Dynojet 250iPX Installation Guide

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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:______________________________________________________

Page 3

ABLE OF

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

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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

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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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

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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

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 7

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

Page 8

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.

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 9

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

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Page 11

C HAPTER

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

PERATING

EQUIREMENTS

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

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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.

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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

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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).

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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

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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

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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)

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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.

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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.

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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

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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

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Page 23

C HAPTER

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

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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

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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

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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

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dyno electronics assembly P/N 76199001P

blower assembly P/N 76722005

optional accessory

Page 27

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

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

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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

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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

Page 29

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

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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

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Eddy Current Brake Installation

EDDY CURRENT BRAKE INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 2-39 and “Wiring the Breakout Board” on page 2-43.

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.

You will need the following parts:

• 62919004 Eddy Current Brake

• 37620622 Woodruff Key, 3/8 x 1-3/8"

• 62240070 Driveline Assembly

INSTALLATION

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 Place the ends of a nylon loop strap through the lifting eyes on either side of the

brake and hook onto the shaft. 4 Using a forklift, lift the eddy current brake from the crate and place the brake in

the pit near the drum module making sure not to hit the driveline assembly. 5 Record the eddy current brake number on the inside cover of this manual.

RECORD

Be sure you record the eddy current brake number on the inside cover of this manual.

lifting eye

eddy current brake number

Figure 2-4: Record the Eddy Current Brake Number

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CHAPTER 2

Eddy Current Brake Installation

INSTALLING THE EDDY CURRENT BRAKE

1 Insert the key into the keyway on the drum module shaft. 2 Use a c-clamp to press the key in.

key

key way on dyno shaft

PD108

Figure 2-5: Install the Key

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INSTALLATION

Eddy Current Brake Installation

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). 4 Remove the starter brace and set aside. 5 Keeping the panels parallel, slide the eddy current brake towards the dyno. Slide

the driveline assembly over the key on the dyno shaft. You will need to support

the driveline assembly as you slide it onto the dyno shaft. 6 Continue sliding the eddy current brake towards the dyno until the uprights on

the brake and dyno are flush. 7 Loosely secure the connector plates to the dyno frame using the eight bolts,

washers, and six nuts removed earlier.

Note: Do not tighten the bolts.

8 Replace the existing set screws on the driveline assembly with the thread-lock set

screws provided. 9 Tighten the driveline assembly set screws.

brake shaft

set screw

Figure 2-6: Tighten the Set Screws

dyno shaft

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CHAPTER 2

iPX Drum Module Installation

IPX DRUM MODULE INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

When you receive your iPX upgrade kit, 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 the iPX drum module and related items. You will need to provide equipment capable of lifting a minimum of 363 kg. (800 lb.) to move the crated drum into position in your dyno room.

REMOVING THE ITEMS FROM CRATE

1 Move the crate 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. 3 Remove the following parts from the crate and set aside.

part description part description

drum guard mounting bracket P/N 21200025

pit cover, middle P/N 61100005

drum safety cover P/N 21200038

cable track mounting bracket (to trike carriage adapter) P/N 21200069

drum guard (2) P/N 21229106

screw, 1/4-20 x 5/8", pan-head, torx (12) P/N 36561045

pit cover, right P/N 61100006

retarder driveline assembly P/N 62240070

drum module, pit P/N 63200002

trike carriage adapter assembly P/N 71300002

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INSTALLATION

iPX Drum Module Installation

part description part description

bolt, 3/8-16 x 1/2", buttonhead, flange, allen (6) P/N 36580434

ground hook kit (4) P/N 79190001 see list of parts below

woodruff key, 3/8 x 1-3/8" P/N 37620622

The following parts are included in each Ground Hook Kit P/N 79190001:

ground hook/D-ring P/N 10111

D-ring bracket, surface mount P/N 10112

washer, 3/8", splitlock, steel (2) P/N 36932100

nut, crush, 1/4-20 (4) P/N DM150-020-005

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

4 Remove the crate braces that support the top portion of the crate. 5 Remove the four lag bolts and washers securing the drum to the crate base using

a 9/16-inch socket, open or box end wrench.

