Dynojet 250iPX Installation Guide
©2008-2009 Dynojet Research, Inc. All Rights Reserved.
Installation Guide For In Ground Model 200iPX and 250iPX Motorcycle Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual is furnished under license and may only be used
or copied in accordance with the terms of such license. This manual is furnished for
informational use only, is subject to change without notice, and should not be construed
as a commitment by Dynojet. Dynojet assumes no responsibility or liability for any error
or inaccuracies that may appear in this manual. Except as permitted by such license, no
part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any
form or by any means, electronic, mechanical, recording, or otherwise, without the prior
written permission of Dynojet.
The Dynojet logo is a trademark of Dynojet Research, Inc.
Any trademarks, trade names, service marks, or service names owned or registered by any
other company and used in this guide are the property of their respective companies.
Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA.
Printed in USA.
Part Number: 98200018 Version 2 (01/2009)
RECORD
Dynamometer Number: ____________________________________________________
iPX 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
Confirmation of Compliance Testing and Certification . . . . . . . . . . . . . . . . 1-3
Your Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . .1-5
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Verify the Pit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
i
TABLE OF CONTENTS
Chapter 2 Installation
Dyno Drum Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unpacking the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Placing the Dyno in the Pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
iPX Drum Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Removing the Items from Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Installing the iPX Drum Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Lining up and Securing the Module Uprights . . . . . . . . . . . . . . . . . . . . . .2-16
Secure the Drum and Brake Module to the Pit Floor . . . . . . . . . . . . . . . . 2-17
Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Left Side Blower and Monitor Arm Installation . . . . . . . . . . . . . . . . . . . . .2-19
Installing the Left Blower Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Installing the Monitor Support and the Junction Box . . . . . . . . . . . . . . . .2-21
Installing the Left Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-22
Installing the Monitor Arms and Monitor Tray . . . . . . . . . . . . . . . . . . . . .2-23
Trike Carriage Adapter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Installing the Trike Carriage Adapter Plate . . . . . . . . . . . . . . . . . . . . . . . .2-24
Installing the Right Blower Mount and Blower Assembly . . . . . . . . . . . . .2-25
Installing the Cable Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Routing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-29
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Accessing the CPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Routing the Control Panel, Pendant Cables, and RPM Cable . . . . . . . . . .2-33
Routing the High Pressure Blower Cables . . . . . . . . . . . . . . . . . . . . . . . . .2-37
Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . . 2-38
Routing the Eddy Current Brake, Battery, and Dyno Power Cables . . . . . .2-39
Routing the Pickup Card and Dyno Electronics Cables . . . . . . . . . . . . . . . 2-41
Routing the Air Pump Power, Air Fuel Sensor, and Dyno Electronics
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-43
Carriage Assembly and Power Carriage Installation . . . . . . . . . . . . . . . . .2-45
Installing the Carriage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Installing the Tire Stop and Cable Track Adapter Bracket . . . . . . . . . . . . .2-47
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
High Pressure Blower Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . .2-49
Trike Adapter Assembly Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . .2-49
Pit Covers Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Junction Box Cover, Cable Cover, and End Cap . . . . . . . . . . . . . . . . . . .2-58
Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
Ground Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-60
ii
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
Chapter 3 Accessories
Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Routing the Air Brake Cable and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Compressed Air Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Installing the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . .3-19
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 Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . .5-5
Connecting The Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Pre-Run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Version 2 In Ground Model 200iPX/250iPX Motorcycle 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 and Installation
Locations Using 60 Hz Power (North America and 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
Appendix E Dyno Preparation for Upgrade Installation
Dyno Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Removing the Cable Cover, End Cap, and Junction Box Cover . . . . . . . . . . E-2
Removing the Monitor Tray and Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Disconnecting the Cable Track and Moving the Cables. . . . . . . . . . . . . . . . E-5
Removing the Monitor Support and Junction Box. . . . . . . . . . . . . . . . . . . . E-6
Removing the Carriage and Carriage Plate . . . . . . . . . . . . . . . . . . . . . . . . . E-7
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
iv
In Ground Model 200iPX/250iPX Motorcycle 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 Power Requirements
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.
