The optional air brake comes installed and ready to use. You will need to provide an
air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply (60 psi, 415
kilopascal, max constant line pressure) to the dynamometer. Once air pressure is
connected and the air brake cable is routed, the air brake is ready to use.
Note: For information on installing the air brake, refer to the Air Brake and EEC
Kit Installation Guide for Model 200i/250i and 200iP/250iP Motorcycle
Dynamometer, P/N 98123114.
ACCESSORIES
Air Brake
PARTS LIST
The following table lists all of the parts included in the Air Brake (P/N 63920005)
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
21222201 Brake Caliper Stop 1
21222601 Brake Adjusting Shim 1
21622201 Brake Bracket 1
32904080 Hairpin Cotter, 7/16-3/4" shaft size 3
32920128 Clevis Pin, 5/8 x 4" 2
36488100 Nut, 3/8-16, Nylock 1
36581270 Bolt, 3/8-16 x 3/4", with Taper lock 2
36585670 Bolt, 3/8-16 x 3-1/2", Hex 1
36820840 Bolt, 5/8-11 x 1, Hex 2
36952100 Washer, 5/8", splitlock, stl 2
37620844 Woodruff Key, 1/2 x 2-3/4", #1622-1 1
63920004 Air Brake Assembly 1
63990002 Rotor/Taper Lock Assembly with Hub and Key 1
BR102-055 Brake Spring 1
DM150-002-007 Washer, 5/16", Flat 3
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-3
CHAPTER 3
Air Brake
ROUTING THE AIR BRAKE CABLE AND AIR HOSE
1 Open the CPI front panel to access the breakers and Breakout board.
2 Route the air brake cable from the air brake solenoid to the CPI.
Note: The CPI end of the air brake cable splits in two.
3 Connect the cable with the two black wires to the Breakout board wiring block
labeled Brake.
4 Attach the 4-pin connector to port P7 on the CPI board.
P7 on the
CPI board
brake wiring block
on breakout board
Figure 3-2: Routing the Air Brake Cable
3-4
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
to 60 psi
cl e a n d ry a ir
ACCESSORIES
Air Brake
5 Route the air brake air hose through the access hole in the drum module upright
and through the pit conduit.
6 Connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line
pressure) to the air hose.
air brake
pit conduit
air hose
access hole
Figure 3-3: Connecting the Air Hose
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-5
CHAPTER 3
0
Air Brake
INSTALLING THE EMERGENCY STOP STICKER
A properly installed air brake option adds an emergency stop function to the dyno
shutdown button. With the air brake installed, activating the dyno shutdown button
applies the brake and stops the drum. Installing the emergency stop sticker indicates
the added functionality applied to the dyno shutdown button.
1 Remove the control panel rear cover.
1a Remove the two nuts from the top of the cover and set aside.
1b Remove the screw on the top of the cover and set aside.
1c Remove the screw on the side of the cover and set aside.
1d Remove the four screws on the back of the cover and set aside.
1e Remove the control panel rear cover and set aside.
top screw
top nut
CP01
side screw
rear screw
Figure 3-4: Remove the Control Panel Rear Cover
3-6
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ACCESSORIES
2 Remove the Button board.
2a Remove the four screws securing the Button board to the control panel and
set aside.
2b Remove the Button board and set aside.
Air Brake
screw
button board
Figure 3-5: Removing the Button Board
3 Unscrew the black switch body nut and remove the switch body. Set the nut and
switch body aside.
switch body
switch body nut
Figure 3-6: Removing the Switch Body
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-7
CHAPTER 3
Air Brake
4 Place the emergency stop sticker over the dyno shutdown sticker.
place emergency
stop sticker here
Figure 3-7: Placing the Emergency Stop Sticker
3-8
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
switch body nut
ACCESSORIES
Air Brake
5 Secure the switch body to the control panel using the switch body nut removed
earlier.
switch body
control panel
screw
Figure 3-8: Replacing the Emergency Stop Button
6 Secure the Button board to the control panel using the four screws removed
earlier.
button board
Figure 3-9: Securing the Button Board
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-9
CHAPTER 3
Air Brake
rear screw
7 Secure the rear cover to the control panel.
7a Replace the four screws on the back of the cover removed earlier.