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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Page 36

CHAPTER 2

iPX Drum Module Installation

INSTALLING THE IPX DRUM MODULE

You will need the following parts:

• 37620622 Woodruff Key (2)

• 62240070 Driveline Assembly

• 63200002 iPX Drum Module 1 Place the nylon loop strap around the shaft on either side of the drum module. 2 Remove the two existing screws from each side of the dyno frame where the

connector plates will attach. 3 Insert the woodruff key into the keyway on the drum module shaft. 4 Insert the woodruff key into the keyway on the dyno shaft. 5 Using a forklift, lift the drum module from the crate and place the drum module

in the pit with the stepped end of the shaft towards the dyno. Make sure the

panels on the drum module and the dyno are parallel. 6 Slide the driveline over the key on the drum module shaft. 7 Keeping the panels parallel, slide the drum module towards the dyno. Slide the

driveline over the key on the dyno shaft. You will need to support the driveline as

you slide it onto the dyno shaft. 8 Continue sliding the drum module towards the dyno until the side panels on the

drum module and the dyno are flush.

PD109

existing screws

woodruff key

existing screws

woodruff key

iPX drum module

driveline

Figure 2-7: Install the Driveline and the iPX Drum Module

2-14

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 37

INSTALLATION

iPX Drum Module Installation

9 Secure the connector plate on either side of the iPX drum module to the dyno

drum module using the bolts removed earlier. 10 Loosen the four bolts on either side of the iPX drum module as shown in

Figure 2-8. 11 Align the iPX drum module panels until they are flush with the top of the pit floor

and the dyno drum module panels. 12 Once you have verified the panels are flush and parallel, tighten all the screws. 13 Tighten the driveline set screws.

Note: Dynojet recommends using red loctite on the set screws.

14 Install upright bar removed earlier to the side of the iPX drum module using the

two 1/4-20 screws removed earlier.

dyno drum

module panel

PD110

secure connector plate

iPX drum module

panel

upright bar

loosen these bolts on both

sides of iPX drum module

Figure 2-8: Install the Drum Module to the Dyno

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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CHAPTER 2

iPX Drum Module Installation

LINING UP AND SECURING THE MODULE UPRIGHTS

1 Verify the uprights on the drum and eddy current brake modules are flush with

the top of the pit floor before you tighten the connector plates.

1a Loosen all upright bolts.

1b Place two straight edges across the drum module uprights.

1c With the upright tight against the straight edges and flush with the pit floor,

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.

1d Tighten the upright bolts and nuts on the drum module.

1e Repeat this for the eddy current brake module uprights. 2 Secure the starter brace to the starter using the washer and nut removed earlier. 3 Remove the straight edges.

eddy current brake

module upright

drum module

upright

loosen bolts

securing uprights

connector

plate bolts

2-16

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Figure 2-9: Secure the Uprights

PD144

Page 39

Secure the Drum and Brake Module to the Pit Floor

SECURE THE DRUM AND BRAKE MODULE TO THE PIT FLOOR

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 left and right blower mounts along

with the trike adapter mounting plate this time. Refer to page 2-19 for the left

blower mount instructions, page 2-24 for the trike adapter mounting plate

instructions, and page 2-25 for the right blower mount instructions.

You will need the following parts:

• 37513200 Anchor, Redhead, 3/8" (8)

• DM150-002-007 Washer, 5/16", Flat (8)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (8)

1 Mark and drill each hole needed to secure the drum and brake modules to the pit

floor. 2 Install the Red Head anchors. Refer to Appendix A for installation instructions.

INSTALLATION

PD143

drill holes

Figure 2-10: Secure the Drum and Brake Module to the Pit Floor

drill holes

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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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 2-41 for instructions on routing and connecting the pickup

card cable.

PD111

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 2-11: Install the Pickup Card

2-18

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 41

Left Side Blower and Monitor Arm Installation

LEFT SIDE BLOWER AND MONITOR ARM INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use the following instructions to install the left side blower mount, monitor support, and junction box along with the left blower assembly and monitor tray. The right blower mount and assembly will be installed later.

You will need the following parts:

• 21221500 Blank Plate, Junction Box

• 21228000 Junction Box Base

• 26215520 Washer, 1/8", Poly, for Monitor Support (3)

• 35521420 Cap Plug, for Monitor Support (4)

• 61329100 Monitor Arm (2)

• 61329101 Monitor Tray

• 61329500 Monitor Support

The following parts are included in the Blower Assembly, P/N 76722005:

• 21600015 Lower Blower Arm

• 26215220 Washer, 3/8", Metal

• 26215520 Washer, 1/8", Poly (2)

• 26215521 Washer, 1/4", Poly (2)

• 35521420 Cap Plug (4)

• 35712991 Clamp Lever

• 37513200 Anchor, Redhead, 3/8" (4)

• 61328101 Blower Assembly

• 61329601 Blower Mount

• 63413001 Upper Blower Arm

• DM150-002-007 Washer, 5/16", Flat (4)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (4)

INSTALLATION

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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CHAPTER 2

Left Side Blower and Monitor Arm Installation

INSTALLING THE LEFT BLOWER MOUNT

If this is an iX upgrade to an existing 200iP/250iP dyno, skip these instructions and refer to Appendix E for upgrade instructions.