Potentially Lethal Voltages
Components attached to and within the dynamometer operate with potentially lethal voltages. To
provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power
source before servicing electrical components or wiring. Disconnect all power cords before servicing
electrical components for the greatest assurance of safety.
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
v
WARN IN GS
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 ant of sta tic sho ck 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 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 handing 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
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
WAR NIN GS
Other Potential Hazards
The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for
disconnect before service.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Any dyno room design must incorporate sufficient exhaust extraction.
Always wear proper ear and eye protection when operating the dynamometer.
Never operate the dynamometer with the covers removed.
Never stand behind the dynamometer when in operation.
Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems
before proceeding.
Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured to the dynamometer.
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 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
vii
C HAPTER
S
PECIFICATIONS AND
Thank you for purchasing Dynojet’s In Ground Model 200iPX/250iPX Motorcycle
Dynamometer. Dynojet’s software and dynamometers will give you the power to get
the maximum performance out of vehicles you evaluate. Whether you are new to the
benefits of a chassis dynamometer or an experienced performance leader, the
repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer
will give you the professional results you are looking for.
This document provides instructions for installing the in ground motorcycle
dynamometer (dyno) along with the kart upgrade. This document will walk you
through operating requirements, installation, accessories, and basic dyno operation.
To ensure safety and accuracy in the procedures, perform the procedures as they are
described.
Document Part Number: 98200018
O
PERATING
R
EQUIREMENTS
1
Versio n 2
Last Updated: 01-12-09
This chapter is divided into the following categories:
•Introduction, page 1-2
• Dynamometer Specifications and Requirements, page 1-5
• Dyno Electronics, page 1-10
• Verify the Pit Dimensions, page 1-11
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
1-1
CHAPTER 1
Introduction
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before installing your dyno, please take a moment to read this guide for installation
instructions, dyno features, and other important information.
This guide is designed to be a reference tool in your everyday work and includes the
following chapters and information:
SPECIFICATIONS AND OPERATING REQUIREMENTS
This chapter describes the requirements and specifications for the dyno.
INSTALLATION
This chapter describes the procedures for installing the dyno.
ACCESSORIES
This chapter lists each dyno accessory alphabetically and describes the procedures for
installing and using the accessory.
CONTROL PANEL INTERFACE OPERATION
This chapter describes the Control Panel Interface (CPI) operating procedures.
BASIC DYNO OPERATION
This chapter describes basic dyno operating procedures.
RED HEAD INSTALLATION
This appendix describes the procedures for installing the Red Head anchors.
POWER REQUIREMENTS
This appendix describes the power requirements and installation instructions for all
locations excluding North America.
EEC FINGER GUARD & DOOR SAFETY SWITCH KIT
This appendix describes the procedures for installing the EEC finger guards and door
safety switch.
THETA CONTROLLER
This appendix describes how to make power adjustments to the theta controller.
DYNO PREPARATION FOR UPGRADE INSTALLATION
This appendix describes how to prepare an existing dyno for installing the iPX
upgrade kit.
1-2
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
CONVENTIONS USED IN THIS MANUAL
The conventions used in this manual are designed to protect both the user and the
equipment.
example of convention description
The Caution icon indicates a potential hazard to the
dynamometer equipment. Follow all procedures
exactly as they are described and use care when
performing all procedures.
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
The Record # icon reminds you to record your
RECORD
#
dynamometer and/or eddy current brake (retarder)
number on the inside cover of this manual.
Introduction
Bold Highlights items you can select on in the software
!
interface, including buttons and menus.
The arrow indicates a menu choice. For example,
“select
File !Open” means “select the File menu,
then select the
Open choice on the File menu.”
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, 3D visualizations, and press releases
about our latest product lines.
CONFIRMATION OF COMPLIANCE TESTING AND CERTIFICATION
Dynojet Model 200iP, 200iPX, 250iP, and 250iPX dynamometers have
been tested to NFPA 79:2002 and UL 508(A) standards and pass the
requirements.