7b Replace the screw on the top of the cover removed earlier.
7c Replace the screw on the side of the cover removed earlier.
7d Replace the two nuts removed from the top of the cover removed earlier.
top screw
top nut
side screw
Figure 3-10: Replace the Control Panel Rear Cover
AIR BRAKE FINAL ADJUSTMENTS AND TESTS
1 Verify the dyno is set up properly, the dyno electronics is powered up and
operational, and the air supply is connected properly.
2 Use the red brake button on the pendant or the emergency stop button on the
control panel to activate and deactivate the brake. Listen for air leaks and double
check all connections.
3 Verify the brake pads release far enough so they do not touch the rotor. There
should be equal pad clearance on both sides of the rotor. If the pads touch the
rotor during a run, the information provided by the dyno will be inaccurate.
Refer to page 3-16 for instructions on adjusting the brake pad clearance.
3-10
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
CHANGING THE BRAKE PADS
To prevent possible injury, disconnect the battery and unplug the dyno.
1 Open the CPI’s front panel access and turn off the main breaker.
2 Unplug the dyno power cable. Refer to page 3-2.
3 Remove the eight button-head screws securing the right drum cover and set aside.
4 Remove the right drum cover and set aside.
5 For safety, apply the brake and disconnect the air supply.
6 Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor.
ACCESSORIES
Air Brake
outboard brake pad
adjust castle nut
remove hairpin cotter
Figure 3-11: Loosen the Castle Nut
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-11
CHAPTER 3
Air Brake
7 Using a 9/16-inch ratchet and wrench, remove the bolt, washer, and nut securing
the spring to the brake assembly. The spring is located on the drum side of the
brake assembly.
nut, washer, and spring
bolt
nut, washer,
and spring
bolt
Figure 3-12: Remove the Brake Spring
3-12
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ACCESSORIES
Air Brake
8 Remove the two bolts and two washers securing the brake caliper stop to the
brake bracket and remove the brake caliper stop.
brake caliper stop
9 Remove the hairpin cotter from the bottom clevis pin located on the front of the
brake bracket
Figure 3-13: Remove the Brake Caliper Stop
air brake assembly.
hairpin cotter
Figure 3-14: Remove Bottom Hairpin Cotter
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
bottom clevis pin
3-13
CHAPTER 3
Air Brake
10 Push the bottom clevis pin towards the back of the assembly (drum side). You do
not need to remove the pin completely.
11 Remove the hairpin cotter from the top clevis pin located on the drum side of the
air brake assembly.
top hairpin cotter
Figure 3-15: Remove Bottom Pin and Top Hairpin Cotter
12 Remove the top clevis pin.
top clevis pin
bottom clevis pin
Figure 3-16: Remove the Top Clevis Pin
3-14
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
top clevis pin
ACCESSORIES
Air Brake
13 Lift the air brake assembly up and away from the dyno.
air brake assembly
Figure 3-17: Remove the Brake Assembly
14 Remove the brake pad retaining springs and slide the pads out.
Note: You will need to use pliers to remove the spring securing the outside pad
(closest to the castle nut).
15 Install the new brake pads and secure the pads with new springs.
16 Place the air brake assembly back on the brake bracket. Refer to Figure 3-17.
17 Replace the top and bottom clevis pins and secure with the hairpin cotters
removed earlier. Refer to Figure 3-14, Figure 3-15, and Figure 3-16.
18 Using two bolts and two washers, secure the brake caliper stop to the brake
bracket. Refer to Figure 3-13.
19 Secure the spring using the bolt, washer, and nut you removed earlier. Refer to
Figure 3-12.