1 Mark the left blower mount placement as shown in Figure 2-12. 2 Using the blower mount as a template, mark and drill the four holes needed to

secure the blower mount to the floor. 3 Install the Red Head anchors. Refer to Appendix A for installation instructions.

111.76 cm (44.00 in.)

184.05 cm (72.46 in.)

PD152

Figure 2-12: Install the Left Blower Mount

2-20

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 43

Left Side Blower and Monitor Arm Installation

INSTALLING THE MONITOR SUPPORT AND THE JUNCTION BOX

1 Place the blower mount where you installed the Red Head anchors on page 2-20. 2 Secure the blower mount, monitor support arm, and junction box to the pit floor

using four 3/8 x 1-inch bolts and four washers.

Note: The left blower mount is secured under the support arm.

3 Verify the blank plate is secured to the junction box as shown in Figure 2-13. 4 Verify the fan connectors are secured to the junction box in the location shown in

Figure 2-13.

INSTALLATION

PD113

support arm

blower mount

(under support arm)

blank plate

fan connectors

junction box

Figure 2-13: Install the Monitor Support Arm and Junction Box

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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CHAPTER 2

Left Side Blower and Monitor Arm Installation

INSTALLING THE LEFT BLOWER ASSEMBLY

1 Insert a plastic cap in both ends of each arm. 2 Place one 1/4-inch thick poly washer around the pin on the blower mount. 3 Place the lower blower arm over the blower mount pin. 4 Place a 3/8-inch thick metal washer on top of the lower blower arm. 5 Secure the lower blower arm using the clamp lever. 6 Place a 1/8-inch thick poly washer around the pin on the upper blower arm. 7 Insert the pin on the upper arm into the lower arm. 8 Place a 1/8-inch thick poly washer around the pin on the blower assembly. 9 Insert the pin on the blower assembly into the upper arm.

Note: The right blower assembly will be installed later.

blower

assembly

PD114

poly washer

lower blower arm

clamp lever

(not visible)

metal washer

(not visible)

poly washer

Figure 2-14: Install the Left Blower Assembly

poly washer

upper blower arm

2-22

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 45

INSTALLING THE MONITOR 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.

tray

INSTALLATION

Left Side Blower and Monitor Arm Installation

arms

monitor support

PD115

Figure 2-15: Install the Monitor Arms and Monitor Tray

washers

washer

left blower

assembly

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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Page 46

CHAPTER 2

Trike Carriage Adapter Installation

TRIKE CARRIAGE ADAPTER INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use the following instructions to install the trike carriage adapter plate, right blower assembly, and the cable track.

The installation instructions are the same for both the standard and the extended carriage; verify you use the correct dimensions for the type of carriage you are installing.

INSTALLING THE TRIKE CARRIAGE ADAPTER PLATE

You will need the following parts:

• 15331100 Chain Lube

• 37513200 Anchor, Redhead, 3/8" (8)

• 71300002 Trike Carriage Adapter Assembly

• DM150-002-007 Washer, 5/16", Flat (8)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (8) 1 Mark the trike carriage adapter plate placement as shown in Figure 2-16. 2 Using the trike carriage adapter plate as a template, mark and drill eight 1/2-inch

holes needed to secure the adapter plate to the floor. 3 Install the Red Head anchors. Refer to Appendix A for installation instructions. 4 Secure the adapter plate to the floor using eight 3/8-16 x 1-inch bolts and eight

5/16-inch flat washers. 5 Lube the tracks with the included lube or use grease.

PD116

mark and trill for redhead anchors

0.635 cm (0.25 in.)

Figure 2-16: Install the Trike Carriage Adapter Plate

standard carriage

72.39 cm (28.50 in.) extended carriage

97.79 cm (38.50 in.)