Certificate Number: US72080032.01
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
1-3
CHAPTER 1
Introduction
YOUR DYNO ROOM
This section is not meant to imply that a dyno room is essential to repeatable results
on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan,
exhaust extraction, and noise reduction capabilities can add a new dimension to your
shop.
A proper dyno room design will help to ensure repeatable, accurate runs. A good
dyno room should do the following:
• minimize noise
• provide a controlled environment for testing
• provide a view window (safety glass) for customers
• be designed with safety in mind
Intake Air Fan—After building your dyno room, you will need to supply an intake air
fan. The intake air fan supplies air to cool the bike’s engine while supplying fresh
oxygen for you and your bike to breathe. It is a common misconception that you
cannot tune a bike without a large fan simulating exact road conditions; however, a
good cooling fan is the only requirement for consistent diagnostics and tuning. The
installed fan should be 5200 CFM.
Equalizer Box—If the air flow rate coming into the dyno room is greater than the air
flow rate leaving the dyno room, the room will become pressurized. A pressurized
dyno room will make measured power misleading. To compensate, you need an
equalizer box. The equalizer box is a baffled (to reduce noise) vent to the outside of
your dyno room. The size of the equalizer box is dependent on the size of your dyno
room and the size of your fans.
Exhaust Extraction—An exhaust fan is needed to remove exhaust gasses, especially
carbon monoxide, from the dyno room. Carbon monoxide is potentially lethal to
people if not removed from the room and will affect engine power when mixed with
fresh air. 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).
1-4
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following specifications and requirements will help you set up your dyno area
and verify you have the requirements to operate your dyno safely.
BATTERY REQUIREMENTS
Your 200iPX/250iPX 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 2-31.
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.)
iPX drum module 76.20 cm (30.00 in.)
pit covers 137.16 cm (54.00 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
dyno with upgrade 271.42 cm (106.86 in.)
pit covers with eddy current brake 310.29 cm (122.16 in.)
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)/1,089 kg (2400 pounds)
200iPX/250iPX drum module/crated 136 kg (300 pounds)/363 kg (800 pounds)
Drum
diameter 45.72 cm (18.00 in.)
width 50.80 cm (20.00 in.)
diameter, 200iPX/250iPX upgrade 45.72 cm (18.00 in.)
width, 200iPX/250iPX upgrade 55.88 cm (22.00 in.)
Frame structural steel
Maximum Speed 322 KPH (200 MPH)
Maximum Motorcycle Length (front of front
wheel to center of rear wheel)
standard carriage 213.00 cm (84.00 in.)
extended carriage 256.54 cm (101.00 in.)
Remote Switches remote software control
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
1-5
CHAPTER 1
Dynamometer Specifications and Requirements
standard carriage
304.80 cm (120.00 in.)
extended carriage
355.60 cm (140.00 in.)
137.16 cm
(54.00 in.)
45.72 - 46.67 cm
(18.00 - 18.38 in.)
PD104
239.00 cm (91.10 in.)
pit covers
310.29 cm (122.16 in.)
including eddy current
brake cover
271.42 cm
(106.86 in.)
76.20 cm
(30.00 in.)
Figure 1-1: Model 250iPX Dyno Dimensions
1-6
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
Control Panel
Interface
houses all electronics
(not shown)
PD105
Eddy Current
Brake
Monitor Support
and Tray
Control Panel
Wheel Clamp
Option
Power Carriage
Tri k e A d ap t er
Assembly
High Pressure
Blower
Air Brake Option
(not shown)
Model 250iP
Dyno Module
iPX Drum
Module
Figure 1-2: Model 250iPX Dyno with Accessories
Air Pump Option
(not shown)
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
1-7
CHAPTER 1
Dynamometer Specifications and Requirements
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)
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
DRILL AND DRILL BIT REQUIREMENTS
description specifications
Te mp e r at u r e
Humidity 0 to 95% non condensing
You will need to provide a drill and drill bit capable of drilling holes in concrete. Refer
to Appendix A for more information on installing Red Head Anchors.
