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Above Ground Model 200iX/250iX Installation Guide

1. 2 16 f AP115 air hose to the pump air hose to the pump Figure 2 12 Installing the Air Hose with the Air Brake Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake This section will walk you through removing the eddy current brake or retarder from the crate and attaching the brake to your dyno For more information on routing the temperature sensor cable and the theta controller refer to Routing the Eddy Current Brake Cables on page 2 38 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 PSN WARNING To prevent possible injury unplug all power cords and disconnect the battery You will need the following parts 36561045 36580404 37620622 62240070 66411003 Screw 1 4 20 x 5 8 PH Torx 2 Screw Set 3 8 16 x 5 16 w Tlok 2 Woodruff Key 3 8 x 1 3 8 Driveline Assembly Theta 2 Controller 240V Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 2 17 CHAPTER 2 f amp Eddy Current Brake UNPACKING THE EDDY CURRENT BRAKE 1 Remove the top and sides of the crate 2 Remove the four screws securing the top cover and set aside Remove the cover
2. lifting eye ae z bolt and washer not visible from this view a ol a Figure 2 5 Remove the Dyno from the Crate Base Version 1 Dyno Installation gt a J J a bolt and washer lifting eye H ee ae bolt and washer 2 9 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Ay CHAPTER 2 F amp Dyno Installation 3 Route the single loop strap through the lifting eyes in front of the drum as shown in Figure 2 6 Note The dyno should only be lifted using the lifting eyes Verify no other part of the dyno is interfering with the strap Do not place the strap around the cable routing bracket or any other part of the dyno lifting eye loop strap cable routing bracket __ _ lt 4 lifting eye Figure 2 6 Loop Strap Placement 4 Carefully lift the dyno off the crate DCOISA Figure 2 7 Lift the Dyno off the Crate VO JEt Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Sx Dyno Installation N Locate the power cable inside the dyno Slide the strain relief on the power cable through the opening in the dyno frame Tighten the jam nut Hand tighten the knurled nut Move the dyno into position in your dyno room CANA cut away view from inside dyno opening in dyno frame jam nut knurled nut strain relief around inside dyno outside dyno power co
3. 3 Using a hammer drive the anchor flush with the surface of the concrete or below the surface if the hole depth exceeds minimum embedment N N LLY RANNAN TNL N SA NW SSS V SSS SSS OA N Z Wy S ify ff h Head Anchor Drive the Anchor Flush N X GH003 2a Figure A 3 Re 4 Using a hammer expand the anchor with the setting tool The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor Note Use only Ramset Red Head setting tools to insure proper installtion setting tool GH004 Figure A 4 Red Head Anchor Expand the Anchor Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION Different countries have different standards for delivery of AC alternating current electricity to homes and buildings The frequency number of cycles per second in Hertz Hz varies from country to country North America typically uses 60 Hz power Western Japan including the Osaka Kyoto Nagoya Hiroshima regions also uses 60 Hz power Eastern Japan including the Tokyo Kawasaki Sapporo Yokohama and Sendai regions uses 50 Hz power Many other countries such as Germany the Netherlands and most European Union countries have standardized on 50 Hz To ensure safety and accuracy in the procedures perform the procedures as they are described This Appendix is divided into the fol
4. Note When running an ATV you may need to increase the tire pressure so the tire does not come in contact with the decking Visually inspect the vehicle Make sure it is in safe running order Make sure ear protection and safety glasses are used when the dyno is being operated Check the tie down straps to make sure that they are tight and secured Check the drive tires to be sure that they are aligned correctly on the dynamometer s drums Keep all rotating components clear at all times Only the operator should be near the dyno or the vehicle during the test Never allow any person s to stand behind the dyno or vehicle when it is being operated Perform any other safety inspections appropriate to running your vehicle on the dyno WOT ae Never allow any person s to stand behind the dyno or vehicle when it is being operated Only the operator should be near the dyno or the vehicle during the test Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 5 7 xy CHAPTER 5 yoy Pre Run Inspection BEFORE STARTING THE ENGINE Connect an exhaust hose or hoses if dual exhaust on the vehicle make sure the hose fits over the tail pipe is not plugged or kinked and the hose is vented correctly out of the dyno room WARNING PEN Engine exhaust contains poisonous carbon monoxide gas Breathing it could cause death Operate machine in well ventilated area ENGINE WARM UP Warm the vehi
5. As you hold the button the wheel clamp mechanism will close on the bike s wheel and tire The wheel clamp status light will blink as the clamp is closing SWOT PON For proper and safe operation the wheel clamp must grip the wheel as well as the tire If the front tire is too wide to allow the clamp pads to grip the wheel you must use the wheel strap 2 Continue to hold the button down as the clamp applies pressure to the wheel and tire During this process the CPI is monitoring the current that is going to the wheel clamp When the wheel clamp has reached sufficient clamping force to secure the bike the current drive to the wheel clamp is cut and the wheel clamp indicator light will turn on steady indicating that the wheel is secured AW Do not operate the dyno if the wheel clamp indicator light is not on steady 3 Pull back on the bike to verify the bike is secured 4 Adjust the carriage to align the rear bike tire on the dyno drum 5 Secure the bike with the tie down straps SWZ PAN Never perform a dyno run if the tie down straps are not in place or they are damaged OPENING THE WHEEL CLAMP 1 Press and hold the right hand yellow square button first then press the left hand yellow button The wheel clamp will start opening The status indicator light will be blinking to indicate the wheel is not secured and a dyno run should not be attempted 2 Continue to open the clamp far enough to allow the
6. 8 Secure the dyno side cover to the bulkheads using the eleven screws removed earlier dyno side cover Figure 2 26 Securing the Dyno Side Cover 2 32 C Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Sx iX Drum Module Installation y 9 Secure the dyno top cover to the bulkheads using the five screws removed earlier 10 Secure the drum side cover to the drum module using the eight 1 4 20 x 5 8 inch button head screws removed earlier dyno top cover drum side cover Figure 2 27 Securing the Dyno Top Cover and Drum Side Cover AELA Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Ay CHAPTER 2 fry Routing Cables ROUTING CABLES For the following instructions the support arm and control panel are shown mounted on the left side of the dyno Open the control panel interface CPI front panel to access the breakers and Breakout board monitor support and tray control panel control panel dyno interface electronics CPD Figure 2 28 Dyno Room Layout 234 TG Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION J ons Routing Cables BATTERY REQUIREMENTS The model 200iX 250iX 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
7. INSTALLING THE WALL RECEPTACLE The wall receptacle is included with your dyno and is shipped in a box in the center of your dyno or may be shipped in advance in a separate package The wall receptacle is a single phase 240 volt 30A dedicated circuit with a neutral connection and a ground The neutral connection is required to split the 240 volt into two 120 volt connections internal to the dyno The cable carrying the power to this receptacle should be ten gauge or larger Check with local building codes for the correct size 1 Connect one of the 240V legs line 1 to the X terminal gold colored screw 2 Connect the other 240V leg line 2 to the Y terminal gold colored screw 3 Connect the neutral conductor to the W or WH terminal silver screw 4 Connect the ground conductor to the green grounding screw B 3 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy APPENDIX B Vale Locations Using 60 Hz Power North America and Japan TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet AW If the voltage readings do not match the following table DO NOT connect the dyno You must have a licensed electrician correct the power connection Connecting the dyno to the incorrect voltage can result in damage to the dyno and will void the dyno warranty Contact Dynojet with any questions Using a voltmeter that is capable of me
8. colors are brown blue black and green yellow 1 Connect 240VAC single phase power between the brown and the blue wire connection points 2 Connect the green yellow wire to the ground connection point Cut off the black wire 4 Refer to the previous table for testing and probe the new connections as follows e blue wire as location 1 Qe e brown wire as location 3 e green yellow wire as location 2 HARD WIRING TO THE BUILDING Use the following instructions to wire the dyno directly to the building The dyno must connect to a two pole disconnect switch to allow the removal of all power to the dyno for servicing This box may contain fusing circuit breakers or the circuit protection may be upstream in the building power system The circuit must be protected to 30A with slow blow fuses or time delayed circuit breakers The power cord that attaches to the dyno has four conductors internally and their colors are brown blue black and green yellow 1 Remove the dyno power plug and connect 240VAC single phase between the brown and the blue wires through the disconnect switch 2 Connect the green yellow wire to the ground connection Cut off the black wire 4 Refer to the previous table for testing and probe the new connections as follows e blue wire as location 1 Qe e brown wire as location 3 e green yellow wire as location 2 Version 1 POWER REQUIREMENTS AND INSTALLATION Locations Using 50 Hz Power Location
9. internet access 1 9 power 50 Hz B 7 power 60 Hz B 2 tie down straps 1 9 routing cables air brake 3 3 air hose 3 4 control 2 38 control panel 2 37 eddy current brake 2 38 input power 2 38 pendant 2 37 power 2 11 power carriage 2 40 RS232 2 37 temperature sensor 2 38 wheel clamp 2 40 RPM pickup connecting 5 4 primary inductive pickup 5 6 secondary inductive pickup 5 5 Index iv S safety switch C 7 secondary inductive pickup 5 5 setting tool A 3 side cover drum 2 33 dyno 2 25 2 32 specifications 1 5 starter brace 2 19 starter using 4 5 status indicator 4 3 4 6 T technical support 1 3 temperature sensor cable routing 2 38 wiring to breakout board 2 39 testing dyno test run 5 9 high pressure blowers 2 62 power carriage 2 62 trike carriage adapter 2 62 wheel clamp 2 62 testing voltages 50 Hz B 9 60 Hz B 4 theta controller dip switches D 2 installing 2 24 power adjustment D 2 power line frequency D 2 power line voltage D 3 replacing fuses 4 10 wiring to breakout board 2 39 tie down straps 1 9 5 3 tie downs installing 2 51 tire lock 2 50 tire stop 2 50 toe kick bracket 2 31 top cover dyno 2 25 2 33 dyno drum 2 44 iX drum 2 45 trike carriage adapter base 2 47 3 17 installing 2 47 3 17 testing 2 62 U unpacking dyno 2 2 using the dyno 5 9 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide W warnings V weight 1 5 wheel clamp closing 4 7 connecting the cable 3 2
10. 16 Remove the Top Clevis Pin ASA Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 4 7 CHAPTER 3 xy Air Brake 3 14 10 11 12 13 14 15 16 17 18 19 20 Lift the air brake assembly up and away from the dyno AB049 Figure 3 17 Remove the Brake Assembly 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 Install the new brake pads and secure the pads with new springs Place the air brake assembly back on the brake bracket Refer to Figure 3 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 Using two bolts and two washers secure the brake caliper stop to the brake bracket Refer to Figure 3 13 Secure the spring using the bolt washer and nut you removed earlier Refer to Figure 3 12 Tighten the castle nut and replace the hair pin cotter Refer to Figure 3 11 Adjust the brake pad clearance Refer to page 3 15 for complete instructions Replace the top and right side covers Connect your shop air Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 ACCESSORIES 5 eS Air Brake ot ADJUSTING THE BRAKE PAD CLEARANCE There should be equal pad clearance on both sides of the rotor If the pads touch the roto
11. Dimensions 6 er EG Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS Sx Dynamometer Specifications and Requirements N Folding Ramp Option Eddy Current Control Panel Monitor Support Dyno Module Brake and Tray High Pressure i Blower S Wheel Clamp Sn Option te Power Carriage Folding Ramp Option Option ees Model 250i Dyno iX Drum Module Trike Adapter Assembly Air Pump Option Air Brake Option not shown not shown Figure 1 2 Model 250iX Dyno with Accessories ey iy Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 1 vy Dynamometer Specifications and Requirements COMPRESSED AIR REQUIREMENTS The following requirements are needed when the optional air brake is included e regulator set to 65 psi max 450 kilopascal e air dryer e shut off valve e gauge on the regulator e 1 4 inch NPT pipe thread connector to attach air to the dyno The following requirements are needed for the on board compressed air pump assembly e Clean and dry air 100 psi or greater 5 CFM or better flow e Fittings to hook your air system to a 3 8 inch inside diameter hose if no air brake is present optional air regulator 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
12. OF CONTENTS WARNINGS ssri eee E E vi Chapter 1 Specifications and Operating Requirements IntrodUCHON seseSeeccacceatoeenees kieroo oenen senen O a ees 1 2 Conventions Used In This Manual 0 0 0 0 eee eee eee 1 3 Technical Support 2 ete teen eee 1 3 Your Dyno ROOM 3 0 8 ee ee eee eee aed eedeiee ie id ree i ele lee ee a 1 4 Dynamometer Specifications and Requirements 1 5 Battery Requirements 0 0 ccc eee ee 1 5 Chassis Specifications 0 0 2 eee ee eee eee 1 5 Compressed Air Requirements 0 0 eee eee eee tenes 1 8 Computer Specifications 0 ee eens 1 8 Drill and Drill Bit Requirements 0 0 ce eee eee ee eee 1 8 Electrical Requirements 0 eee eee ee ee eee ene 1 8 Environmental Requirements 0 0 e eee eee eee ee 1 9 Forklift Requirements 0 20 eee ee eee eens 1 9 Ground Hook Requirements 00 e eee eee eee eee 1 9 Phone and Internet Access 0 0 eee ee ee eee eee nee 1 9 Tle DOWN Staps ac ccc s6 ee eg ee ew ewes anit ee PENE E E ar erarere 1 9 Dyno Electronics 3555ss0ss55eeree ee ee REDE Cee SoCo eee eeees 1 10 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide TABLE OF CONTENTS yy Ay Chapter 2 Installation Dyno Installation 054 6254 oobi ees ee mee dan Relanecieentddaed dade es 2 2 Unpacking the Dyno eke eee ee eens 2 2 Removing the Dyno from