2-24

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 47

Trike Carriage Adapter Installation

INSTALLING THE RIGHT BLOWER MOUNT AND BLOWER ASSEMBLY

You will need the following parts:

• 21600015 Lower Blower Arm

• 26215220 Washer, 3/8", Metal

• 26215520 Washer, 1/8", Poly (2)

• 26215521 Washer, 1/4", Poly (2)

• 35521420 Cap Plug (4)

• 35712991 Clamp Lever

• 37513200 Anchor, Redhead, 3/8" (4)

• 61328101 Blower Assembly

• 61329601 Blower Mount

• 63413001 Upper Blower Arm

• DM150-002-007 Washer, 5/16", Flat (4)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (4)

1 Using Figure 2-17 as a guide, place the blower mount in a location that works best

for your dyno application.

2 Using the blower mount as a template, mark and drill the four holes needed to

secure the blower mount to the floor. 3 Install the Red Head anchors. Refer to Appendix A for installation instructions. 4 Secure the blower mount to the floor using four 3/8-16 x 1-inch hex bolts and

four 5/16-inch flat washers.

INSTALLATION

63.50 cm

(25.00 in.)

111.76 cm (44.00 in.)

PD145

Figure 2-17: Install the Right Blower Mount

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CHAPTER 2

Trike Carriage Adapter Installation

5 Insert a plastic cap in both ends of each arm. 6 Place two 1/4-inch thick poly washers around the pin on the blower mount. 7 Place the lower blower arm over the blower mount pin. 8 Place a 3/8-inch thick metal washer on top of the lower blower arm. 9 Secure the lower blower arm using the clamp lever. 10 Place a 1/8-inch thick poly washer around the pin on the upper blower arm. 11 Insert the pin on the upper arm into the lower arm. 12 Place a 1/8-inch thick poly washer around the pin on the blower assembly. 13 Insert the pin on the blower assembly into the upper arm.

The blowers can run at any time once the cord is plugged into a power source.

right blower

assembly

PD146

clamp lever

aluminum washer

Figure 2-18: Install the Right Blower Assembly

upper blower

arm

lower blower

arm

1/4-inch thick

poly washer

2-26

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 49

INSTALLING THE CABLE TRACK

You will need the following parts:

• 134260301 Nut, 4-40, Hex (4)

• 136206141 Screw, 4-40 x 3/8", Flat-Head (4)

• 21200069 Cable Track Mounting Bracket, to Trike Adapter Assembly

• 21626217 Cable Track Mounting Bracket

• 43432150 Cable Track

1 Remove the two 5/16-inch bolts and washers securing the carriage clamp as

shown in Figure 2-19. 2 Secure the cable track mounting bracket to the carriage clamp using the

two 5/16-inch bolts and washers removed earlier.

INSTALLATION

Trike Carriage Adapter Installation

mounting bracket

carriage clamp

PD117

Figure 2-19: Install the Cable Track Mounting Bracket

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CHAPTER 2

Trike Carriage Adapter Installation

3 Secure the cable track to the mounting bracket on the trike adapter assembly

using two 4-40 x 3/8-inch screws and two 4-40 nuts. 4 Secure the cable track mounting bracket to the cable track using two

4-40 x 3/8-inch screws and two 4-40 nuts.

PD118

Figure 2-20: Install the Cable Track and Mounting Bracket

2-28

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 51

ROUTING CABLES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

junction box

cable track

INSTALLATION

Routing Cables

route communications

cables in designated

conduit

dyno

electronics

control panel

interface

(CPI)

route power cables

in designated conduit

monitor support

and tray

control panel

Figure 2-21: Pit Dyno Room Layout

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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CHAPTER 2

Routing Cables

BATTERY REQUIREMENTS

The model 200iPX/250iPX 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 3/4-inches 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 2-31.

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.

2-30

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Page 53

INSTALLING THE BATTERY

1 Secure the battery to the tray with the battery hold-down. 2 Refer to page 2-39 for instructions on routing and connecting the battery cable.

INSTALLATION

Routing Cables

battery

PD120

Figure 2-22: Install the Battery

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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: Access the CPI

2-32

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 55

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

route communications cables

in designated conduit

PD121

Figure 2-24: Route the Control Panel, Pendant Cables, and RPM Cables

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CHAPTER 2

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

2-34

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 57

6 Route the control panel cable and RPM cable through the access hole on the side

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 3-5 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

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CHAPTER 2

Routing Cables

install control pod spindle if you did not purchase the monitor

tray

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 2-59 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.

control

panel

dyno

electronics

CPI

PD122

Figure 2-28: Install the Control Panel

2-36

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Page 59

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.

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. 3 Attach the two blower connectors to the junction box using 4-40 screws.

Note: The blower connectors are attached to the blower cables.