20 Tighten the castle nut and replace the hair pin cotter. Refer to Figure 3-11.
21 Adjust the brake pad clearance. Refer to page 3-16 for complete instructions.
22 Replace the right drum cover using the eight button-head screws remove earlier.
23 Connect your shop air.
24 Turn the dyno power on using the main breaker. Refer to page 3-2.
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-15
CHAPTER 3
Air Brake
ADJUSTING THE BRAKE PAD CLEARANCE
There should be equal pad clearance on both sides of the rotor. If the pads touch the
rotor during a run, the information provided by the dyno will be inaccurate. Use the
following steps to adjust the clearance.
1 Loosen the brake caliper stop bolts.
2 Insert the brake adjusting shim between the inboard brake pad and the brake
rotor. Refer to Figure 3-18.
3 Remove the hairpin cotter and hand tighten the castle nut on the caliper assembly
to clamp the brake pads against the rotor and shim. Refer to Figure 3-11 for
hairpin and castle nut location.
4 Tighten the brake caliper stop bolts.
5 Loosen the castle nut and remove the shim.
6 Adjust the clearance between the outboard brake pad and rotor. Loosen the castle
nut to increase the clearance.
There should be equal space on both sides of the rotor.
7 Replace the hair pin cotter in the castle nut.
Note: Cycle the brake to verify the brake pads release far enough so they do not
touch the rotor. If the pads touch the rotor during a run, the information
provided by the dyno will be inaccurate.
brake adjusting shim
Figure 3-18: Adjust the Brake Pad Clearance
rotor
inboard brake pad
brake caliper stop bolts
3-16
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
Air Pump and Filter Assembly
AIR PUMP AND FILTER ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refer to the Air Fuel Ratio Module Installation and User Guide (P/N 98295110) for
proper operating and maintenance procedures. Refer to the Flow Meter User Guide
(P/N 98129104) to test your air pump for accuracy. Failure to follow proper
procedures may result in inaccurate data or damage to the equipment. These manuals
can be found on your WinPEP CD or at www.dynojet.com.
Note: The Air Pump Assembly has a twelve month warranty.
• Dynojet recommends running the pump between dyno runs to help reduce the
chance of moisture contamination on the sensor.
• Remember to empty the exhaust collection bottles regularly.
• Leaks in the system will result in erroneous readings. Verify there are no cracks or
holes in the hoses and filter bowl. Verify the sensor is seated properly in the sensor
block.
• Do not allow the filter bowl to fill with water during operation. Refer to the Air Fuel
Ratio Module User Guide for filter bowl information.
• Before turning the pump on, verify there is no water in the filter bowl. Always
empty the bowl before turning the pump on.
• Always allow the air pump to run after the dyno runs are complete to clear all water
from the filter bowl and allow the air pump to cool.
ACCESSORIES
Leaded racing fuels and two-stroke applications will contaminate the sensor
and dramatically shorten its service life.
The sensor is not covered by a warranty. Be sure to read and understand the Air
Fuel Ratio Module manuals.
Running the pump with the filter clogged, hose kinked, or filter removed will
damage the pump and void the warranty.
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-17
CHAPTER 3
Extended Carriage
EXTENDED CARRIAGE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
part number description quantity
150-300 Power Carriage Option, M/C Dyno 1
21224104 Carriage Clamp, M/C3 3
DM150-016-007 M/C Carriage, Right Screw Support 1
DM150-019-004 M/C Dyno Carriage Ratchet 1
DM150-019-012 Bolt, 3/8-16 x 1", Hexagonal 4
DM150-053 Bolt, 5/16 x 1" 8
21224105 Carriage Clamp Spacer, M/C3 3
21224106 Nut Driver Spacer, M/C3 1
21224114 Carriage Easy Removal Plate 1
21229107 Plate, Extended M/C Pit Carriage 1
32822100 Snap Ring, 5/8" External 1
36561045 Screw, 1/4-20 x 5/8", Pan head, Torx 4
36561670 Bolt, 1/4-20 x 1", Hexagonal 2
36580434 Bolt, 3/8-16 x 1/2", Button-head-Flange, Allan 8
36581270 Bolt, 3/8-16 x 3/4", w/tlok 1
36912100 Washer, 1/4", Splitlock, Steel 2
36932100 Washer, 3/8", Splitlock, Steel 1
37513200 Anchor, Redhead, 3/8" 4
37932100 Ratchet Strap, 2" x 3’, Black 1
61124871 Extended Carriage Trough Assembly, M/C3 1
61324102 Nut Driver Assembly, M/C3 1
61324502 Tire Stop Assembly, M/C 3 1
63310901 Tirelock Assembly with Stickers, M/C3 1
DM150-002-004 5/16" Lockwashers 8
DM150-002-007 Washer, 5/16", Flat 4
DM150-011-004 Nut, 3/8-16, Hexagonal 1
DM150-016-004 M/C Dyno Carriage Screw Bearing 1
DM150-016-005 M/D Dyno Carriage Screw 1
The extended carriage option increases the maximum wheel base (measured from the
front of the front wheel to the center of the rear wheel) from 84 inches to 101 inches
for testing raked cruisers and drag bikes.