13. P N 98200006 Failure to follow proper procedures may result in inaccurate data or damage to the equipment This manual can be found on your WinPEP CD or at www dynojet com 4 3 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Zay f 4 4 CHAPTER 4 y Basic CPI Operation USING THE EMERGENCY STOP DYNO SHUTDOWN The emergency stop dyno shutdown button is designed to deactivate the dyno outputs whenever the button is pressed or the external E Stop circuit is opened When E Stop is activated the blowers will be turned off the power carriage will stop and the wheel clamp will stop The starter will be deactivated as well as the AFR air pump and the retarder will be de activated If the dyno is properly equipped with the air brake option the air brake will be applied stopping the dyno drum If the air brake is not installed the drum will freewheel During an E Stop condition the Status Indicator light will be flashing with two short blinks on and long pause off USING THE HIGH PRESSURE BLOWERS The CPI allows the dyno operator to toggle the optional high pressure blowers on and off from the control panel If the E Stop is activated the blowers will be automatically turned off The indicator light by each button will light up when that blower output is turned on If the toggle switch on the blower is turned off the blower will not operate even if the CPI output is on ATU The blower outlets on the front o
14. Stop Sticker 00000000 3 5 Air Brake Final Adjustments and Tests 2 2 0 eee eee 3 8 Changing the Brake Pads 0 cece ee ee eee ee 3 9 Adjusting the Brake Pad Clearance 0 2 0 eee eee eee 3 15 Compressed Air Pump Assembly 0 00 ee eee eee eee eee 3 16 Extended Carriages 4 sosiaa eeu ae E E E E o a ia AN 3 17 Installing the Extension Support and Trike Carriage Adapter Assembly 3 17 Installing the Extended Carriage Assembly 22 0000 3 19 Power Carriage ston Pai Foe cenit oS EAEEREN ARAE a ane enews 3 20 Removing the Hand Crank 2 eee eee ene 3 20 Installing the Power Carriage 2 2 0 eee ee ee eee 3 21 WiNGelSClaM Pimstnt ante be bob he cee ebaae a eae eats 3 24 Final Adjustments and Tests 2 0 4444 des area here nad Heeleces byes 3 28 Turning On the Dyno Power 20 eee eee ee eens 3 28 Power Carriage Final Adjustments and Tests 04 3 28 Wheel Clamp Final Adjustments and Tests 2 00005 3 28 Chapter 4 Control Panel Interface Operation Basic CPLOpPEration 4 3 aii ese dd eon hkl iaado irio aaan iaaa ete 4 2 Using the Air Fuel Ratio Air Pump 00 e eee eee eee 4 3 Using the Emergency Stop Dyno Shutdown 2 00006 4 4 Using the High Pressure Blowers 0 0 ee eee eee eee eee 4 4 Understanding Interlocks 2 0 2 ee eee eee eee 4 4 Using the Power Car
15. TABLE OF CONTENTS Sx Appendix D Theta Controller Power AdjUStMents 23251455 2 22020 26te csi Sseeedeeeseeseusees D 2 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide WARNINGS 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 ATU Equipment Power Requirements The dynamometer has specific power requirements Connecting the dynamometer to the incorrect voltage will
16. The flange bearing must be facing so the grease zerk is accessible facing down Note Dynojet recommends using a 1 4 inch ratchet drive with an extension and a 7 16 inch shallow socket to secure the flange bearing bolts flange bearing motor mount coupler jaw Figure 3 23 Install the Motor Mount 3 21 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xe CHAPTER 3 F Power Carriage 5 Bring the power carriage cable two pin connector from the front of the dyno over to the motor mount The routing for this cable was shown on page 2 32 6 Secure the power carriage cable strain relief to the side of the motor assembly cover 7 Insert the plastic coupler spider on the carriage screw half of the coupler power carriage cable strain relief coupler spider motor assembly cover PC 038 Figure 3 24 Secure the Strain Relief 3 22 irre 7 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES S Power Carriage 8 Place the power carriage motor assembly near the motor mount and plug the motor connector into the power carriage cable 9 Turn the carriage screw to align the coupler jaws with each other and slide the coupler jaws together until the motor assembly cover is flush with the motor mount 10 Secure the motor assembly cover to the motor mount with four 1 4 20 x 1 2 inch button head screws removed earlier motor assembly co
17. Vehicle Top View 5 3 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 5 J Connecting the RPM Pickup CONNECTING THE RPM PICKUP Your Dynojet dynamometer includes a primary wire inductive pickup and two secondary wire inductive pickups These small clothespin like inductive pickups are used to sense RPM An RPM pickup is required if you want to view torque graphs Generally you will use one secondary wire inductive pickup on a spark plug wire Vehicles with wasted spark ignition systems may require two secondary inductive pickups On a wasted spark ignition typically one coil will be connected to two spark plug wires Attach one secondary pickup to each of these wires If the pickups are connected to two plug wires that do not fire at the same time an erratic RPM readout may occur The primary wire inductive pickup senses RPM pulses from the coil Although this pickup location generally works better it is harder to find the correct location to connect the RPM pickup Note If a pickup is not being used disconnect it from the dyno electronics to prevent any stray pick up of signals AGU Inductive pickups are very fragile The ferrite core can easily be damaged and is not covered under warranty Dropping snapping vibration and heat can all damage the ferrite core The dyno electronics RPM module contains the electronics that sense the RPM pulses An auto gain circuit looks at
18. 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 PSN WARNING The sensor and the copper sample tube are hot Before touching the sensor or the sample tube make sure it has cooled ACE 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 3 16 A 5 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide lt ACCESSORIES S Extended Carriage EXTENDED CARRIAGE Use the following instructions to install t
19. 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 ins
20. control panel to activate the power carriage allowing you to center the bike s rear tire on the dyno drum The power carriage and wheel clamp cannot be activated at the same time Note When operating the power carriage with a bike on the dyno make sure the bike is in neutral Note Always loosen or remove the bike tie down straps before moving the carriage Replace and tighten the straps when the bike is in the proper position SWZ PAN Never perform a dyno run if the tie down straps are not in place or they are damaged If the carriage movement is slow during parts of its travel investigate and correct the source of the problems If you reach the end of travel of the carriage or the carriage binds and you continue to hold down the carriage movement button the motor will draw too much current and blow the carriage fuse F2 There is a short time delay built into the button operation to allow the carriage motor to coast to a stop before it moves in the opposite direction This delay is needed to prevent the motor from drawing too much current by rapidly reversing the motor USING THE STARTER The built in starter allows you to use the momentum of the drum to start motorcycles that are not equipped with an on board starting system The starter requires a battery to operate Refer to page 2 35 for more information on the battery If the E Stop button is pressed the starter will not engage If the interlock circuit is open the
21. cord refer to your dyno installation guide The dedicated wall receptacle is a twist lock four wire grounded 30A NEMA L14 30 type and must be wired in accordance with local building codes and requirements If the facility does not have 120 240 volt single phase power and it does have 120 208 volt three phase Y power then it is acceptable to connect the four wire receptacle with two of the three phase lines the neutral and the ground With this arrangement there will only be 208 volts between line 1 and line 2 instead of 240 volts This is acceptable but performance of the retarder will be reduced In no case shall all three phase lines be connected to the receptacle Installation may require a licensed electrician and must conform to UL and NEC safety standards Note If you are installing your dyno in North America or Japan and the dyno is not equipped with twist lock four wire grounded plug contact Dynojet before attempting to connect the dyno Local and national electrical codes require a grounded receptacle box e This circuit should have a dedicated 30A double pole circuit breaker e The dyno should be the only device connected to this circuit e It may be necessary to install a delayed trip breaker due to the inrush current drawn by the high pressure blowers Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION Les Locations Using 60 Hz Power North America and Japan
22. page 3 20 e Wheel Clamp page 3 24 Final Adjustments and Tests page 3 28 3 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide f 3 2 CHAPTER 3 ay 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 circuit breaker to turn power on and off to the dyno The main circuit 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 UDUNAOSURRAEAONECEOE TLLA E AN T power plug main breaker r5 Figure 3 1 Main Dyno Power Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES y Air Brake 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 con
23. 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 the monitor support The carriage and support arm are fastened to the bottom of the crate monitor support EN carriage Figure 2 1 Remove the Tire Carriage and Monitor Support from the Crate 2 2 A D Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Sx Dyno Installation N 4 Remove the six 1 4 inch screws securing the center panel on the dyno and remove the center panel Note Dynojet recommends using a T30 Torx driver Snap On PFTx30E to remove the 1 4 inch screws For dynos with serial numbers lower than 2030152 Dynojet recommends using a hardened 5 32 inch hex driver such as Snap On FA5E A standard allen key may round off in the shallow screw head center panel f 8 af 8 i i i 1 1 I I i 1 i Figure 2 2 Remove the Center Panel n3 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 Dyno Installation g Remove the eight screws securing the top drum cover to the dyno and set aside Remove the drum cover and set aside 5 6 Remove the two top screws securing each side drum cover to the dyno and set aside top drum cover side drum cover 5 gt e s g Z v aS nD Remove the Top Drum Cover Figure 2 3 2 4 Above Gr
24. removing the top cover Route the air hose through the air access holes in the front of the dyno Attach the hose to your air supply Attach the sensor Attach the silicone hose and copper sample tube to the sensor block Attach the sensor cable to the corresponding cable from the inside back panel of the dyno Attach the connector from the pump solenoid to the cable on the inside back panel of the dyno Replace the top center cover and carriage assembly Replace the drum module panel using the screws removed earlier solenoid connector Figure 2 11 Installing the Sensor and Copper Sample Tube 2 15 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 A xy Compressed Air Pump Assembly INSTALLING THE AIR HOSE WITH THE AIR BRAKE Use the following instructions to install the air hose when the air brake is installed 1 Install the tee la Cut the hose running from the air brake as shown in Figure 2 12 1b Slide a hose clamp over each piece of hose 1c Insert the tee 1d Secure the hose clamps Measure the distance from the tee to the air pump assembly and cut a piece of hose Attach the hose to the air pump assembly This connection does not require a hose clamp Slide a hose clamp over the hose Note The hose clamp is only needed on the tee end Slide the hose over the tee Secure the hose clamp air hose to the brake air hose to the brake cut here
25. 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 Continue sliding the drum module towards the dyno until the side panels on the drum module and the dyno are flush existing screws woodruff key driveline existing screws Figure 2 22 Installing the Driveline and the Drum Module Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 11 12 13 14 15 16 INSTALLATION Secure the connector plate on either side of the drum module to the dyno frame using the screws removed earlier Verify the panels on the drum module and the dyno line up These covers must be flush and parallel If these covers are not flush place shims between the floor and the drum module or the dyno until they are flush Once aligned tighten all screws Secure the side panels on the drum module to the panels on the dyno using one 1 4 20 x 5 8 inch screw Replace the existing set screws on the driveline assembly with the thread lock set screws provided Tighten the driveline set screws not visible from this view secure connector plate Figure 2 23 Securing the Drum Module to the Dyno Fa kd Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 2 29 CHAPTER 2 ay iX Drum Module Installation INSTALLING THE BULKHEADS You w
26. support Figure 2 47 Installing the Monitor Support and Tray OO Do SZ Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Ay CHAPTER 2 J Monitor Support Tray and Control Panel 8 Remove the control panel rear cover 8a Remove the two nuts from the top of the cover and set aside 8b Remove the screw on the top of the cover and set aside 8c Remove the screw on the side of the cover and set aside 8d Remove the four screws on the back of the cover and set aside 8e Remove the control panel rear cover and set aside Figure 2 48 Remove the Control Panel Rear Cover 9 Route the control panel cable through the access hole on the side of the control panel box and through the cable tie 10 Attach the control panel cable to the Button board access hole button board control panel cable with cable harness wrap cable tie C030 Figure 2 49 Attach the Control Panel Cable to the Button Board 2 54 ayaa Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 11 12 13 14 15 16 INSTALLATION gt Monitor Support Tray and Control Panel Tighten the cable tie If you purchased the optional air brake install the Emergency Stop Sticker at this time Refer to page 3 5 for directions Secure the rear cover to the control panel 13a Replace the four screws on the back of the cover removed earlier 13b Replace the screw on the top
27. that can be altered Be sure not to damage any other parts on the circuit board Do not attempt any other adjustments 1 Access the dip switches through a hole in the bottom of the theta controller 2 Usea small screwdriver to set the dip switches for the desired line voltage Power Line Frequency Adjustment The theta controller is shipped with the dip switch set for 60 Hz In some cases the dip switch is set based on the country it is shipping to However you will need to determine the correct line frequency and set the switch accordingly 60 Hz Power Line Frequency Adjustment For all of North America this switch should be set to the 60 Hz position In Japan there may be either 50 Hz or 60 Hz power line frequency determine the correct line frequency and set the switch accordingly Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 THETA CONTROLLER Power Adjustment Power Line Voltage Adjustment The theta controller is shipped with the dip switch set for normal NORM line voltage In the NORM position the controller is calibrated for a nominal 235 to 240 VAC line voltage In some cases in Europe or Japan it may be necessary to set the dip switch to the LO position when the AC line voltage is consistently around or below 225 VAC and combined with reduced brake performance e Measure the AC line voltage with all normal AC loads running in the shop lights heater etc