4 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. Plug the power cord from this blower into the supplied blower extension cable and into the power source located on the junction box.

blower connectors

in junction box

INSTALLATION

Routing Cables

dyno

electronics

CPI

route power cables

in designated conduit

extension cable

PD123

Figure 2-29: Route the High Pressure Blower Cables

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CHAPTER 2

Routing Cables

ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES

The wheel clamp is an optional accessory. After you install the wheel clamp you can finish routing the cables, refer to “Wheel Clamp” on page 3-17 for installation instructions. If you did not order this accessory, it is still necessary to route the cable to the junction box.

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 2-30.

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. 4 Press each cable into the cable track.

Figure 2-30: Route the Power Carriage and Wheel Clamp Cables

2-38

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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Page 61

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 2-32 on page 2-40 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 Breakout board, see Figure 2-35.

4 Route the dyno power cable from the CPI to your power source, but do not plug

it in yet.

dyno power cable

INSTALLATION

Routing Cables

dyno

electronics

CPI

eddy current

brake cable

theta

controller

temperature sensor cable

battery cable

route power cables

in designated conduit

battery

starter cable

PD125

starter

Figure 2-31: Route the Eddy Current Brake, Battery, and Power Cables

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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CHAPTER 2

Routing Cables

5 Connect the battery and starter cables.

Be sure to route the cables through the cable routing bracket. Secure the cables to the bracket using cable ties.

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

cable routing

bracket

starter brace

black cable

blue cable

Figure 2-32: Connect the Battery and Starter Cables

blue/yellow cable

starter solenoid

brown cable

battery

red cable

PD151

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Page 63

ROUTING THE PICKUP CARD AND DYNO ELECTRONICS CABLES

pickup card

9-pin cable to

computer

INSTALLATION

Routing 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 2-35 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.

25-pin

cable to

breakout

board

pickup card cable

dyno

electronics

CPI

25-pin cable to

breakout board

PD126

Figure 2-33: Route the Pickup Card and Dyno Electronics Cables

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CHAPTER 2

Routing Cables

ROUTING THE AIR PUMP POWER, AIR FUEL SENSOR, AND DYNO ELECTRONICS POWER CABLES

dyno electronics

power cable

dyno

electronics

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.

CPI

air fuel

sensor cable

air pump

Figure 2-34: Route the Air Pump Power, Air Fuel Sensor, and Dyno Electronics Power Cables

2-42

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

air pump

power cable

PD127

Page 65

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 2-39.

• 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.

INSTALLATION

Routing Cables

• 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 2-35.

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.

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CHAPTER 2

Routing Cables

5 Close the CPI front access panel. Refer to page 2-32.

temp

load control

J2 J1

eddy current brake only or eddy current brake and air

brake with control panel

pick-up card

J1J2

air brake

only

Figure 2-35: Wire the Breakout Board

2-44

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 67

Carriage Assembly and Power Carriage Installation

CARRIAGE ASSEMBLY AND POWER CARRIAGE INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use the following instructions to install the standard carriage (or optional extended carriage) and the power carriage along with securing the cable track.

INSTALLING THE CARRIAGE ASSEMBLY

Use the following instructions to install the standard carriage or the extended carriage.

You will need the following parts:

• 36561045 Screw, 1/4-20 x 5/8", Pan-Head, Torx (4)

• 78100004 Standard Carriage Assembly or

78100005 Extended Carriage Assembly 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 Using the control panel to run the power carriage, run the carriage screw through

the nut block and into the screw support bracket on the carriage assembly.

4 Secure the bearing bracket to the carriage assembly using four 1/4-20 x 1/2-inch

button-head screws.

INSTALLATION

PD128

Figure 2-36: Install the Carriage Assembly

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CHAPTER 2

Carriage Assembly and Power Carriage Installation

INSTALLING THE POWER CARRIAGE

You will need the following part:

• 82943001 Power Carriage 1 Remove the four screws securing the power carriage cover and set aside. 2 Bring the power carriage cable (two-pin connector) from the cable track over to

the motor mount. 3 Secure the strain relief to the side of the power carriage motor mount.s 4 Place the power carriage motor assembly near the motor mount and plug the

motor connector into the power carriage cable. 5 Secure the power carriage cover using the four screws removed earlier. 6 Verify the carriage moves without binding. Refer to “Final Adjustments and Tests”

on page 2-48.