The extended carriage comes with a 58-inch cable carrier, instead of the standard
40-inch cable carrier. For cable routing instructions refer to “Routing the Power
Carriage and Wheel Clamp Cables” on page 2-28.
The tire carriage is fastened to the bottom of the crate next to the dyno. Refer to page
2-2 for instructions on removing the tire carriage from the crate.
PARTS LIST
The following table lists all of the parts included in the Extended Carriage Assembly
(P/N 71323005). 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.
3-18
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
TC063
ACCESSORIES
Extended Carriage
INSTALLING THE EXTENDED CARRIAGE PLATE
1 Remove the four bearing plate screws and slide the extended carriage from the
extended carriage plate.
carriage plate
carriage screw
nut block
bearing plate
screws
Figure 3-19: Remove the Extended Carriage From the Plate
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-19
CHAPTER 3
Extended Carriage
2 Use the extended carriage plate to mark and drill mounting holes as shown in
Figure 3-20.
2a Using the extended carriage plate as a template, drill four 1/2-inch holes.
2b Install the Red Head anchors according to the instructions in Appendix A.
40.32 cm
(15.875 in)
66.04 cm
(26.0 in)
Figure 3-20: Extended Carriage Plate Mounting Dimensions
3-20
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ACCESSORIES
Extended Carriage
3 Secure the extended carriage plate to the floor using four 3/8 x 1-inch bolts and
5/16-inch washers.
Figure 3-21: Install the Extended Carriage Plate
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-21
CHAPTER 3
Extended Carriage
INSTALLING THE EXTENDED TIRE CARRIAGE
1 Starting from the back of the dyno, slide the carriage under the carriage clamps.
2 Slide the carriage screw and the bearing bracket toward the nut block until the
carriage screw is touching the nut block.
3 Secure the bearing bracket to the carriage using the four 1/4-20 x 1/2-inch
button-head flange bolts removed earlier.
TC064
carriage
carriage
clamp
carriage
screw
nut block
bearing bracket
Figure 3-22: Install the Extended Carriage
3-22
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ACCESSORIES
High Pressure Blower
HIGH PRESSURE BLOWER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The high pressure blower supplies air to cool the bike’s engine. This section will walk
you through the blower installation procedures.
PARTS LIST
The following table lists all of the parts included in the High Pressure Blower
Assembly (P/N 76722003). Check your kit against the parts listed to make sure you
have received all of the parts. If any part is missing, contact Dynojet Technical
Support.
part number description quantity
26215520 Washer, 1.87 x 1.25 IDx .12THK 4
26215521 Washer, 1.87x1.25 IDx .25THK 2
35521420 Cap Plug, 1-3/4 x 1/2", Black 8
35712991 Clamp Lever, 3/8-16 x 3/4" 4
35712992 Clamp Lever, 3/8-16 x 1-1/2" 2
42303160 Cable-Retractable, 3-Cond, 16-3 1
43814131 AC Plug, Cord, Hi-Currency, 16A/250V 2
61328101 Blower Housing Assembly-Generic 2
63413001 Pivot Arm-Top Assembly 2
63413004 Lower Blower Arm Assembly 2
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-23
CHAPTER 3
High Pressure Blower
INSTALLING THE HIGH PRESSURE BLOWERS
Refer to page 2-16 for blower mount installation instructions.