28. the Crate 0 00 eee eee eee 2 9 PICKUP Card 3452525596 so9Rss tepes EE EEEE EEE E EEEE 2 12 Compressed Air Pump Assembly 0 00 ee cece ee eee ees 2 13 Wamihg S cesme se oe ase we ale a d s 6 dn BR AS a a Ma Meera 2 13 Compressed Air Requirements 0 0 0 eee eee 2 14 Installing the Pump Assembly on the Dyno 05 2 14 Installing the Air Hose with the Air Brake 0000 2 16 Eddy Current Brake ssssi0 ee eee eee Reena seeaebewebeyeess 2 17 Unpacking the Eddy Current Brake 0 cee eee eee 2 18 Installing the Eddy Current Brake 2 2 0 0 0 eee eee ee eee 2 20 Securing the Drum and Brake Module to the Floor 2 23 Installing the Theta Controller 22 0 eee eee ee eee 2 24 Remove the Dyno Covers deveutdeucdectduedusliieddudedeteke tess 2 25 iX Drum Module Installation 0 0 eee eee eee eee 2 26 Removing the Items from Crate 2 0 cee eee ene 2 26 Installing the iX Drum Module 0 0 e eee eee 2 28 Installing the Bulkheads 0 0 e eee eee ee eee 2 30 Routing Cables svescvesveeed eleede deeee2eee oe dekscetekscess 2 34 Battery Requirements 0 0 cece eee eee eee 2 35 Routing the Pendant RS232 Computer Cable and Control Panel Cable 2 37 Routing the Eddy Current Brake Cables 000000 2 38 Wiring the Breakout Board 0 eee eee eee 2 39 Routing the Power Ca
29. the dyno shutdown sticker place emergency stop sticker here o by D n x a co CP015 Figure 3 7 Placing the Emergency Stop Sticker 3 6 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES Sx Air Brake N 5 Secure the switch body to the control panel using the switch body nut removed earlier switch body nut p control panel J gt CP033 Figure 3 8 Replacing the Emergency Stop Button 6 Secure the Button board to the control panel using the four screws removed earlier button board screw Figure 3 9 Securing the Button Board re wy Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 3 vy Air Brake 7 Secure the rear cover to the control panel 7a 7b 7c 7d Replace the four screws on the back of the cover removed earlier Replace the screw on the top of the cover removed earlier Replace the screw on the side of the cover removed earlier Replace the two nuts removed from the top of the cover removed earlier 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 List
30. void the dynamometer warranty Installation may require a licensed electrician PN WARNING 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 feat vi Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide WARNINGS yy Ay PSN WARNING Ele Electrostatic Discharge Precautions ctrostatic 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 dynamometers to be very tolerant of static shocks 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 t
31. 1 9 equalizer box 1 4 ESD precautions vi exhaust extration 1 4 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide extended carriage 3 17 extension support 3 17 installing 3 19 trike carriage adapter 3 17 extension support 3 17 F final adjustments and tests 3 28 fire suppression 1 4 forklift requirements 1 9 front bulkhead 2 30 fuses power distribution assembly 4 11 theta controller 4 10 G ground hooks 1 9 installing 2 60 H hand crank 2 49 hard wiring power 50 Hz B 10 60 Hz B 5 hazards vii height 1 5 high pressure blowers circuit breakers 4 8 control panel 4 3 installing 2 58 testing 2 62 using 4 4 Industrial Noise Control Inc 1 4 input power cable 2 38 inspection 5 7 installing power receptacle 50 Hz B 8 60 Hz B 3 intake air fan 1 4 interlocks 4 4 ix drum module bulkheads 2 30 connector plate 2 29 driveline assembly 2 28 installing 2 28 removing from the crate 2 26 woodruff key 2 28 jumpers 2 39 Version 1 L layout dyno room 2 34 length 1 5 lifting eyes dyno 2 10 eddy current brake 2 19 loading the vehicle 5 2 M main circuit breaker 2 61 3 2 4 8 maintenance 5 10 making arun 5 9 manuals finding on WinPEP cd 3 1 middle bulkhead 2 30 monitor support installing 2 52 remove from crate 2 2 monitor support brace 2 30 monitor tray installing 2 53 monitor support 2 2 P PDA see also power distribution assembly pendant routing cables 2 37 phon
32. 15521 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 2 27 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide yy Ay 2 28 CHAPTER 2 iX Drum Module Installation INSTALLING THE IX DRUM MODULE You will need the following parts e 36561045 Screw 1 4 20 x 5 8 PH Torx 2 e 37620622 Woodruff Key 2 e 62240070 Driveline Assembly e 63200001 iX Drum Module Remove the drum safety cover from the ix drum module Remove the six screws securing the ix drum cover and set aside Remove the cover and set aside SQN Be sure you record the iX drum module number on the inside cover of this manual 3 4 OMAN DW woodruff key iX drum module Place the nylon loop strap around the shaft on either side of the drum module Using a forklift lift the drum module from the crate and place the drum module near the dyno with the stepped end of the shaft towards the dyno Make sure the panels on the drum module and the dyno are parallel Remove the two existing screws from the dyno frame where the connector plates will attach Insert the woodruff key into the keyway on the drum module shaft Insert the woodruff key into the keyway on the dyno shaft Slide the driveline over the key on the drum module shaft Keeping the panels parallel
33. 2 eee eee eee 5 8 Making a Test Run 22 2545 eer bere oeeedeeeseeseues eee yes eee de 5 9 Preventative Maintenance as ca videvdertiunatenedsswiwdwioeeeews 5 10 Red Head Anchor Installation WAINGS ei erener rererere reoi CREE eORebeeee ses wes ee eeT3 A 1 Contact Information for ITW Ramset Red Head 005 A 1 istallato seese rer ireririitet kee eee eee TNTE T ee E A 2 Power Requirements and Installation Locations Using 60 Hz Power North America and Japan B 2 Installing the Wall Receptacle 2 eee eee nee B 3 Testing for Correct Voltages 2 2 eee eee eee B 4 Replacing the Power Plug 0 eee ee eee ee eee eens B 5 Connecting the Dyno 2 eee eee eee B 6 Locations Using 50 Hz Power Locations other than North America and Japan B 7 Installing the Wall Receptacle 2 eee eee eee B 8 Testing for Correct Voltages 2 eee ee eee nee B 9 Replacing the Power Plug 2 cee eee eee eee nee B 10 Connecting the Dyno 2 ete ne eee B 11 EEC Finger Guard and Door Safety Switch Installation EEC Finger Guards 55 45 26502 es ecb bstdedgeeiaduansenemisaae oe C 2 Installing the EEC Finger Guards 2 2 0 0 0 eee eee ee nee C 4 Adjusting the EEC Finger Guards 0 0 0 eee eee eee C 6 Door Safety SWihcescexieaseeeeendvdedudewaedeetecrecestueeens C 7 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide
34. 25 25A Fuse Little Fuse KLK 15 e Fast Blow Dynojet P N 54212501 e Fast Blow Dynojet P N 54211501 remove blanking plate reach through opening to theta controller fuses Figure 4 3 Replace Theta Controller Fuses Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 CONTROL PANEL INTERFACE OPERATION Maintenance and Troubleshooting TROUBLESHOOTING CPI FUSES Fuses F3 and F4 fuse the 240VAC as it enters the CPI board One fuse is used for each leg of the 240VAC If either of these fuses are blown there will be no power to the CPI board or any of the accessories The Status Light on the board as well as the button panel will be off Replace with a 5x20 mm 3A fast blow fuse Fuse F5 provides protection for the DC power that is produced by the on board power supply and routed to the CPI board If this fuse is blown there will be no power to the CPI board or any of the accessories The Status Light on the board as well as the button panel will be off Replace with a 5x20 mm 3A fast blow fuse Fuse F6 provides protection for the power that is provided for the 12VDC accessories from the dyno owner installed car battery This also protects the charging circuit to the battery If this fuse is open the power carriage and the wheel clamp will not function Replace with a 15A mini auto fuse Fuse F1 protects the wheel clamp drive circuit If this fuse is open the wheel clamp motor will not activate Repla
35. 36561045 Screw 1 4 20 x 5 8 PH Torx 6 1 Secure the drum top cover to the drum module using the six 1 4 20 x 5 8 inch screws removed earlier drum top cover E Figure 2 39 Securing the Drum Module Top Cover lt Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide om 2 45 xe CHAPTER 2 Side and Top Cover Installation e 2 Secure the center cover to the bulkheads using six 1 4 20 x 5 8 inch screws center cover Figure 2 40 Securing the Center Cover 3 Place the drum safety cover over the drum This cover has two pins to keep it in place PSN WARNING Risk of injury Never run a motorcycle on the dyno without this cover in place drum safety cover Figure 2 41 Installing the Drum Safety Cover 246 L MG Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Ss Trike Carriage Adapter and Carriage Assembly TRIKE CARRIAGE ADAPTER AND CARRIAGE ASSEMBLY You will need the following parts e 15331100 Chain Lube e 36500008 Capscrew 5 16 UNC x 1 Button head 6 e 36500009 Capscrew 3 8 16UNC x 1 Button head 2 e 63310902 Tire Stop Assembly e 71300002 Trike Carriage Adapter Assembly e 71323002 Carriage Assembly INSTALLING THE TRIKE CARRIAGE ADAPTER ASSEMBLY 1 Secure the trike carriage adapter assembly to the dyno using six 5 16 x 1 inch button head bolts where the carriage assembly was installed and two 3 8 x 1 in
36. 39 theta controller 2 39 wiring 2 39 bulkheads blower extension cable 2 32 front 2 30 installing 2 30 middle 2 30 monitor support brace 2 30 toe kick bracket 2 31 C cable wrap tool 2 63 cables air brake 3 3 control panel 2 37 control eddy current brake 2 38 eddy current brake 2 38 input power 2 38 pendant 2 37 pickup card 2 39 power carriage 2 40 RS232 2 37 temperature sensor 2 38 2 39 wheel clamp 2 40 carriage hand crank 2 49 installing extended 3 19 installing standard 2 48 remove from crate 2 2 tire lock 2 50 tire stop 2 50 center cover dyno 2 44 iX dyno 2 46 Index i Above Ground Model 200ix 250iX Motorcycle Dynamometer Installation Guide INDEX yy Ay chassis specifications 1 5 height 1 5 length 1 5 weight 1 5 width 1 5 compressed air 1 8 compressed air pump 2 13 3 16 air hose installing 2 16 compressed air requirements 2 14 installing 2 14 warnings 2 13 computer specifications 1 8 connecting computer 2 37 connecting power to the dyno 50 Hz B 11 60 Hz B 6 connector plate 2 29 control panel air pump 4 3 blowers 4 3 4 4 dyno shutdown 4 3 4 4 emergency stop 4 3 4 4 features 4 2 installing 2 55 power carriage 4 3 4 5 routing cables 2 54 starter 4 3 4 5 status indicator 4 3 wheel clamp 4 3 4 6 control panel interface basic operation 4 2 battery charger 2 35 conventions 1 3 CPU module 2 37 crate remove dyno 2 9 unpacking eddy current brake 2 18 unpacking iX dyno 2 26 D
37. 6 installing 3 24 maintenance 4 9 opening 4 7 routing cables 2 40 testing 2 62 3 28 troubleshooting 4 9 using 4 6 width 1 5 WinPEP finding manuals on 3 1 wiring breakout board jumpers 2 39 pickup card cable 2 39 temperature sensor cable 2 39 theta controller cable 2 39 woodruff key 2 28 Y your dyno room 1 4 equalizer box 1 4 exhaust extraction 1 4 fire suppression 1 4 intake air fan 1 4 noise control 1 4 Z zip tube 2 63 Version 1 INDEX Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ka r Index v
38. 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 INSTALLING THE DOOR SAFETY SWITCH 1 2 3 Turn off the main breaker inside the CPI door Unplug the dyno power cable Remove the tire carriage and center panel Refer to Figure 3 4 on page 3 5 and Figure 3 5 on page 3 6 Remove the three screws securing the CPI cover and set aside Remove the CPI cover and set aside See ot hh Sa tet ene okt CPI cover MCO082 Figure C 5 Remove the CPI Cover C 7 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide APPENDIX C x9 Door Safety Switch remove jumper C 8 Loosen the screws that hold the jumper wires in place and remove the wire Route the black and yellow wire from the safety switch through the dyno Make sure the switch will not get caught in any moving components or chafed on any edges Attach the yellow wire to the 1A position on the J2 connector Attach the black wire to the 6B position on the J4 connector wire 10 11 12 13 14 15 yellow wire to 1A black wire to 6B on J2 connector on J4 connector MCO83 Figure C 6 Wire the Safety Switch Replace the CPI cover using the screws removed earlier The door safety switch needs to be mounted at the entry of the dyno roo
39. BLY This section describes how to install the compressed air pump assembly on your motorcycle dynamometer For more detailed information refer to the Compressed Air Air Fuel Ratio Module Installation and User Guide P N 98200006 The following parts are included in P N 64100002 On Board Compressed Air Air Fuel Ratio Assembly e 34100001 Fitting Tee 3 8 ID Brass e 34200000 Clamp 5 16 x 1 2 29 32 Screw 3 e 36561045 Screw 1 4 20 x 5 8 PH Torx 4 e 64193011 Air Fuel Wand Sub Assembly WARNINGS P WARNING The sensor and the copper sample tube are hot Before touching the sensor or the sample tube make sure it has cooled ATU 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 eve
40. 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 viii Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS Thank you for purchasing Dynojet s Above Ground Model 200iX 250iX Motorcycle Dynamometer Dyno
41. Current Brake INSTALLING THE EDDY CURRENT BRAKE 1 Insert the key into the keyway on the drum shaft 2 Usea c clamp to press the key in key keyway on dyno shaft connector plate Figure 2 15 Install the Key 2 20 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 INSTALLATION Eddy Current Brake 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 Continue sliding the eddy current brake towards the dyno until the covers on the brake and dyno are flush Loosely secure the connector plates to the dyno frame using the eight bolts washers and nuts removed earlier Note Do not tighten the bolts Verify the covers on the brake and the dyno line up These covers must be flush and parallel If these covers are not flush place shims between the floor and the eddy current brake or the dyno until they are flush Once aligned tighten all connector plate bolts and nuts Secure the starter brace to the starter using the washer and nut removed earlier N starter brace connector plate three bolts not visible from this view bS N Figure 2 16 Secure the Connector Plates and Starter Brace lt Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide om 2 21 CHAPTER 2 xy E
42. Guide Ay CHAPTER 2 J Routing Cables ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES The power carriage and wheel clamp are optional accessories These cables will only be used if you ordered the accessories For installation instructions refer to Power Carriage on page 3 42 and Wheel Clamp on page 3 47 for more information 1 Remove the two screws securing the cable pass through cover on the front of the dyno and set aside 2 Locate the cables bundled inside the dyno 3 Route the power carriage and wheel clamp cables through the opening in the front of the dyno J Me eer route cables vg ee through cable pass through cover KD046 Figure 2 33 Remove the Cable Pass Through Cover 2 40 apa Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 INSTALLATION g Routing Cables S Place a split snap bushing around the wheel clamp cable and secure into place in one hole on the cable pass through cover Place a split snap bushing around the power carriage cable and secure into place in the other hole on the cable pass through cover Secure the cable pass through cover to the dyno with the two screws removed earlier 2 pin wheel clamp cable 3 pin power carriage cable Figure 2 34 Routing Wheel Clamp and Power Carriage Cables 2 41 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xe CHAPTER 2 J Side and Top Cover