PD129

Figure 2-37: Install the Power Carriage

2-46

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 69

Carriage Assembly and Power Carriage Installation

INSTALLING THE TIRE STOP AND CABLE TRACK ADAPTER BRACKET

If you ordered the optional wheel clamp, refer to chapter 3 for instructions on securing the cable track and connecting the wheel clamp cable. If you did not order the wheel clamp, the wheel clamp cable will hang from the cable track.

You will need the following parts:

• 21626218 Cable Track Adapter Bracket

• 36561045 Screw, 1/4-20 x 5/8", Pan-Head, Torx

• 63310902 Tire Stop

• DM150-002-004 Washer, 5/16", Lock (4)

• DM150-002-007 Washer, 5/16", Flat (4)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (4)

1 Secure the tire stop to the carriage using three 3/8-16 x 1-inch bolts, three

5/16-inch flat washers, and three 5/16-inch lock washers. 2 Secure the cable track adapter bracket to the tire stop and carriage using the

remaining 3/8-16 x 1-inch bolt, 5/16-inch flat washer, and 5/16-inch lock washer. 3 Secure the cable track to the adapter bracket using one 1/4-20 x 5/8-inch pan-head

torx screw.

INSTALLATION

cable track

adapter bracket

torx screw

PD130

Figure 2-38: Install the Cable Track Adapter Bracket

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CHAPTER 2

Final Adjustments and Tests

FINAL ADJUSTMENTS AND TESTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

TURNING ON THE DYNO POWER

1 Replace the CPI cover if it was removed. Refer to page 2-32 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

2-48

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 71

HIGH PRESSURE BLOWER TEST

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.

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 2-38.

Using the Control Panel, press the carriage forward and backward buttons and verify that the motor does turn.

TRIKE ADAPTER ASSEMBLY TEST

1 Using the supplied chain lube or grease, lube the front and rear adapter slides

(unpainted part). 2 Pull the pin up to slide the carriage until the pin locks into the next location.

Verify the carriage slides left and right on the trike adapter plate.

INSTALLATION

Final Adjustments and Tests

WHEEL CLAMP FINAL ADJUSTMENTS AND TESTS

The wheel clamp is an optional accessory. To install the wheel clamp refer to “Wheel Clamp” on page 3-17. To route the wheel clamp cables refer to “Routing the Power Carriage and Wheel Clamp Cables” on page 2-38.

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.

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CHAPTER 2

Pit Covers Installation

PIT COVERS INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Use the following instructions to install the pit covers.

You will need the following parts:

• 21200025 Drum Guard Mounting Bracket, iPX module

• 21200038 Drum Safety Cover

• 21226105 Left Pit Cover

• 21226106 Eddy Current Brake Pit Cover

• 21229106 Drum Guard, iPX module (2)

• 21229111 Drum Guard, Dyno Module (2)

• 21624103 Drum Guard Mounting Bracket, Dyno Module

• 36561045 Screw, 1/4-20 x 5/8", Pan-Head, Torx (24)

• 36580434 Bolt, 3/8-16 x 1/2", Button-Head, Flange, Allen (18)

• 61100005 Middle Pit Cover

• 61100006 Right Pit Cover

• DM150-020-005 Nut, crush, 1/4-20 (8) 1 Place the eddy current brake cover over the brake module. 2 Loosely secure the eddy current brake cover using four 3/8-16 x 1/2-inch

button-head flange screws. Do not tighten.

Figure 2-40: Install the Eddy Current Brake Pit Cover

2-50

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

PD134

Page 73

INSTALLATION

Pit Covers Installation

Note: If this is a European dyno, you will need to install the EEC finger guards. Refer to Appendix C 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 5/8-inch pan-head torx 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.

PD135

Figure 2-41: Install the Dyno Module Drum Guard Bracket

drum guard bracket

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CHAPTER 2

Pit Covers Installation

4 Place the left side drum cover over the drum module. 5 Verify all the cables are routed under the left drum cover and through the cable

6 Loosely secure the left side drum cover using four 3/8-16 x 1/2-inch button-head

routing opening.

flange screws. Do not tighten.

cable routing opening

Figure 2-42: Install the Left Side Drum Cover

2-52

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

PD136

Page 75

INSTALLATION

Pit Covers Installation

7 Loosely install the iPX module drum guard mounting bracket to the underside of

the middle pit cover using four 1/4-20 x 5/8-inch pan-head torx screws.

pit cover

drum guard mounting

Figure 2-43: Install the iPX Module Drum Guard Mounting Bracket

bracket

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CHAPTER 2

Pit Covers Installation

8 Loosely install the middle pit cover to the dyno module drum guard mounting

9 Place the middle pit cover on the dyno drum module uprights and align the

10 Loosely install the middle pit cover to the dyno drum module uprights using the

11 Loosely install the middle pit cover to the iPX drum module uprights using two

bracket using four 1/4-20 x 5/8-inch pan-head torx screws.

middle pit cover with the existing dyno pit cover.

four 3/8-16 x 1/2-inch button-head flange screws.