Repeat the following steps for each blower assembly.
1 Place two 1/4-inch thick poly washers around the pin on the blower mount.
Note: Only use one 1/4-inch thick poly washer with the blower mount installed
with the support arm.
2 Place the lower blower arm over the blower mount pin.
3 Place a 3/8-inch thick metal washer on top of the lower blower arm.
4 Secure the lower blower arm using the clamp lever.
5 Place a 1/8-inch thick poly washer around the pin on the upper blower arm.
6 Insert the pin on the upper arm into the lower arm.
7 Place a 1/8-inch thick poly washer around the pin on the blower assembly.
8 Insert the pin on the blower assembly into the upper arm.
blower
assembly
poly washer
upper arm
poly washer
lower arm
poly washer
blower mount
clamp lever
Figure 3-23: Install the High Pressure Blowers
metal washer
blower assembly
only one 1/4-inch
poly washer
3-24
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
ATTACHING THE BLOWER CABLES
A
The blower cables were routed from the CPI to the junction box on page 2-27. Refer
to “Routing the High Pressure Blower Cables” on page 2-27 for more information.
1 Attach the two blower connectors to the junction box using 4-40 screws.
Note: The blower connectors are attached to the blower cables.
2 Connect the cables from each blower to the connectors on the junction box.
Note: There is an extension cable (P/N 76950317) for the blower furthest from
the junction box.
3 Test the blowers by pressing the appropriate buttons on the control panel. If the
right-hand blower turns on when the left-hand blower button is pressed, shut off
the blowers and switch the cables at the junction box.
connectors
ACCESSORIES
High Pressure Blower
extension cable
dyno
electronics
CPI
PD032
Figure 3-24: attach the Blower Cables
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-25
CHAPTER 3
Wheel Clamp
WHEEL CLAMP
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The wheel clamp allows you to easily adjust for various wheel thicknesses with the
press of a button.
Refer to “Using the Wheel Clamp” on page 4-6 for more information on using the
wheel clamp.
INSTALLING THE WHEEL CLAMP
1 Remove the six 1/4-20 x 1-inch screws securing the wheel clamp cover. Remove
the cover and set the cover and screws aside.
cover
Figure 3-25: Remove the Wheel Clamp Cover
2 Place the wheel clamp on the carriage. Align the four holes on the wheel clamp
with the holes on the carriage.
3 Secure the wheel clamp to the carriage using four 3/8-16 x 1/2-inch bolts.
Figure 3-26: Secure the Wheel Clamp to the Carriage
3-26
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
cable track
ACCESSORIES
Wheel Clamp
4 Bring the wheel clamp cable (three-pin connector) from the cable track over to
the wheel clamp. This cable was routed on page 2-28.
5 Install the wheel clamp cable strain relief to the side of the wheel clamp.
6 Plug the wheel clamp cable into the connector on the wheel clamp motor.
7 Replace the wheel clamp cover.
wheel clamp
motor connector
strain relief
wheel clamp cable
Figure 3-27: Secure the Strain Relief and Cable
WHEEL CLAMP FINAL ADJUSTMENTS AND TESTS
1 Place a stack of catalogs into the wheel clamp.
2 Using the Control Panel, press the close button and observe that the wheel clamp
does close. Hold the button until the motor turns off and the status light is on
steady.
3 Press and hold the right hand wheel clamp button then press the left hand button
to open the clamp.
Refer to “Using the Wheel Clamp” on page 6-6 for more information on using the
Control Panel.
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
3-27
C
ONTROL
P
ANEL INTERFACE
C HAPTER
O
PERATION
4
This chapter will walk you through the basic operating procedures and how to
maintain and troubleshoot the components associated with the Control Panel
Interface (CPI). To ensure safety and accuracy in the procedures, perform the
procedures as they are described.