43. Installation SIDE AND TOP COVER INSTALLATION Before replacing the center panel install the air hose the EEC Kit the door safety switch and any additional accessories you may have ordered Refer to the appropriate sections of this manual for installation instructions 1 Secure the eddy current brake side cover to the eddy current brake using the eight 1 4 20 x 5 8 inch screws removed earlier Figure 2 35 Secure the Eddy Current Brake Side Cover 2 42 Baga Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Sx Side and Top Cover Installation N 2 Secure the eddy current brake top cover to the eddy current brake six 1 4 20 x 5 8 inch screws removed earlier Figure 2 36 Secure the Eddy Current Brake Top Cover eee eee 7 43 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xe CHAPTER 2 F Side and Top Cover Installation 3 Secure the drum top cover to the drum using the eight 1 4 20 x 5 8 inch screws removed earlier Figure 2 37 Secure the Dyno Drum Top Cover 4 Secure the center cover to the dyno using the six 1 4 20 x 5 8 inch screws removed earlier Figure 2 38 Secure the Dyno Top Center Cover a a5 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 INSTALLATION Side and Top Cover Installation INSTALLING THE IX COVERS You will need the following parts e 21200037 Center Cover iX e
44. T RESEARCH INSTALLATION GUIDE For Above Ground Model 200iX 250iX Motorcycle Dynamometers P N 98200026 01 2010 Dynojet Research Inc All Rights Reserved Installation Guide For Above Ground Model 200iX and 250iX 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 98200026 Version 1 05 2010 Dynamometer Number iX Dynamometer Number Eddy Current Brake Retarder Number TABLE
45. TS Using the control panel press the carriage forward and backward buttons and verify that the motor does turn Refer to Using the Power Carriage on page 4 5 for more information on using the power carriage WHEEL CLAMP FINAL ADJUSTMENTS AND TESTS 1 Place a stack of catalogs into the wheel clamp 2 Using the control panel press the close button and observe that the wheel clamp does close Hold the button until the motor turns off and the status light is on steady 3 Press and hold the right hand wheel clamp button then press the left hand button to open the clamp Refer to Using the Wheel Clamp on page 4 6 for more information on using the control panel 3 28 ayaa 5 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CONTROL PANEL INTERFACE OPERATION This chapter will walk you through the basic operating procedures and how to maintain and troubleshoot the components associated with the Control Panel Interface CPI To ensure safety and accuracy in the procedures perform the procedures as they are described This chapter is divided into the following categories Basic CPI Operation page 4 2 e Power Distribution Assembly page 4 8 e Maintenance and Troubleshooting page 4 9 4 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide oy CHAPTER 4 yn y Basic CPI Operation BASIC CPI OPERATION The control panel may be mounted to either side of the tray for easy acces
46. User Guide P N 98128104 9 pin hand held pendant RPM inductive system expansion 25 pin socket pickup socket connector A lt atmospheric sensing module a RPM module lt ____ input output module f a CPU module HS038 power 9 pin RS 232 socket 3 pin power plug Figure 1 3 The Dyno Electronics 110 apenas Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS Sx Dyno Electronics N The standard dyno electronics is located inside the dyno electronics enclosure which is already mounted to the dyno chassis as shown in Figure 1 4 Cables which you will route later in this manual are pre wired to the dyno electronics or to the CPI You will connect the free ends of the cables to the appropriate devices CPI cables are pre attached to the dyno electronics located inside the dyno electronics enclosure dyno electronics enclosure dyno electronics enclosure Figure 1 4 Location of Dyno Electronics 1 11 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION This chapter will walk you through unpacking and installing the dynamometer To ensure safety and accuracy in the procedures perform the procedures as they are described This chapter is divided into the following categories Dyno Installation page 2 2 e Pickup Card page 2 12 e Compressed Air P
47. 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 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 24 To route the wheel clamp cables refer to Routing the Power Carriage and Wheel Clamp Cables on page 2 40 1 Place a stack of catalogs into the wheel clamp 2 Using the Control Panel press the close button and observe that the wheel clamp does close Hold the button until the motor turns off and the status light is on steady 3 Press and hold the right hand wheel clamp button then press the left hand button to open the clamp Refer to Using the Wheel Clamp on page 4 6 for more information on using the Control Panel 2 62 ayaa 35 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION gt Zip Tube ZIP TUBE The zip tube encases the multiple cables running to the control panel You will need to use the cable wrap tool P N 16510001 to insert the cables into the zip tube 1 Rotate the cable holder to the open position 2 Insert the cable s into the cable holder e Pendant Cable e Control Panel Cable e RPM cable s e Additional cables if desired cable holder a RY Sai ee cable s end of cables i Figure 2 56 Inser
48. and set aside 3 Remove the hardware box and theta controller from the crate and verify the hardware box contents using the parts list For more information on mounting the theta controller refer to page 2 24 Ce SQN Be sure you record the eddy current brake number on the inside cover of this manual top cover ee a 8060 eddy current brake number Figure 2 13 Remove the Covers 2B MTG Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Sx Eddy Current Brake N Remove the four bolts securing the brake to the crate 5 Remove the side drum cover if not already removed from the dyno Refer to Figure 2 4 on page 2 5 6 Place the nylon loop strap through the lifting eyes on either side of the brake 7 Using a forklift lift the eddy current brake from the crate and place the brake near the dyno making sure the panels on the brake and dyno are parallel 8 Remove the eight bolts washers and nuts from the dyno frame where the connector plates will attach 9 Remove the starter brace if present 9a Remove the three bolts washers and nuts securing the starter brace and set aside 9b Remove the starter brace and set aside starter brace line up panels remove bolts washers and 27 lifting eye nuts from dyno frame i Figure 2 14 Move the Brake Next to the Dyno AANA Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide P CHAPTER 2 Eddy
49. ank shaft the plug fires number is incorrect b Stop the vehicle return to the MakeRun Configuration dialog box and enter the correct value for the plug firing order 5 Press the red brake button to apply 100 braking and slow down the vehicle ACW Using the vehicle s own brakes to slow or stop the drum at speeds over 30 m p h can severely over heat the brake parts Dynojet dynamometers with the air brake or eddy current brake accessory can be used to slow the vehicle and drum to a full stop at any speed The vehicle s brakes should be used in an emergency stop situation only 6 Shut the engine off and put the vehicle in gear manual transmission or park automatic transmission 7 Set the vehicle s parking brake and leave the dyno brake on 8 Perform a final inspection e Verify the drive tire s alignment on the dyno drums e Make any adjustments to the tie down straps as needed e Perform any other safety checks that you deem appropriate to your particular situation You are now ready to make a high speed run on the dyno Refer to your WinPep 7 User Guide for more detailed instructions 5 9 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 5 jn y Preventative Maintenance PREVENTATIVE MAINTENANCE This section contains basic preventative maintenance and troubleshooting information for the wheel clamp and CPI fuses To maintain proper dynamometer operation Dynojet r
50. asuring AC voltage measure between the points listed below and verify that the correct voltages are present probe 1 probe 2 desired voltage measurement 2 4 216V to 260V 1 4 108V to 130V 1 2 108V to 130V 1 3 lt 5V 3 box lt 5V If using two of the three phase lines of a 120 208V 3 phase Y system then expect to see 187V to 225V Figure B 1 Dedicated Power Receptacle B 4 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION g Locations Using 60 Hz Power North America and Japan REPLACING THE POWER PLUG Use the following instructions to replace the four wire plug and socket The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of four conductors The power cord that attaches to the dyno has four conductors internally and their colors are brown blue black and green yellow 1 Connect 240VAC single phase power between the brown and the blue wire connection points 2 Connect the green yellow wire to the ground connection point 3 Wrap the black wire with the white tape to denote that it is a neutral connection and connect it to the neutral connection point 4 Refer to the previous table for testing and probe the new connections as follows e blue wire as location 2 brown wire as location 4 e black wire as location 1 e green
51. ce with a 15A mini auto fuse Fuse F2 protects the power carriage drive circuit If this fuse is open the power carriage motor will not activate Replace with a 15A mini auto fuse o o T Hol er s pp047 control panel F6 interface board F5 F1 F2 status light Figure 4 4 CPI Fuses hes DR 4 11 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION This chapter includes instructions for basic dyno operation For more detailed instructions refer to the WinPEP 7 User Guide This manual can be found on your WinPEP CD or at www dynojet com This chapter is divided into the following categories Loading the Vehicle page 5 2 e Connecting the RPM Pickup page 5 4 Pre Run Inspection page 5 7 Making a Test Run page 5 9 Preventative Maintenance page 5 10 5 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 5 xO Loading the Vehicle LOADING THE VEHICLE Use the following steps to load a vehicle on the dyno For detailed information on loading a motorcycle on the dyno refer to your motorcycle dyno installation guide PSN WARNING Risk of injury Always wear proper eye and ear protection when operating the dyno 1 Verify your computer is running Set the dyno brake on by pressing the red button on the hand held pendan
52. ch button head bolts as shown in Figure 2 42 2 Lube the tracks with the included lube or use grease 5 16 x 1 inch bolts trike carriage ae adapter assembly 3 8 x 1 inch bolts KU044 Figure 2 42 Installing the Trike Carriage Adapter Assembly 2 47 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 2 I Trike Carriage Adapter and Carriage Assembly INSTALLING THE CARRIAGE ASSEMBLY 1 Remove the four 1 4 x 20 inch button head screws securing the bearing bracket 2 Remove the bearing bracket and the carriage screw IN SA screw ys carriage screw bearing bracket F Figure 2 43 Remove the Bearing Bracket and Carriage Screw 2 48 ayaa aS Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION amp Trike Carriage Adapter and Carriage Assembly Os Starting from the back of the dyno slide the carriage under the carriage clamps 4 Slide the carriage screw and the bearing bracket toward the nut block until the carriage screw is touching the nut block 5 Slide the hand crank onto the end of the carriage screw 6 Secure the hand crank to the screw shaft by tightening the set screw using a 5 32 inch allen wrench 7 Using the hand crank or 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 8 Secure the bearing bracket to t
53. cle s engine and drivetrain before beginning testing Consistent engine temperatures will assure your runs are repeatable AFTER ENGINE WARM UP Always leave the vehicle in neutral automatic transmission or in first gear manual transmission with the engine off and make sure the park brake and the dyno brake are on when you get off the vehicle on the dyno Fix any fuel oil or coolant leaks that may have shown up after engine warm up and check the carburetor for leaks Any loud or unusual engine noises or excessive exhaust smoke should be resolved before continuing 5 8 yma 5 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION J Making a Test Run MAKING A TEST RUN Dyno runs provide safe reliable road testing right in the shop The dyno allows you to measure record and diagnose performance problems quickly The dyno combined with WinPEP 7 produces consistent easily interpretable power graphs Use the following instructions to ensure repeatable and accurate measurements 1 Verify the vehicle is secured properly 2 Place the vehicle in a low gear and release the dyno brake using the hand held pendant 3 Slowly accelerate the vehicle to 20 m p h 4 Test the tachometer operation a Rev the engine The gauges on the computer screen should be moving If the tachometer is moving but not registering the correct RPM values the number of degrees of revolution of the cr
54. ddy Current Brake 9 Secure the side panels on the eddy current brake to the panels on the dyno using a 1 4 20 x 5 8 inch screw Do this on each side not visible from this view Figure 2 17 Secure the Side Panels to the Dyno 10 Replace the existing set screws on the driveline assembly with the thread lock set screws provided 11 Tighten the driveline assembly set screws brake shaft dyno shaft set screw Figure 2 18 Tighten the Set Screws 222 _ _ _ JEt Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION os Eddy Current Brake SECURING THE DRUM AND BRAKE MODULE TO THE FLOOR Dynojet recommends you anchor the eddy current brake along with the dyno to the 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 You will need the following parts 37513200 Anchor Redhead 3 8 7 e DM150 002 007 Washer 5 16 Flat 7 DM150 019 012 Bolt 3 8 16 x 1 Hex 7 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 MC122 E j 1 f mark and drill holes for red head anchors mark and drill holes for red 1 head anchors mark and drill holes f
55. dimensions 1 6 dip switches D 2 disclaimers v document part number 1 1 drill and drill bit requirements 1 8 driveline assembly eddy current brake 2 21 iX drum module 2 28 drum safety cover 2 46 dyno contents 2 5 2 6 height 1 5 installing 2 2 length 1 5 secure to floor 2 23 unpacking 2 2 weight 1 5 width 1 5 Index ii dyno covers installing center cover dyno 2 44 center cover iX dyno 2 46 drum safety cover 2 46 side cover drum 2 33 side cover dyno 2 32 side cover eddy current brake 2 42 top cover dyno 2 33 top cover dyno drum 2 44 top cover eddy current brake 2 43 top cover iX drum 2 45 dyno covers removing side cover dyno 2 25 top cover dyno 2 25 dyno electronics 1 10 dyno power 2 61 3 2 main circuit breaker 2 61 3 2 dyno room 1 4 equalizer box 1 4 exhaust extraction 1 4 fire suppression 1 4 intake air fan 1 4 layout 2 34 noise control 1 4 dyno room layout 2 34 dyno shutdown 4 3 4 4 dyno shutdown sticker 3 6 E eddy current brake 2 17 driveline assembly 2 21 installing 2 20 jumpers 2 39 routing cables 2 38 secure to floor 2 23 side cover 2 42 starter brace 2 19 theta controller 2 24 theta controller fuses 4 10 top cover 2 43 unpacking 2 18 wiring breakout board 2 39 EEC finger guards C 2 adjusting C 6 installing C 4 safety switch C 7 electrical requirements 1 8 electrostatic discharge vi emergency stop 4 3 using 4 4 emergency stop sticker 3 5 environmental requirements