3/8-16 x 1/2-inch button-head flange screws.

Figure 2-44: Install the Middle Pit Cover to the Dyno and iPX Drum Module

2-54

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

PD137

Page 77

INSTALLATION

Pit Covers Installation

12 Place the right pit cover on the iPX drum module uprights and align the right pit

cover with the middle pit cover.

13 Loosely install the right pit cover to the iPX module drum guard mounting

bracket using four 1/4-20 x 5/8-inch pan-head torx screws.

14 Loosely install the right pit cover to the iPX drum module uprights using four

3/8-16 x 1/2-inch button-head flange bolts.

15 Center the drum guard mounting bracket over the drum. Verify the drum does

not contact the mounting bracket.

16 Tighten all screws.

PD138

Figure 2-45: Install the Right Pit Cover to the iPX Drum Module

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CHAPTER 2

Pit Covers Installation

17 Install each drum guard to the drum guard mounting bracket using two

1/4-20 x 5/8-inch pan-head torx screws and two 1/4-20 nuts.

Note: Verify the drum does not contact the drum guards.

Note: If you installed the EEC finger guards, you will need to adjust them now.

Refer to “Adjusting the EEC Finger Guards” on page C-3 for detailed instructions.

drum guards

Figure 2-46: Install the Drum Guards

2-56

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

PD139

Page 79

INSTALLATION

Pit Covers Installation

18 Place the drum safety cover over the drum. This cover has two pins to keep it in

place.

Risk of injury. Never run a vehicle on the dyno without this cover in place.

drum safety cover

PD140

Figure 2-47: Install the Drum Safety Cover

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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.

You will need the following parts:

• 21228517 Cable Routing Cover

• 21228519 Cable Channel End Cap

• 21228521 Junction Box Cover

• 21626902 Cable Cover, Pit to Junction Box

• 36540643 Screw, 8-32 x 3/8", Pan-Head, Phil (13) 1 Secure the junction box cover to the junction box using two 8-32 x 3/8-inch pan-

head screws. 2 Secure the end cap to the pit cover using two 8-32 x 3/8-inch pan-head screws. 3 Secure the cable cover to the end cap using four 8-32 x 3/8-inch pan-head screws. 4 Secure the cable cover to the junction box cover using one 8-32 x 3/8-inch pan-

head screw.

Note: Verify the cables are placed inside the cable cover.

5 Secure the cable routing cover to the middle pit cover using four 8-32 x 3/8-inch

pan-head screws.

end cap

cable cover

junction box cover

Figure 2-48: Install the Junction Box Cover, End Cap, and Cable Cover

2-58

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

cable routing

cover

PD141

Page 81

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

INSTALLATION

Zip Tube

guide body

end of cables

Figure 2-49: Insert the Cable(s) Into the 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

end of cables

Figure 2-50: Secure the Cable(s) Into the Zip Tube

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CHAPTER 2

Ground Hook Installation

GROUND HOOK INSTALLATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Using Figure 2-51 as a guide, place the ground hooks in a location that works best for your dyno application.

You will need the following parts:

• 10111 Ground Hook/D-Ring (4)

• 10112 D-Ring Bracket (4)

• 36932100 Washer, 3/8", Splitlock, Steel (8)

• 37513200 Anchor, Redhead, 3/8" (8)

• DM150-002-007 Washer, 5/16", Flat (8)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (8)

1 Using the ground hook as a template, mark and drill each hole needed to secure

the ground hooks to the floor. 2 Install the Red Head anchors. Refer to Appendix A for installation instructions. 3 Secure each ground hook to the floor using two 3/8-16 x 1-inch hex bolts, two

5/16-inch flat washers, and two 3/8” lock washers.

64.52 cm

(25.40 in.)

6.10 cm

(2.40 in.)

standard carriage

172.21 cm (67.80 in.) extended carriage

223.00 cm (87.80 in.)

PD142

43.69 cm

(17.20 in.)

Figure 2-51: Ground Hook Placement

2-60

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

145.54 cm (57.30 in.)

87.12 cm

(34.30 in.)

Page 83

C HAPTER

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

• Compressed Air Pump Assembly, page 3-16

• Wheel Clamp, page 3-17

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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CHAPTER 3

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.