This chapter is divided into the following categories:
• Basic Operation, page 4-2
• Control Panel Interface, page 4-8
• Maintenance and Troubleshooting, page 4-9
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
4-1
CHAPTER 4
Basic CPI Operation
BASIC CPI OPERATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The control panel may be mounted to either side of the tray for easy access by the
dyno user while seated on the bike. The graphics on the control panel are grouped
together according to function and color coded for ease of identification.
A description of the functions and displays follows:
status indicator
light
Figure 4-1: Control Panel Features
4-2
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
CONTROL PANEL INTERFACE OPERATION
Basic CPI Operation
control panel feature description
Air Fuel Ratio Air Pump This optional accessory allows control of the internal air pump
of the air fuel ratio sampling system. Refer to page 4-3 for more
information.
Emergency Stop/Dyno Shutdown Deactivates the dyno outputs whenever the button is pressed or
the external E-Stop circuit is opened. Refer to page 4-4 for more
information.
High Pressure Blowers (Blowers) This optional accessory allows you to toggle the blowers on and
off to control the temperature of the bike. Refer to page 4-4 for
more information.
Power Carriage This accessory requires the CPI and battery to operate. The
power carriage allows you to move the bike forward and
backward by remote control to center the bike's rear tire on the
dyno drum. Refer to page 4-5 for more information.
Starter Allows for spinning up the dyno drum to bump start bikes that
may not have a starter. Refer to page 4-5 for more information.
Status Indicator Provides information on the status of the CPI control and the
various inputs to the CPI.
Wheel Clamp This optional accessory requires the CPI and battery to operate.
The wheel clamp allows for quicker loading and unloading of
the bike. Refer to page 4-6 for more information.
USING THE AIR FUEL RATIO AIR PUMP
The CPI allows control of the optional internal air pump that is part of the air fuel
ratio (AFR) sampling system. This air pump is built into the dyno to draw exhaust
gases over the AFR sensor. The button on the control panel allows the dyno user to
turn this pump on and off. The indicator light on the control panel will illuminate
when power is provided to the pump.
If the pump does not run, check the following:
• Verify the switch on the pump assembly is on.
• Verify fuses F3 and F4 on the CPI board.
• If the E-Stop button is pressed or the external E-Stop circuit is open then the AFR
pump will not run.
Refer to the Air Fuel Ratio Module Installation and User Guide for proper operating
and maintenance procedures (P/N 98295110). Failure to follow proper procedures
may result in inaccurate data or damage to the equipment. This manual can be found
on your WinPEP CD or at www.dynojet.com.
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
4-3
CHAPTER 4
Basic CPI Operation
USING THE EMERGENCY STOP/DYNO SHUTDOWN
The emergency stop/dyno shutdown button is designed to deactivate the dyno
outputs whenever the button is pressed or the external E-Stop circuit is opened.
When E-Stop is activated the blowers will be turned off, the power carriage will stop,
and the wheel clamp will stop. The starter will be deactivated as well as the AFR air
pump and the retarder will be de-activated. If the dyno is properly equipped with the
air brake option, the air brake will be applied stopping the dyno drum. If the air brake
is not installed the drum will freewheel. During an E-Stop condition the Status
Indicator light will be flashing with two short blinks on and long pause off.
USING THE HIGH PRESSURE BLOWERS
The CPI allows the dyno operator to toggle the optional high pressure blowers on and
off from the control panel. If the E-Stop is activated the blowers will be automatically
turned off. The indicator light by each button will light up when that blower output is
turned on. If the toggle switch on the blower is turned off the blower will not operate
even if the CPI output is on.
The blower outlets on the front of the dyno are designed to only work with
Dynojet provided blowers. Connecting other electrical loads or other blowers
to the outlets on the dyno may damage the dyno and void the warranty.
If the blower indicator light on the control panel is on but the blower is not running,
perform the following steps.
1 Verify the switch on the blower is on.
2 Verify the blower power plug is firmly plugged into the dyno.
3 Verify the blower circuit breakers in the CPI.
If the button on the breaker is extended, an overload has occurred and the
breaker has tripped. Press in the breaker button to reset the breaker. If the
breaker continues to trip, contact Dynojet.