56. e INSTALLING THE EXTENDED CARRIAGE ASSEMBLY 1 Version 1 If not already removed remove the carriage screw from the extended carriage assembly by removing the four 1 4 20 x 1 2 inch button head screws securing the bearing bracket and set aside Place the carriage screw with the bearing bracket into the nut block Using the hand crank or the control panel to run the power carriage run the carriage screw through the nut block until the screw is all the way in the nut block Starting from the back of the dyno slide the extended carriage under the carriage clamps Verify the carriage screw is seated into the screw support bracket on the extended carriage assembly Secure the bearing bracket to the extended carriage assembly using the four 1 4 20 x 1 2 inch button head screws removed earlier Run the extended carriage assembly through the full range of motion and verify there is no binding Figure 3 21 Installing the Extended Carriage Assembly 3 19 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Ay CHAPTER 3 yn y Power Carriage POWER CARRIAGE The power carriage replaces the standard hand crank with an electrically powered tire carriage allowing you to easily adjust for various wheel base distances with the press of a button This option is ideal for dynos that are recessed where the hand crank is difficult to access The power carriage will also reduce the time spent making adjustmen
57. e For clarity the eddy current brake and dyno are not shown screw NN gg drum module hood MC103 Figure C 1 Remove the Drum Module Hood c 3 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy APPENDIX C J EEC Finger Guards INSTALLING THE EEC FINGER GUARDS 1 Secure each EEC finger guard to the drum module hood using two 1 4 20 x 5 8 inch pan head screws Q yee screw g peee module hood MC104 lt woe finger guard w Figure C 2 Secure the EEC Finger Guards to the Drum Module Hood c 4 feat Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Fa EEC Finger Guards S EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION 2 Secure the drum module hood with the EEC finger guards to the dyno using the eight 1 4 20 x 5 8 inch pan head screws removed earlier Note For clarity the eddy current brake and dyno carriage are not shown PN WARNING Do not operate the dynamometer without the EEC finger guards properly installed The gap between the finger guards and the drum must be less than 0 64 centimeters Refer to page C 6 for instructions on adjusting the gap a sd ae drum module hood Figure C 3 Replace the Drum Module Hood C 5 Version 1 Above Ground Model 200iX 25 0iX Motorcycle Dynamometer Installation Guide oy APPENDIX C JA EEC Finger Guards ADJUSTING THE EEC FINGER GUARDS Once the dru
58. e internet access 1 9 pickup card installing 2 12 wiring to breakout board 2 39 power 50 Hz B 7 60 Hz B 2 connecting the dyno 50 Hz B 11 connecting the dyno 60 Hz B 6 hard wiring 50 Hz B 10 hard wiring 60 Hz B 5 installing receptacle 50 Hz B 8 installing receptacle 60 Hz B 3 installing 50 Hz B 7 installing 60 Hz B 2 replacing power plug 50 Hz B 10 replacing power plug 60 Hz B 5 requirements 50 Hz B 7 requirements 60 Hz B 2 routing cable 2 11 testing voltages 50 Hz B 9 testing voltages 60 Hz B 4 verifying operation 50 Hz B 11 verifying operation 60 Hz B 6 power cable routing 2 11 power carriage connecting the cable 3 22 flange bearing 3 20 hand crank 3 20 installing 3 21 Index iii Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INDEX yy Ay routing the cable 2 40 testing 2 62 3 28 using 4 5 power distribution assembly 4 8 blower circuit breakers 4 8 fuses 4 11 main circuit breaker 4 8 troubleshooting 4 11 power line frequency D 2 power line voltage D 3 pre run inspection 5 7 preventative maintenance 5 10 primary inductive pickup 5 6 R red head anchor contact information A 1 installation A 2 setting tool A 3 warnings A 1 replacing power plug 50 Hz B 10 60 Hz B 5 requirements 1 5 battery 1 5 chassis specifications 1 5 compressed air 1 8 computer specifications 1 8 drill and drill bit 1 8 electrical 1 8 environmental 1 9 forklift 1 9 ground hooks 1 9 phone
59. e left blower circuit These breakers do not provide a manual disconnect main dyno circuit breaker and disconnect PD047 blower circuit breakers right blower on top Figure 4 2 CPI Circuit Breakers 48 Gaya Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 CONTROL PANEL INTERFACE OPERATION g ons Maintenance and Troubleshooting MAINTENANCE AND TROUBLESHOOTING This section contains basic maintenance and troubleshooting information for the wheel clamp theta controller fuses and CPI fuses MAINTAINING AND TROUBLESHOOTING THE WHEEL CLAMP Make sure the bike tire and wheel are clean to reduce the possibility of scratching the rim Keep the wheel clamp pads clean using Isopropyl Alcohol Do not allow any products to be applied or transferred to the wheel clamp that could interfere with the gripping action If you run the clamp all the way open against the hard stops the CPI will turn off the motor before any damage can occur Follow the prescribed service for the wheel clamp lubrication for frequency and type of lube Grease or lube the screw and slides monthly or every 500 bikes Do not run into the edges of the wheel clamp pads with the bike tire If the wheel clamp movement is binding for any reason stop using the wheel clamp and correct the problem It is possible for the wheel clamp to bind and give a false indication tha
60. e Green wire connects to G1 e White wire connects to W1 e Black wire connects to B1 e Red wire connects to R1 e 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 e Black wire connects to V Red wire connects to V e White wire connects to O e Green wire connects to O e 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 Red wire connects to R1 e Black wire connects to B1 e White wire connects to W1 e 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 32 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 or the optional door interlock is installed and activated 5 Close the CPI enclosure door a temp J2 J1 eddy current brake only or eddy current brake and air brake with control panel ea TE ew pickup card JJ load control Gin air brake e 5 OJYNOLET B e A only p CRONR Figure 2 32 Wire the Breakout Board 2 39 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation
61. e Ifthe line voltage is reduced to or below 225 VAC and remains at these levels move the switch to the LO position This will boost the output current with the lower AC power voltages Note If the AC power voltage returns above the 230 VAC range while the dip switch is set to LO overheating and damage to the eddy current brake or fuse failure may result Review the LO NORM dip switch position setting and re measure your incoming AC line voltage ON NOR LO Figure D 1 Theta Controller Dip Switch Settings 1 2 O i i Ye MC0004 hes eo D 3 Above Ground Model 200ixX 250iX Motorcycle Dynamometer Installation Guide 50 Hz power B 7 60 Hz power B 2 A accessories 1 7 air brake 3 3 compressed air pump 3 16 eddy current brake 2 17 extended carriage 3 17 power carriage 3 20 wheel clamp 3 24 adjusting EEC finger guards C 6 air brake adjustments and tests 3 8 brake pads changing 3 9 brake pads clearance 3 15 emergency stop sticker 3 5 jumpers 2 39 routing air hose 3 4 routing cables 3 3 air pump assembly 3 16 using 4 3 B battery 1 5 charger 2 35 dimensions 1 5 installing 2 36 requirements 1 5 2 35 type 1 5 using a charger 2 35 battery hazards vi blower extension cable 2 32 blowers circuit breakers 4 8 control panel 4 3 installing 2 58 testing 2 62 using 4 4 INDEX brake pads 5 10 changing 3 9 clearance 3 15 brake pressure 5 10 breakout board jumpers 2 39 pickup card 2
62. ecommends you make routine checks of the dyno Drum keep the drum clean and keep all objects clear of the drum Brake Pads check the brake pad clearance regularly Change the brake pads when they are worn to less than 0 060 inch thick e Carriage Slide keep the carriage slide and screw clean and lightly lubricated e Check all air fittings for leaks monthly Correct any leaks found e Once per month verify that the drum brake pressure gauge reads 55 to 65psi 380 to 450kPa Adjust regulator if pressure is out of specification 5 10 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi Set II Anchors The anchors will be used to secure the dyno to concrete To ensure safety and accuracy in the procedures perform the procedures as they are described Be sure to read and understand the warnings included in this appendix WARNINGS SOTO PEN Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors ANTT ITW Ramset Red Head Multi Set II Anchors are designed to operate properly only when installed with ITW Ramset Red Head brand Setting Tools The use of a 24 to 40 ounce hammer is recommended for expanding Multi Set II anchors The use of carbide drill bits manufactured with ANSI B94 12 77 drill bit diameter requirements is rec
63. en 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 3 8 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 ACCESSORIES Sx Air Brake N CHANGING THE BRAKE PADS You will need the following part e 78122005 Brake Pad Kit AUTA PEN To prevent possible injury open the CPI door and set the main breaker to the off position and unplug the dyno Refer to Figure 3 1 for breaker location 1 Remove the top and right side covers from the dyno 2 For safety apply the brake and disconnect the air supply at the front of the dyno 3 Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor outboard brake pad adjust castle nut remove hairpin cotter Figure 3 11 Loosen the Castle Nut 3 9 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 3 x Air Brake 4 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 Note For clarity the drum is not shown nut washer and spring nut washer and spr
64. engine electrical wires or stray RF interference may result SOTO ae The inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration Do not drop the inductive pickup or snap the pickup closed Use extreme care in handling and placement of the pickups 1 Clip the secondary inductive pickup around one spark plug wire Note On a wasted spark ignition system two secondary inductive pickup wires may be needed 2 Route the inductive pickup cable clear of devices that produce electronic noise spark plug wires coil wire coil etc to the dyno electronics RPM module Note Inductive pickup placement is important Position the inductive pickup so that it is not making contact with any other spark plug wires Separate the spark plug wire from the spark plug wire bundle for proper operation Note You must ground the vehicle to the dyno for the electronics to function properly coil connect secondary inductive pickup on ae the coil wire connect secondary inductive pickup on the coil wires O D Figure 5 3 Connect the Secondary Inductive Pickup 5 5 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 5 J Connecting the RPM Pickup CONNECTING THE PRIMARY INDUCTIVE PICKUP The primary inductive pickup cannot be in contact with or it s connecting wire be crossing other engine electrical wires or stray RF interference may result PS WARNING The
65. ers to the dyno For more information on connecting the blowers refer to your dyno installation guide Turn on the main dyno breaker Test the blowers for operation Turn on the dyno electronics and verify operation Test the control panel operations For more information refer to your dyno installation guide Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION J ons Locations Using 50 Hz Power Locations other than North America and Japan LOCATIONS USING 50 HZ POWER LOCATIONS OTHER THAN NORTH AMERICA AND JAPAN The next section of this appendix contains the power requirements and instructions for dyno installations excluding North America and 60 Hz areas of Japan Note Refer to page B 2 for power requirements and instructions for North America and Japan The model 200iX 250iX dynamometer excluding North America and Japan requires a dedicated wall receptacle which must be wired for operation and is included with the dyno or may be shipped in advanced in a separate package The dyno is equipped with a ten foot power cord with a three pin IEC plug pre wired on the end The power cord is located at the front of the dyno but is shipped inside of the dyno For more information on the location and routing instructions for the power cord refer to your dyno installation guide The model 200iX 250iX dynamometer requires a dedicated 240VAC single phase power outlet rated
66. f the bike Refer to page 4 4 for more information This accessory requires the CPI and battery to operate The power carriage allows you to move the bike forward and backward by remote control to center the bike s rear tire on the dyno drum Refer to page 4 5 for more information Allows for spinning up the dyno drum to bump start bikes that may not have a starter Refer to page 4 5 for more information Provides information on the status of the CPI control and the various inputs to the CPI This optional accessory requires the CPI and battery to operate The wheel clamp allows for quicker loading and unloading of the bike Refer to page 4 6 for more information USING THE AIR FUEL RATIO AIR PUMP Y PAN The CPI allows control of the optional internal air pump that is part of the air fuel ratio AFR sampling system This air pump is built into the dyno to draw exhaust gases over the AFR sensor The button on the control panel allows the dyno user to turn this pump on and off The indicator light on the control panel will illuminate when power is provided to the pump If the pump does not run check the following e Verify the switch on the pump assembly is on Verify fuses F3 and F4 on the CPI board Ifthe E Stop button is pressed or the external E Stop circuit is open then the AFR pump will not run Refer to the Compressed Air Air Fuel Ratio Module Installation and User Guide for proper operating and maintenance procedures
67. f the dyno are designed to only work with Dynojet provided blowers Connecting other electrical loads or other blowers to the outlets on the dyno may damage the dyno and void the warranty If the blower indicator light on the control panel is on but the blower is not running perform the following steps 1 Verify the switch on the blower is on 2 Verify the blower power plug is firmly plugged into the dyno 3 Verify the blower circuit breakers in the CPI If the button on the breaker is extended an overload has occurred and the breaker has tripped Press in the breaker button to reset the breaker If the breaker continues to trip contact Dynojet UNDERSTANDING INTERLOCKS The interlock circuit provides inputs for normally closed switches which open when it is not safe to run the dyno Typically these switch inputs will be tied to safety gates and safety switches that are required in Europe If the Interlock circuit is open the Status Indicator light will blink on and off with the on time equal to the off time This will continue until this circuit is closed or an overriding E Stop condition is sensed In a dyno configured to comply with CE requirements the interlock signal will activate the drum air brake Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CONTROL PANEL INTERFACE OPERATION Mes Basic CPI Operation USING THE POWER CARRIAGE This accessory requires the CPI and battery to operate Use the