Note: 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

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 85

AIR BRAKE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The optional air brake (P/N 63920005) 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.

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.

ACCESSORIES

Air Brake

PD149

P7 on the

CPI board

brake wiring block on breakout board

Figure 3-2: Route the Air Brake Cable

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CHAPTER 3

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.

access hole

air brake

to 60 psi

cl ean d ry a ir

pit conduit

PD150

Figure 3-3: Connect the Air Hose

3-4

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 87

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

ACCESSORIES

Air Brake

side screw

CP01

rear screw

Figure 3-4: Remove the Control Panel Rear Cover

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CHAPTER 3

Air Brake

screw

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.

button board

switch body nut

Figure 3-5: Remove the Button Board

3 Unscrew the black switch body nut and remove the switch body. Set the nut and

switch body aside.

switch body

Figure 3-6: Remove the Switch Body

3-6

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 89

4 Place the emergency stop sticker over the dyno shutdown sticker.

ACCESSORIES

Air Brake

place emergency stop sticker here

Figure 3-7: Place the Emergency Stop Sticker

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CHAPTER 3

Air Brake

switch body nut

5 Secure the switch body to the control panel using the switch body nut removed

earlier.

switch body

control panel

screw

Figure 3-8: Replace the Emergency Stop Button

6 Secure the Button board to the control panel using the four screws removed

earlier.

button board

Figure 3-9: Secure the Button Board

3-8

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Page 91

rear screw

ACCESSORIES

Air Brake

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

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 3-15 for instructions on adjusting the brake pad clearance.

side screw

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CHAPTER 3

Air Brake

CHANGING THE BRAKE PADS

You will need the following part:

• 78122005 Brake Pad Kit

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.

outboard brake pad

remove hairpin cotter

3-10

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

Figure 3-11: Loosen the Castle Nut

adjust castle nut

Page 93

ACCESSORIES

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

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CHAPTER 3

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.

Figure 3-14: Remove the Bottom Hairpin Cotter

3-12

In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

hairpin cotter

bottom clevis pin

Page 95

ACCESSORIES

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 the Bottom Pin and Top Hairpin Cotter

12 Remove the top clevis pin.

top clevis pin

bottom clevis pin

top clevis pin

Figure 3-16: Remove the Top Clevis Pin

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CHAPTER 3

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 3-15 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.

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Page 97

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.

ACCESSORIES

Air Brake

brake adjusting shim

Figure 3-18: Adjust the Brake Pad Clearance

rotor

inboard brake pad

brake caliper stop bolts

Version 2 In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide

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Page 98

CHAPTER 3

Compressed Air Pump Assembly

COMPRESSED AIR PUMP ASSEMBLY

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Refer to the Compressed Air Air Fuel Ratio Module Installation and User Guide (P/N 98200006) 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.

The sensor and the copper sample tube are hot. Before touching the sensor or the sample tube, make sure it has cooled.

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 Compressed Air Air Fuel Ratio Module Installation and User manual.

Before turning the pump on, verify there is no water in the hose.

Warm up the vehicle before placing the copper sample tube in the exhaust to avoid drawing excess water through the pump assembly.

Keep the air pump assembly upright. Tipping the pump assembly may result in damage to the sensor.

Leaks in the system will result in erroneous readings. Verify there are no cracks or holes in the hose. Verify the sensor is seated properly in the sensor block.

To ensure accurate readings, pump maintenance should be performed every six months, or sooner, depending on usage. Refer to the Compressed Air Air Fuel Ratio Module Installation and User Guide for more information.

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Page 99

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.

You will need the following parts:

• 71329000 Wheel Clamp Assembly

• DM150-002-004 Washer, 5/16", Lock (4)

• DM150-002-007 Washer, 5/16", Flat (4)

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (4)

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.

ACCESSORIES

Wheel Clamp

Figure 3-19: Remove the Wheel Clamp Cover

cover

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Page 100

CHAPTER 3

Wheel Clamp

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-inch bolts,

four 5/16-inch lock washers, and four 5/16-inch flat washers.

PD131

Figure 3-20: Secure the Wheel Clamp to the Carriage

4 Bring the wheel clamp cable (three-pin connector) from the cable track over to

the wheel clamp. This cable was routed on page 2-38. 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

cable track

PD132

Figure 3-21: Secure the Strain Relief and Cable

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In Ground Model 200iPX/250iPX Motorcycle Dynamometer Installation Guide