UNDERSTANDING INTERLOCKS
The interlock circuit provides inputs for normally closed switches which open when it
is not safe to run the dyno. Typically these switch inputs will be tied to safety gates
and safety switches that are required in Europe. If the Interlock circuit is open the
Status Indicator light will blink on and off with the on time equal to the off time. This
will continue until this circuit is closed or an overriding E-Stop condition is sensed. In
a dyno configured to comply with CE requirements the interlock signal will activate
the drum air brake.
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Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
USING THE POWER CARRIAGE
This accessory requires the CPI and battery to operate. Use the control panel to
activate the power carriage allowing you to center the bike’s rear tire on the dyno
drum.
The power carriage and wheel clamp cannot be activated at the same time.
Note: When operating the power carriage with a bike on the dyno, make sure the
bike is in neutral.
Note: Always loosen or remove the bike tie-down straps before moving the
carriage. Replace and tighten the straps when the bike is in the proper position.
Never perform a dyno run if the tie-down straps are not in place or they are
damaged.
If the carriage movement is slow during parts of its travel, investigate and correct the
source of the problems. If you reach the end of travel of the carriage or the carriage
binds and you continue to hold down the carriage movement button, the motor will
draw too much current and blow the carriage fuse F2. There is a short time delay built
into the button operation to allow the carriage motor to coast to a stop before it
moves in the opposite direction. This delay is needed to prevent the motor from
drawing too much current by rapidly reversing the motor.
CONTROL PANEL INTERFACE OPERATION
Basic CPI Operation
USING THE STARTER
The built-in starter allows you to use the momentum of the drum to start motorcycles
that are not equipped with an on-board starting system. The starter requires a battery
to operate. Refer to page 2-20 for more information on the battery.
If the E-Stop button is pressed, the starter will not engage. If the interlock circuit is
open, the starter will not operate.
1 Make sure the dyno brakes are not activated.
2 Verify the bike is in neutral or disengage the clutch.
3 Press and hold the green starter button until the drum reaches maximum speed.
4 Release the green starter button.
5 Use the momentum of the drum to start the bike.
Note: Do not re-engage the starter while the drum is turning.
Version 2 Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
4-5
CHAPTER 4
Basic CPI Operation
USING THE STATUS INDICATOR
The status indicator provides information on the status of the CPI control and the
various inputs to the CPI.
• Status: Off—indicates the CPI may not be receiving power due to the dyno being
turned off or lack of power being applied to the dyno.
• Status: Steady On—indicates all inputs into the CPI are okay for normal dyno
operation and the CPI is receiving power.
• Status: Blinking—If the status indicator light is flashing with two short blinks on
and a long pause off, the Emergency Stop circuit is open. This can be caused by the
red button on the control panel being pressed or an external E-Stop (Emergency
Stop) condition is being fed to the CPI board. The E-Stop circuit must be closed to
allow for normal dyno operation.
• Status: Blinking—If the status indicator light is blinking with equal on and off time,
the interlock signal into the CPI board is open. This signal monitors the condition
of optional safety switches that will be attached to safety guards or the dyno room
door when guards are not used; this will allow dyno operation only when the
guards are in place or the door is closed. The E-Stop circuit takes precedence over
the interlock input.
USING THE WHEEL CLAMP
This optional accessory requires the CPI and battery to operate. The wheel clamp
allows for quicker bike loading and unloading. The internal mechanism in the wheel
clamp closes on the bike's front wheel and tire to a calibrated amount of pressure
securing the bike. The indicator light between the wheel clamp buttons provides
status of the current state of the wheel clamp.
Pinch hazard. Keep hands, body parts, and other loose items clear. Failure to
follow these instructions can result in serious injury or equipment damage.
Risk of injury. Be sure the wheel clamp is free and clear of any obstruction. Do
not operate the dyno if the wheel clamp indicator light is not on steady.
4-6
Model 200iP/250iP Motorcycle Pit Dynamometer Installation Guide
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