68. for 30A for proper operation Failure to follow these instructions could result in personal injury or damage to the dyno Connecting the dyno to the incorrect voltage will void the dyno warranty Contact Dynojet with any questions The dedicated wall receptacle is a three pin IEC grounded 30A type and must be wired in accordance with local building codes and requirements Installation may require a licensed electrician to conform to applicable safety standards AGU If you are installing your dyno in a location other than North America or Japan and the dyno is not equipped with a three pin IEC grounded plug contact Dynojet before attempting to connect the dyno Local and national electrical codes will require that the box containing the receptacle is grounded e This circuit should have a dedicated 30A double pole circuit breaker The dyno should be the only device connected to this circuit e It may be necessary to install a delayed trip breaker due to the inrush current drawn by the high pressure blowers B 7 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide APPENDIX B wy Locations Using 50 Hz Power Locations other than North America and Japan INSTALLING THE WALL RECEPTACLE The wall receptacle is a single 240 volt 30A dedicated circuit with a ground The cable carrying the power to this receptacle should be 4 0 mm ten gauge or larger Check with local building codes for the co
69. gt WinPEP 7 Help or visit www winpep com accessible with a valid user name and password Refer to the section on Computer Specifications in the WinPEP documentation P N 98118103 for the specific computer system requirements DRILL AND DRILL BIT REQUIREMENTS 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 e drill bit size 1 2 inch e minimum hole depth 1 5 8 inch 41 2 mm ELECTRICAL REQUIREMENTS The Model 200iX 250iX 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 1 8 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements ENVIRONMENTAL REQUIREMENTS description specifications Temperature operating min max 10 C 50 C 50 F 122 F storage min max 0 C 60 C 32 F 140 F Humidity 0 to 95 non condensing FORKLIFT REQUIREMENTS You will need to provide equipment capable of lifting a minimum of 2268 kg 5000 lb to lift the dyno off the crate and into position in your dyno room You will also need a pair of straps capab
70. h pendant COVEE route 9 pin RS232 cable to your computer 15 pin control panel cable labelled Button Panel P1 Figure 2 30 Route the Control Panel and Pendant Cables 2 37 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ay CHAPTER 2 F amp Routing Cables ROUTING THE EDDY CURRENT BRAKE CABLES 1 Attach the input power cable P N 66952004 to the top of the theta controller 2 Route the eddy current brake cable P N 66952003 from the eddy current brake to the bottom of the theta controller 3 Route the control cable from the theta controller out of the side of the dyno chassis to the Breakout board through the hole in the CPI shown in Figure 2 31 4 Route the temperature sensor cable from the eddy current brake through the air hole in the drum bulkhead through the opening on the side of the CPI and over to the Breakout board Note For more information on wiring the Breakout board refer to page 2 39 input power temperature sensor cable control cable breakout board eddy current brake cable Figure 2 31 Route the Eddy Current Brake Cables 2 38 lt _ uy INSTALLATION Ss Routing Cables WIRING THE BREAKOUT BOARD 1 Attach the temperature sensor cable to the Breakout board The temperature sensor cable has five wires which connect to the wiring block labeled TEMP This cable was routed to the Breakout board on page 2 38
71. hat 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 AC 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 Ch vii 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 instructi
72. he Air Hose Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES S Air Brake INSTALLING THE EMERGENCY STOP STICKER A properly installed air brake option adds an emergency stop function to the dyno shutdown button With the air brake installed activating the dyno shutdown button applies the brake and stops the drum Installing the emergency stop sticker indicates the added functionality applied to the dyno shutdown button 1 Remove the control panel rear cover la 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 le Remove the control panel rear cover and set aside Figure 3 4 Remove the Control Panel Rear Cover 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 screw Figure 3 5 Removing the Button Board 3 5 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Ay CHAPTER 3 yn y Air Brake 3 Unscrew the black switch body nut and remove the switch body Set the nut and switch body aside switch body nut switch body CP033 Figure 3 6 Removing the Switch Body 4 Place the emergency stop sticker over
73. he carriage assembly using the four 1 4 20 x 1 2 inch button head screws removed earlier Note If you ordered the power carriage accessory refer to Power Carriage on page 3 42 for installation instructions Figure 2 44 Installing the Carriage Assembly 2 49 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 xO Trike Carriage Adapter and Carriage Assembly 9 Secure the tire stop to the carriage using four 3 8 16 x 1 2 inch button head flange bolts 10 Secure the tire lock to the carriage using four 3 8 16 x 1 2 inch button head flange bolts Note If you purchased the wheel clamp accessory refer to Wheel Clamp on page 3 47 for installation instructions Figure 2 45 Install the Tire Lock and Tire Stop 250 ea Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Tie Down Installation TIE DOWN INSTALLATION You will need the following parts e 36582034 Bolt 3 8 16 x 1 25 Button head Flange 8 e 61300009 Tie Down 2 1 Install the tie downs on the right side of the dyno using four 3 8 16 x 1 25 inch button head flange screws 2 Place the tie down on the left side of the dyno but do not secure Note Do not secure the tie down used with the monitor arm until the monitor arm is in place Refer to step 1 on page 2 52 for more information tie down under monitor supp
74. he extended support P N 78100003 install the trike carriage adapter P N 71300002 and install the extended carriage assembly You will need the following parts e 15331100 Chain Lube e 21600019 Trike Extension Support e 36580434 Bolt 3 8 16 x 1 2 Button head Flange Allen 7 e 71300002 Trike Carriage Adapter Assembly e 36500008 Capscrew 5 16 UNC x 1 Button head 5 e 36500009 Capscrew 3 8 16UNC x 1 Button head 2 INSTALLING THE EXTENSION SUPPORT AND TRIKE CARRIAGE ADAPTER ASSEMBLY 1 Secure the extension support to the dyno using seven 3 8 x 1 2 inch button head flange bolts extension support Figure 3 19 Installing the Extension Support 3 17 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 3 x Extended Carriage E 2 Secure the trike carriage adapter assembly to the dyno and the extended support using five 5 16 x 1 inch button head bolts as shown in Figure 3 20 3 Secure the trike carriage adapter assembly to the dyno and the extended support using two 3 8 x 1 inch button head bolts as shown in Figure 3 20 4 Lube the tracks with the included lube or use grease 5 16 x 1 inch bolts trike carriage adapter assembly extension support 5 16 x 1 inch bolts KU067 Figure 3 20 Install the Trike Carriage Adapter Assembly 3 18 m G Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES ye Extended Carriag
75. iX 250iX dynamometers require guards mounted on the front and back of the drum guard bracket The EEC finger guards provide extra protection from the drum by regulating the distance between the drum and the chassis The placement of the finger guards can be manually adjusted PSN WARNING Do not operate the dynamometer without the FEC finger guards property installed The gap between the finger guards and the drum must be less than 0 64 centimeters 0 25 inches Refer to page C 6 for instructions on adjusting the gap REMOVING THE DRUM MODULE HOOD Before installing the EEC finger guards the drum module hood must be removed PN WARNING Never operate the dynamometer with the drum module hood removed ANE Dynojet recommends using a T30 Torx driver Snap On PFTx30E to remove the 1 4 inch screws For dynos with serial numbers lower than 2030152 Dynojet recommends using a hardened 5 32 inch hex driver such as Snap On FA5E A standard allen key may round off in the shallow screw head Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION amp FEC Finger Guards 1 Turn off the dyno and disconnect the AC power cord from its power source refer to Main Dyno Power on page 3 2 2 Remove the eight 1 4 20 x 5 8 inch pan head screws securing the drum module hood to the dyno and set aside 3 Remove the drum module hood and set aside Not
76. ill need the following parts 21200022 21200024 21600012 36468100 36561045 61300007 76950053 Middle Bulkhead Front Bulkhead Toe Kick Bracket Nut 1 4 20 Nylock 5 Screw 1 4 20 x 5 8 PH Torx 16 Monitor Support Brace Cable Fan Power Extension Place the monitor support brace on the five studs on the front bulkhead Secure the brace to the studs using five 1 4 20 nylock nuts 3 Secure the front bulkhead to the dyno frame using four 1 4 20 x 5 8 inch pan head screws 4 Secure the middle bulkhead to the dyno frame using five 1 4 20 x 5 8 inch pan head screws 2 30 monitor support brace front bulkhead middle bulkhead Figure 2 24 Securing the Front and Middle Bulkheads agers Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ee INSTALLATION iX Drum Module Installation Remove the existing 3 8 inch screw from the drum module and secure the toe kick bracket to the drum module 5 toe kick bracket Figure 2 25 Securing the Toe Kick Bracket 2 31 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 xe CHAPTER 2 Val iX Drum Module Installation 6 Attach the blower extension cable to the existing blower cable disconnected earlier by matching up the colors 7 Attach the blower extension cable to the fan socket e Connect the brown wire to N e Connect the blue wire to L Connect the green yellow wire to ground
77. inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration Do not drop the inductive pickup or snap the pickup closed Use extreme care in handling and placement of the pickups 1 2 Clip the primary inductive pickup around the wire to the primary side of the coil Route the primary wire cable clear of devices that produce electronic noise to the dyno electronics RPM module Note You must ground the vehicle to the dyno for the electronics to function properly coil connect primary p inductive pickup on the negative side of i the coil SS Figure 5 4 Connect the Primary Inductive Pickup 5 6 DA as Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 BASIC DYNO OPERATION J Pre Run Inspection PRE RUN INSPECTION Perform a vehicle inspection before making a run Check the following Check the radiator coolant if applicable and oil levels Check the fuel source Rotate the drum and check for rocks caught in the tire tread that could fly out For motorcycles check the chain and the chain master link Make sure it is lubricated and adjusted to the proper tension Check the tire pressure and tire speed rating Improperly inflated tires or exceeding the maximum speed rating can result in premature wear or severe tire damage Make sure the tire has no major deficiencies cracks in sidewalls tread life etc
78. ing bolt Figure 3 12 Remove the Brake Spring 3 10 ieee Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES Ss Air Brake 5 Remove the two bolts and two washers securing the brake caliper stop to the brake bracket and remove the brake caliper stop Note For clarity the drum and parts of the dyno frame are not shown brake caliper stop brake bracket U ABOS1 Figure 3 13 Remove the Brake Caliper Stop ASA Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 3 x9 Air Brake 6 Remove the hairpin cotter from the bottom clevis pin located on the front of the air brake assembly LL hairpin cotter bottom clevis pin Figure 3 14 Remove the Bottom Hairpin Cotter BV JEt Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES Ya Air Brake 7 Push the bottom clevis pin towards the back of the assembly drum side You do not need to remove the pin completely 8 Remove the hairpin cotter from the top clevis pin located on the drum side of the air brake assembly top hairpin cotter top clevis pin bottom clevis pin oo ke l ABO50A Figure 3 15 Remove the Bottom Pin and the Top Hairpin Cotter 9 Remove the top clevis pin top clevis pin AB0508 Figure 3
79. ing 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 dynamometer and or eddy current brake retarder number on the inside cover of this manual 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 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 and www winpep com where Dynojet provides state of the art technical support on line shopping 3D visualizations and press releases about our latest product lines Fa Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 1 3 Zay r 1 4 CHAPTER 1 y 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 e minimize noise e provide a contro
80. jet 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 above 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 98200026 Version 1 Last Updated 05 05 2010 This chapter is divided into the following categories Introduction page 1 2 Dynamometer Specifications and Requirements page 1 5 Dyno Electronics page 1 10 1 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Zay r 1 2 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 dy
81. le of supporting 2268 kg 5000 Ib to attach to the dyno Dynojet recommends using single loop style straps GROUND HOOK REQUIREMENTS You may wish to install additional ground hooks included with your dyno for securing the motorcycle The tie down loops on the pit covers should work for most motorcycles If you are running motorcycles that require a different tie down location mount the ground hooks accordingly Note Tie down straps MUST pull the motorcycle forward Using the ground hooks as a pattern use the hardware included with the ground hook kit to install the Red Head anchors according to the instructions in Appendix A PHONE AND INTERNET ACCESS Dynojet recommends you have a phone close to the dyno to call for assistance in an emergency You may also wish to contact Dynojet to troubleshoot your dyno Internet access on your computer is desirable for contacting Dynojet and downloading new information and updates TiE DOWN STRAPS Dynojet recommends using motorcycle tie down straps for securing the bike on the dyno You will need to provide the tie down straps 1 9 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 1 F amp 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
82. lled environment for testing e provide a view window safety glass for customers e 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 SWOT PEN Engine exhaust contains poisonous carbon monoxide gas Breathing it could cause death Operate machine in well ventila