• drill bit size: 1/2-inch
• minimum hole depth: 1 5/8-inch (41.2 mm)
ELECTRICAL REQUIREMENTS
The Model 200iPX/250iPX 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
operating min./max 10°C/50°C (50°F/122°F)
storage min./max 0°C/60°C (32°F/140°F)
FORKLIFT REQUIREMENTS
You will need to provide equipment capable of lifting a minimum of 1,089 kg.
(2400 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 1,089 kg. (2400 lb.) to attach to the
dyno. Dynojet recommends using single loop style straps.
1-8
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
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.
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
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.
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
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 1-3: The Dyno Electronics
1-10
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS
VERIFY 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 98229104) you received from your salesman for
more detailed specifications.
• pit depth: 45.00 cm (18.00 in.)
• pit length: 294.64 cm (116.00 in.)
• pit width: 121.00 cm (48.00 in.)
121.00 cm
(48.00 in.)
Verify the Pit Dimensions
294.64 cm
(116.00 in.)
PD106
Figure 1-4: Verify the Pit Dimensions
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
1-11
C HAPTER
2
I
NSTALLATION
This chapter will walk you through unpacking and installing the dynamometer. To
ensure safety and accuracy in the procedures, perform the procedures as they are
described.
This chapter is divided into the following categories:
• Dyno Drum Module Installation, page 2-2
• Eddy Current Brake Installation, page 2-9
• iPX Drum Module Installation, page 2-12
• Secure the Drum and Brake Module to the Pit Floor, page 2-17
• Pickup Card, page 2-18
• Left Side Blower Mount and Monitor Arm Installation, page 2-19
• Trike Carriage Adapter Installation, page 2-24
• Routing Cables, page 2-29
• Carriage Assembly and Power Carriage Installation, page 2-45
• Final Adjustments and Tests, page 2-48
• Pit Cover Installation, page 2-50
• Junction Box Cover, Cable Cover, and End Cap, page 2-58
• Zip Tube, page 2-59
• Ground Hook Installation, page 2-60
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
2-1
CHAPTER 2
Dyno Drum Module Installation
DYNO DRUM MODULE INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When you receive your dyno, examine the exterior of the shipping container for any
visible damage. If damage is detected at this stage, contact the shipper or Dynojet
before proceeding with unpacking.
Use the following steps to unload your dyno. You will need to provide equipment
capable of lifting a minimum of 1,089 kg. (2400 lb.) to move the crated dyno into
position in your dyno room. Refer to “Dynamometer Specifications and
Requirements” on page 1-4 for more information.
Note: If this is an iX upgrade to an existing 200iP/250iP dyno, remove the drum
covers and skip to “Installing the iPX Drum Module” on page 2-14.
UNPACKING THE DYNO
1 Move the crated dyno to a clear area near your dyno room.
2 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the
top and sides of the crate.
Note: At this point, you will want to inspect the exterior of the dyno for any
indications of damage. Report any damage immediately.
3 Remove the tire carriage and support arm and set aside. The tire carriage and
support arm are fastened to the bottom of the crate.