83. lowing categories Locations Using 60 Hz Power North America and Japan page B 2 e Locations Using 50 Hz Power Locations other than North America and Japan page B 7 Da gunan yore B 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide APPENDIX B Zay a B 2 Locations Using 60 Hz Power North America and Japan LOCATIONS USING 60 HZ POWER NORTH AMERICA AND JAPAN The following power requirements and instructions are for North America much of Japan and other locations using 60 Hz power All other locations should refer to the instructions found in Locations Using 50 Hz Power Locations other than North America and Japan on page B 7 The model 200iX 250iX dynamometer requires a dedicated 240VAC single phase power outlet rated for 30A for proper operation Failure to follow these instructions could result in personal injury or damage to the dyno Connecting the dyno to the incorrect voltage will void the dyno warranty Contact Dynojet with any questions The model 200iX 250iX dynamometer requires a dedicated wall receptacle which must be wired for operation and is included with the dyno or may be shipped in advance in a separate package The dyno is equipped with a ten foot power cord with a twist lock plug pre wired on the end The power cord is located at the front of the dyno but is shipped inside of the dyno For more information on the location and routing instructions for the power
84. m Plug the dyno into the power outlet Turn on the main breaker inside the CPI door Open the door safety switch by allowing the plunger to extend The air brake should be applied holding the drum and the status light on the control panel will be flashing Depress the safety switch and the air brake will release and the status light will be on steady Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide THETA CONTROLLER This appendix describes how to make power adjustments on the theta controller To ensure safety and accuracy in the procedures perform the procedures as they are described D 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ry D 2 xy APPENDIX D Power Adjustment POWER ADJUSTMENT The 240 VAC theta controller is calibrated for a nominal 230 to 240 VAC line voltage in certain countries line voltages of 210 to 220 VAC may be encountered and the dip switch can be set to provide full output current of 10 amps even with the reduced line voltage Note This controller cannot be converted to operate on 120 VAC line voltage WARNING PEN Hazardous voltage To avoid risk of electrical shock disconnect the power cord to the theta controller Do not remove the cover No user serviceable parts inside ACCESSING THE DIP SWITCHES Dynojet recommends you set the dip switches at the time of installation ANT The two dip switches are the only adjustments
85. m module hood is installed the EEC finger guards will need to be adjusted 1 Loosen the 1 4 20 inch pan head screws and adjust the EEC finger guards so they are 0 16 cm to 0 64 cm 0625 in to 25 in from the drum Tighten the screws 2 Check the EEC finger guards regularly to verify the clearance has not changed Note For clarity the eddy current brake and dyno carriage are not shown PN WARNING Do not operate the dynamometer without the EEC finger guards properly installed The gap between the finger guards and the drum must be less than 0 64 centimeters a MC109 adjust screw adjust clearance Figure C 4 Adjust the EEC Finger Guard Clearance C4 M Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION Ss Door Safety Switch gt DOOR SAFETY SWITCH Safety requirements of your local country may require that a door safety switch is installed Be sure to follow the safety requirements specific to your country The door safety switch requires the air brake to work This switch is located on the dyno room door and is triggered when the pressure applied to it is released causing the air brake to lock This prevents the dyno from being used when the door is open PSN WARNING Components attached to and within the dynamometer operate with potentially lethal voltages To provide the greatest assurance of safety the
86. mine 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 and install the iX 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 bulkhead support woodruff key 3 8 x 1 3 8 N P N 21200022 P N 37620622 a decking front panel ZF monitor support brace P N 21200024 Pa yee gt P N 61300007 center panel IE fan arm mount 2 P N 21200037 Z P N 61300009 drum safety cover LPI driveline assembly P N 21200038 Fe P N 62240070 toe kick bracket NN drum module P N 21600012 i P N 63200001 2 26 LETA J Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION S iX Drum Module Installation part description part description lower blower arm 2 trike carriage adapter P N 21600015 a gt assembly P N 71300002 washer 1 5 x 38 ID x 187 THK 2 P N 26215220 bolt kit P N 79100000 washer 1 87 x 1 25 ID x 25 THK 2 P N 262
87. namometer Installation Guide INSTALLATION amp Monitor Support Tray and Control Panel S 17 Place the pendant in the slot provided on the control panel and route the cable bundle along the support arms with service loops to allow movement 18 Ifyou plan to route your cables through a zip tube refer to Zip Tube on page 2 63 and skip the following steps 19 Attach the cable bundle with the cable clamps that are provided using 8 32 inch screws Adjust the service loops to allow for easy movement of the monitor arms without pulling on the cables You may want to route the RS232 connector to your computer part way up the support arm along with the control panel and pendant cables depending on where you your computer is located pendant Figure 2 52 Route the Pendant Cable 2 57 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 High Pressure Blowers Zay yey 2 58 HIGH PRESSURE BLOWERS You will need the following parts oo 10 11 e 21600015 Lower Blower Arm 2 e 26215220 Washer 1 5 x 38 ID x 187 THK 2 e 26215521 Washer 1 87 x 1 25 ID x 25 THK 2 e 35712991 Clamp Lever 3 8 16 x 3 4 2 e 76950317 Blower Extension Cord Place a 1 4 inch thick poly washer around the pin on the tie down with the monitor arm Place two 1 4 inch thick poly washers around the pin on the tie down without the monitor arm Replace the existing lower blower arms
88. nected 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 pp149 P7 on the CPI board brake wiring block on breakout board Figure 3 2 Route the Air Brake Cable 3 3 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 3 Zay jn y Air Brake bulkhead fitting 3 4 Route the air hose from the air brake through the access hole in the drum module upright under the carriage frame brace and connect to the bulkhead fitting at the front of the dyno 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 air hose _ access hole ie eee air brake MC115 Figure 3 3 Connect t
89. next bike to be loaded easily 4 7 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 4 yy Power Distribution Assembly POWER DISTRIBUTION ASSEMBLY The Power Distribution Assembly inside the CPI has three circuit breakers to protect the internal dyno circuits the main dyno circuit breaker and two blower circuit breakers MAIN CIRCUIT BREAKER The main circuit breaker is rated for 240VAC at 30A and all of the power into the dyno passes through this breaker In the event of a major overload or failure this breaker will trip This breaker also provides the main disconnect for the dyno When the handle is in the up position the dyno is connected to the incoming power When the handle is in the down position all power into the dyno is turned off PN WARNING Even if this breaker is turned off there is still the potential for lethal voltages to be present in the CPI Always disconnect the main power plug before removing the covers HIGH PRESSURE BLOWER CIRCUIT BREAKERS The high pressure blower blower circuits are protected by the two 15A breakers In the event of a motor failure or other failure with the blowers these breakers could trip The white button pops out to indicate the circuit has tripped Pressing in the white button will reset the breaker The top breaker protects the right blower circuit right side of dyno as you are sitting on the bike and the bottom breaker protects th
90. no 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 amp 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 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 SPECIFICATIONS AND OPERATING REQUIREMENTS Introduction 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 AGU P WARNING SQN Bold gt TECHNICAL SUPPORT The Caution icon indicates a potential hazard to the dynamometer equipment Follow all procedures exactly as they are described and use care when perform
91. o the red cable can reach the positive post on the battery and the black battery cable can reach the negative post Secure the red battery cable to the positive battery post 3 4 Secure the black battery cable to the negative battery post 5 down Secure the battery to the tray with the battery hold Figure 2 29 Install the Battery 2 36 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION amp Routing Cables ROUTING THE PENDANT RS232 COMPUTER CABLE AND CONTROL PANEL CABLE 1 Version 1 Remove the two screws securing the cable pass through cover shown in Figure 2 30 closest to the monitor support and set it aside The cables you will route will be coiled inside the chassis Route the pendant cable 9 pin RS232 computer cable P N 42967090 and the 15 pin control panel cable labelled Button Panel P1 from the dyno electronics CPU Module through the cable pass through cover on the side closest to where you installed your monitor arm Place a split snap bushing around the pendant cable and the RS232 cable and secure them through one hole in the cable pass through cover Place a split snap bushing around the control panel cable and secure it in the other hole on the cable pass through cover The bushing should be around the cable protective wrap Secure the cable pass through cover to the dyno with the two screws removed earlier cable pass throug
92. of the cover removed earlier 13c Replace the screw on the side of the cover removed earlier 13d Replace the two nuts removed from the top of the cover removed earlier Figure 2 50 Replace the Control Panel Rear Cover Secure the control panel to either side of 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 51 Once installed place the pin on the control panel into the support arm where the monitor tray is 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 63 and skip the following steps Route the cable bundle along the support arms with service loops to allow movement as shown below Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 2 55 Ay CHAPTER 2 amp Monitor Support Tray and Control Panel Note 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 e CPo23 install control panel spindle if you did not purchase the monitor Figure 2 51 Install the Control Panel 2 56 C Above Ground Model 200iX 250iX Motorcycle Dy
93. ommended for installation of this anchor Not recommended for use in lightweight masonry material such as block or brick Use of core drills is not recommended to drill holes for use with this anchor Not recommended for use in new concrete which has not had sufficient time to cure Anchor spacing and edge distance requirements anchor installation locations are the responsibility of the engineer of record CONTACT INFORMATION FOR ITW RAMSET RED HEAD Contact ITW Ramset Red Head at 1 630 350 0370 or 1300 North Michael Drive Wood Dale IL 60191 A 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide APPENDIX A Zay rg Installation INSTALLATION Use the table below to determine the catalog number drill bit size minimum hole depth and setting tool catalog number setting tool catalog number drill bit size minimum hole depth catalog number Carbon Steel 1 2 inch 1 5 8 inch 41 2 mm RT 138 RM 38 RL 38 9 5 mm Use the following instructions to install the Red Head anchors 1 Drill the hole in the concrete the same outside diameter as the anchor being used to any depth exceeding minimum embedment 2 GH001 Figure A 1 Red Head Anchor Drill the Hole 2 Insert the anchor anchor L Uj GH002 Figure A 2 Red Head Anchor Insert the Anchor A 2 EEFAJ Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide RED HEAD ANCHOR INSTALLATION lt Installation
94. only the peak voltage of the vehicle s spark ignoring the lower voltages to help reduce electronic noise problems Wasted spark ignition systems will produce a lower voltage level on the exhaust stroke than the compression stroke By definition of the auto gain circuit lower voltage spark levels will be ignored missing every other spark the vehicle would produce RPM Pickup DESCRIPTIONS RPM pickup description Secondaries Non wasted spark system Use one secondary pickup Unplug the other pickup from the RPM module and set the degrees between plug fires to 720 in WinPEP 7 Secondaries Wasted spark ignition Use two secondary pickups Attach one pickup on each spark plug system wire on the same coil and set the degrees between plug fires to 360 in WinPEP 7 Primary pickup Attach the primary wire pickup to the primary side of the coil Set the degrees between plug fires by taking 720 four cycle engines or 360 two cycle engines divided by the number of coils For example the number of degrees between plug fires on a four cylinder four cycle engine with dual coils where each coil fires two cylinders is 720 4 x 2 360 5 4 EEE Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION S Connecting the RPM Pickup CONNECTING THE SECONDARY INDUCTIVE PICKUP The secondary inductive pickup cannot be in contact with or it s connecting wire be crossing other
95. ons 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 arging 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 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide WARNINGS eis PSN WARNING 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
96. ons to install the ground hooks You will need the following parts e 10111 Ground Hook D Ring 4 e 10112 D Ring Bracket 4 e 36932100 Washer 3 8 Splitlock Steel 8 e 37513200 Anchor Redhead 3 8 8 e DM150 002 007 Washer 5 16 Flat 8 e DM150 019 012 Bolt 3 8 16 x 1 Hex 8 1 Mark the ground hook placement as shown in Figure 2 54 Two additional ground hooks are included for installation in front of the dyno placement will vary depending on dyno application 2 Using the ground hook as a template mark and drill each hole needed to secure the ground hooks to the floor 3 Install the Red Head anchors Refer to Appendix A for installation instructions 4 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 o Eo GHOO7 eg 81 28 cm 32 00 in 66 63 cm 3 amp 26 23 in 128 13 cm 50 45 in Figure 2 54 Ground Hook Placement 2 60 ayaa 35 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION amp 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 informa
97. or red head anchors Version 1 Figure 2 19 Secure the Dyno and Brake Module to Floor 2 23 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 mY Eddy Current Brake INSTALLING THE THETA CONTROLLER The theta controller is the interface between the eddy current brake and the dyno electronics The theta controller is shipped in the eddy current brake crate Note The theta controller may already be installed 1 Verify the theta controller dip switch settings Refer to Appendix C for more information 2 Secure the theta controller to the drum module bulkhead using four 8 32 x 3 8 inch screws four 8 32 x 3 8 screws theta controller Figure 2 20 Installing the Theta Controller 224 MG Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Remove the Dyno Covers YS REMOVE THE DYNO COVERS 1 Remove the five screws securing the top cover to the dyno and set aside Remove the top cover and set aside 2 Remove the twelve screws securing the side cover to the dyno and set aside Remove the side cover and set aside top cover side cover Figure 2 21 Removing the Dyno Covers _COCOCOCOCOC CCC 2 25 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 2 vy iX Drum Module Installation IX DRUM MODULE INSTALLATION Exa