4 Remove the following parts, 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
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
INSTALLATION
Dyno Drum Module Installation
5 Verify the contents of the hardware boxes and set aside.
part description part description
nut, 4-40, hex (4)
P/N 134260301
plug, turnlok, 30A,
125/250V
P/N 43816430
screw, 4-40 x 3/8", flat-head
(4)
P/N 136206141
cover, fan connector holes
P/N 21221500
pit cover plate, left
P/N 21226105
cable junction box base
P/N 21228000
cable routing cover
P/N 21228517
receptacle, turnlok, 30A,
125/250V
P/N 43826430
control pod spindle
assembly
P/N 61329000
monitor arm (2)
P/N 61329100
monitor tray
P/N 61329101
monitor support
P/N 61329500
cable channel end cap
P/N 21228519
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
blower mount (2)
P/N 61329601
included on P/N 76722005
2-3
CHAPTER 2
Dyno Drum Module Installation
part description part description
cable hole cover track
mount
P/N 21228520
generic i dyno, pit
P/N 62919003
cable junction box cover
P/N 21228521
drum guard, side (2)
P/N 21229111
drum guard mounting
bracket
P/N 21624103
cable track mounting
bracket
P/N 21626217
cable track adapter bracket
P/N 21626218
retarder module, pit
P/N 62919004
tire stop
P/N 63310902
not included if you ordered
the optional wheel clamp
control panel button subassembly
P/N 66117001
wheel clamp
P/N 71329000
optional accessory
power distribution stand
alone
P/N 76129010
cable cover, pit to junction
box
P/N 21626902
screw, 4-40 x 1/2", BH,
Allen(6)
P/N 36520834
2-4
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
dyno electronics assembly
P/N 76199001P
blower assembly
P/N 76722005
optional accessory
INSTALLATION
Dyno Drum Module Installation
part description part description
screw, 8-32 x 3/8", pan-head,
phil (34)
P/N 36540643
iPX upgrade kit
P/N 77000004
shipped in a separate crate,
refer to page 2-12
screw, 1/4-20 x 5/8", panhead, torx (12)
P/N 36561045
bolt, 3/8-16 x 1/2", buttonhead, flange, allen (16)
P/N 36580434
washer, 3/8", splitlock,
steel (12)
P/N 36932100
anchor, redhead, 3/8" (12)
P/N 37513200
installation tool, redhead
anchor
P/N 37518200
standard carriage
P/N 78100004
or
extended carriage
P/N 78100005
ground hook kit (2)
P/N 79190001
see list of parts below
power carriage
P/N 82943001
included on P/N 78100004
or 78100005
banner, dynojet (2)
P/N D706
inductive secondary
pickup (2)
P/N DE100-109S
woodruff key, 3/8 x 1-3/8"
P/N 37620622
cable harness wrap kit
P/N 43400000
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
inductive primary pickup
clip
P/N DE100-110L
washer, 5/16", flat (18)
P/N DM150-002-007
2-5
CHAPTER 2
Dyno Drum Module Installation
part description part description
cable clamp, 5/8" (7)
P/N 43428232
bolt, 3/8-16 x 1", hex (12)
P/N DM150-019-012
cable track
P/N 43432150
cable track mounting
bracket
P/N 43432151
nut, crush, 1/4-20 (8)
P/N DM150-020-005
The following parts are included in the Retarder Module, Pit P/N 62919004:
pit cover, plate, retarder
P/N 21226106
retarder driveline assembly
P/N 62240070
theta-2 controller-240V
P/N 66411003
temperature probe
assembly
P/N 76955001
The following parts are included in each Ground Hook Kit P/N 79190001:
ground hook/D-ring
P/N 10111
2-6
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
D-ring bracket, surface
mount
P/N 10112
washer, 3/8", splitlock,
steel (2)
P/N 36932100
anchor, redhead, 3/8" (2)
P/N 37513200
washer, 5/16", flat (2)
P/N DM150-002-007
bolt, 3/8-16 x 1", hex (2)
P/N DM150-019-012
REMOVING THE DYNO FROM THE CRATE
This section will walk you through removing the dyno from the crate and installing
the dyno in your pit.
You will need to provide equipment capable of lifting a minimum of 1,089 kg.
(2400 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 1,089 kg. (2400 lb.) to
attach to the dyno. Dynojet recommends using a single loop style strap.
INSTALLATION
Dyno Drum Module Installation
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 2-2: Remove the Dyno From the Crate Base
Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
2-7
CHAPTER 2
Dyno Drum Module Installation
PLACING THE DYNO IN THE PIT
Place the drum module in the pit as shown in Figure 2-3.
Note: Figure 2-3 shows drum placement for an eddy current brake.
PD107
15.24 cm
(6.00 in.)
105.41 cm
(41.50 in.)
Figure 2-3: Drum Module Placement in Pit
2-8
In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide
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