98. ort tie down on right side of dyno Figure 2 46 Installing the Tie Downs 2 51 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 xy 2 52 Monitor Support Tray and Control Panel MONITOR SUPPORT TRAY AND CONTROL PANEL You will need the following parts 26215520 35521420 36582034 61329000 61329100 61329101 61329500 66117001 Washer 1 8 Poly for Monitor Support 3 Cap Plug for Monitor Support 4 Bolt 3 8 16 x 1 25 Button head Flange 4 Control Pod Spindle Monitor Arm 2 Monitor Tray Monitor Support Control Panel Assembly 1 Secure the monitor support to the dyno using four 3 8 16 x 1 25 inch button head flange bolts Note Make sure the tie down is sandwiched in between the dyno panel and the monitor support base Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Sx Monitor Support Tray and Control Panel N Place a 1 8 inch thick poly washer around the pin on the lower monitor arm Insert the pin on the lower monitor arm into the monitor support Place a 1 8 inch thick poly washer around the pin on the upper monitor arm Insert the pin on the upper monitor arm into the lower blower arm Place a 1 8 inch thick poly washer around the pin on the monitor tray UARN Insert the pin on the monitor tray into the upper blower arm washers monitor a support gt tie down under ge monitor
99. ound Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Sx Dyno Installation N 7 Remove the remaining six side screws securing each side drum cover to the dyno and set aside Remove the side drum covers and set aside Note For future reference note the three access holes in the drum bulkhead These access holes will be used to route cables when installing accessories once the top cover is back on PANTEA Be sure you record the dynamometer number on the inside cover of this manual 8 Remove the tire stop tire lock and hardware from the middle of the dyno 9 Verify the contents of the hardware boxes and set aside side drum cover dyno number stamped on frame side drum cover access holes in drum bulkhead only two visible from this view Figure 2 4 Remove the Side Drum Covers A5 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide oy CHAPTER 2_ J Dyno Installation part description part description anchor redhead 3 8 7 P N 37513200 installation tool redhead anchor P N 37518200 woodruff key 3 8 x 1 3 8 P N 37620622 cable harness wrap kit P N 43400000 cable clamp 5 8 7 P N 43428232 plug turnlok 30A 125 250V P N 43816430 receptacle turnlok 30A 125 250V P N 43826430 control pod spindle assembly P N 61329000 2 6 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installa
100. outed on page 2 32 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 strain relief ZZ ZZ ZZ ge 0 0 Z KA Z FA Z FA Z Z Z A wheel clamp cable Figure 3 28 Install Wheel Clamp Strain Relief B26 LLlLll mrmrrr G OG Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES Sx Wheel Clamp N 7 Replace the wheel clamp cover WC015 Figure 3 29 Replace the Wheel Clamp Cover OO FHT Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 3 jn y 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 replacing the top cover if your country requires you install the safety switch please refer to the instructions in Appendix B TURNING ON THE DYNO POWER Use the following steps to connect and disconnect power to the dyno Always turn the power off when connecting and disconnecting cables 1 Turn on the main breaker inside the CPI door 2 Plug the power plug into the power outlet 3 Replace the CPI cover if it was removed Note Use the main breaker to turn power on and off to the dyno POWER CARRIAGE FINAL ADJUSTMENTS AND TES
101. r during a run the information provided by the dyno will be inaccurate Use the following steps to adjust the clearance 1 Loosen the brake caliper stop bolts 2 Insert the brake adjusting shim between the inboard brake pad and the brake rotor Refer to Figure 3 18 3 Remove the hairpin cotter and hand tighten the castle nut on the caliper assembly to clamp the brake pads against the rotor and shim Refer to Figure 3 11 for hairpin and castle nut location 4 Tighten the brake caliper stop bolts 5 Loosen the castle nut and remove the shim 6 Adjust the clearance between the outboard brake pad and rotor Loosen the castle nut to increase the clearance There should be equal space on both sides of the rotor 7 Replace the hair pin cotter in the castle nut Note Cycle the brake to verify the brake pads release far enough so they do not touch the rotor If the pads touch the rotor during a run the information provided by the dyno will be inaccurate brake adjusting shim totor inboard brake pad brake caliper stop bolts AB057 Figure 3 18 Adjust Brake Pad Clearance 3 15 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 3 J 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
102. rd Figure 2 8 Route the Power Cable es ae Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Ay CHAPTER 2 J 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 right 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 Refer to Figure 3 6 on page 3 7 for more information on attaching compressed air to your dyno 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 AW The optical pickup is very delicate Be careful not to damage the optical pickup during alignment tab on dyno optical pickup pickup card LI top view of pickup card optical pickup and tab on dyno bracket tab on dyno MCO56A pickup card Figure 2 9 Install the Pickup Card 2 12 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide INSTALLATION Ss Compressed Air Pump Assembly COMPRESSED AIR PUMP ASSEM
103. riage 2 eee eee ee eens 4 5 Using the Starter s esn seba EKA dakda dada lode eee E RE ee ed 4 5 Using the Status Indicator 2 2 ee eee ee 4 6 Using the Wheel Clamp 0 0 0 2 eee eee ee eee ee 4 6 Power Distribution Assembly 0 eee eee eee eee eee 4 8 Main Circuit Breaker 2 2 eee tenes 4 8 High Pressure Blower Circuit Breakers 0 0 0 eee eee eee 4 8 Maintenance and Troubleshooting 02 e ee eee eee eee 4 9 Maintaining and Troubleshooting the Wheel Clamp 4 9 Replacing the Theta Controller Fuses 0 ce eee ee eee eee 4 10 Troubleshooting CPI Fuses 0 eee eee ee eee 4 11 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide TABLE OF CONTENTS yy wy Chapter 5 Appendix A Appendix B Appendix C Basic Dyno Operation Loading the Vehicle 2 45564 ode een ead e wcaceeeeeeeaddeaedadees 5 2 Connecting the RPM Pickup o 6c cek vices REL RORE CE 0000605050545 5 4 RPM Pickup Descriptions 0 0 cece eee eee eee 5 4 Connecting the Secondary Inductive Pickup 05 5 5 Connecting The Primary Inductive Pickup 000 0000s 5 6 Pre Run Inspection 035605 s65 eecenben re eeeeteerweeeeedoeetex 5 7 Before Starting the Engine 0 cee eee ee ee nee 5 8 Engine Warm Up vnc ei eevee obs b ahs dbo bs eae ebb ae ees 5 8 After Engine Warm Up
104. rrect size 1 Connect one of the 240V legs to the N terminal white 2 Connect the other 240V leg to the L terminal no color 3 Connect the ground conductor to the green terminal X Se eee L terminal N terminal o ground terminal white green Figure B 2 Wire the Wall Receptacle B 8 OTAJ Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION Les Locations Using 50 Hz Power Locations other than North America and Japan TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet Using a voltmeter that is capable of measuring AC voltage measure between the points listed below and verify that the correct voltages are present probe 1 probe 2 desired voltage measurement 1 3 220V to 250V 2 box lt 5V Figure B 3 Test the Wall Receptacle B 9 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Zay f B 10 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide F APPENDIX B Locations Using 50 Hz Power Locations other than North America and Japan REPLACING THE POWER PLUG Use the following instructions to replace the plug and socket The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of three conductors The power cord that attaches to the dyno has four conductors internally and their
105. rriage and Wheel Clamp Cables 2 40 Side and Top Cover Installation 0 0 0 cee eee ee eee 2 42 Installing the iX Covers 2 0 eee eee eee teenies 2 45 Trike Carriage Adapter and Carriage Assembly 2 47 Installing the Trike Carriage Adapter Assembly 0 2 47 Installing the Carriage Assembly 0 0 eee ee eee 2 48 Tie Down Installation ccdccccesceas Se sesedeeersswuesewewewess 2 51 Monitor Support Tray and Control Panel 04 2 52 High Pressure Blowers i046 s s4exvebeenebedcecicsen S See sSeleeds 2 58 Ground Hook Installation 0 2 0 eee ee eee 2 60 Final Adjustments and Tests 2 ce20csccsandeew see eesetseseeseess 2 61 Turning On the Dyno Power 00 ee eee eens 2 61 High Pressure Blower Test 0 0 eee eee eee eee 2 62 Power Carriage Final Adjustments and Tests 0005 2 62 Trike Carriage Adapter Assembly Test 0 000 e eee 2 62 Wheel Clamp Final Adjustments and Tests 0 00005 2 62 Zip NUDE PEE enh aeGaneeueess 2 63 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide TABLE OF CONTENTS Ss ons Chapter 3 Accessories Main Dyno Power 255 2 225 3660 000 c00sicee se nndev eee ees 3 2 Alr Brakes vate Meek Cues See See be se SL heed oe awed dada dae e ae 3 3 Routing the Air Brake Cable and Air Hose 02 0000 3 3 Installing the Emergency
106. ry six months or sooner depending on usage Refer to the Compressed Air Air Fuel Ratio Module Installation and User Guide P N 98200006 2 13 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 2 J Compressed Air Pump Assembly COMPRESSED AIR REQUIREMENTS The following requirements are needed for the on board compressed air pump assembly e Clean and dry air 100 psi or greater 5 CFM or better flow e Fittings to hook your air system to a 3 8 inch inside diameter hose if no air brake is present optional air regulator INSTALLING THE PUMP ASSEMBLY ON THE DYNO 1 Ifnot already removed remove the eight screws securing the drum module panel to the dyno Set the screws and the panel aside 2 Secure the pump housing to the dyno using four 1 4 20 torx screws R ee pump housing AP 109 Figure 2 10 Install the Pump Housing 2 14 U get Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide copper sample silicon tube Version 1 tube sensor o N AUA 10 11 INSTALLATION Pyy Compressed Air Pump Assembly Run the provided air hose from the air pump assembly to the front of your dyno If you have an air brake refer to Installing the Air Hose with the Air Brake on page 2 16 You will need to remove the carriage assembly and top center cover to route the air hose Refer to your dyno installation guide for instruction on
107. s 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 36 CHASSIS SPECIFICATIONS description specifications Length with standard carriage allow 271 78 cm 107 00 in with extended carriage allow 322 58 cm 127 00 in with ramp 370 84 cm 146 00 in Height to top of dyno cover 45 97 cm 18 00 in Width model 200ix 200 69 cm 79 00 in model 250ix 274 32 cm 108 00 in Weight model 200i dyno crated dyno 725 kg 1600 pounds 771 kg 1700 pounds model 250i retarder module crated 953 kg 2100 pounds 1 089 kg 2400 pounds 200iX 250iX 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 200iX 250ix 45 72 cm 18 00 in width 200iX 250ixX 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 1 5 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 1 Dynamometer Specifications and Requirements 274 32 cm 108 00 in 370 84 cm 146 00 in 200 66 cm 103 00 in 79 00 in 203 20 cm 80 00 in 45 72 cm 18 00 in Figure 1 1 Model 250iX Dyno
108. s by the dyno user while seated on the bike The graphics on the control panel are grouped together according to function and color coded for ease of identification A description of the functions and displays follows status indicator STATUS light gt Flashing Error refer to manual indicator light wheel secure AWARNING Risk of injury Eye and Ear protection required Ci A R R l A G E Read and follow all instructions and safety precautions STARTER BLOWERS CAUTI ON FRONT WHEEL MUST BE SECURED AT ALL TIMES TIE DOWN STRAPS MUST BE USED TO STABILIZE THE MOTORCYCLE Ratio Pump filter regularly 97415160 Figure 4 1 Control Panel Features 4 2 A Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide control panel feature CONTROL PANEL INTERFACE OPERATION Basic CPI Operation description Air Fuel Ratio Air Pump Emergency Stop Dyno Shutdown High Pressure Blowers Blowers Power Carriage Starter Status Indicator Wheel Clamp This optional accessory allows control of the internal air pump of the air fuel ratio sampling system Refer to page 4 3 for more information Deactivates the dyno outputs whenever the button is pressed or the external E Stop circuit is opened Refer to page 4 4 for more information This optional accessory allows you to toggle the blowers on and off to control the temperature o
109. s other than North America and Japan CONNECTING THE DYNO 1 N AUA Turn off the main circuit breaker on the dyno The main breaker is located in the CPI door Off is the down position Once you verify the voltages on the receptacle connect the dyno to the receptacle Connect the high pressure blowers to the dyno For more information on connecting the blowers refer to your dyno installation guide Turn on the main dyno breaker Test the blowers for operation Turn on the dyno electronics and verify operation Test the control panel operations For more information refer to your dyno installation guide Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide m rs B 11 EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION This appendix contains instructions for installing the European Economic Community EEC Kit to the model 200iX 250ix motorcycle dynamometer This appendix will walk you through installing the EEC finger guards and door safety switch The finger guards and door safety switch are required only for European dynamometers To ensure safety and accuracy in the procedures perform the procedures as they are described For more information refer to the Air Brake and EEC Kit Installation Guide P N 98123114 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Zay f C 2 APPENDIX C y EEC Finger Guards EEC FINGER GUARDS The European model 200
110. safety switches that will be attached to safety guards or the dyno room door when guards are not used this will allow dyno operation only when the guards are in place or the door is closed The E Stop circuit takes precedence over the interlock input USING THE WHEEL CLAMP This optional accessory requires the CPI and battery to operate The wheel clamp allows for quicker bike loading and unloading The internal mechanism in the wheel clamp closes on the bike s front wheel and tire to a calibrated amount of pressure securing the bike The indicator light between the wheel clamp buttons provides status of the current state of the wheel clamp PSN WARNING Pinch hazard Keep hands body parts and other loose items clear Failure to follow these instructions can result in serious injury or equipment damage PSN WARNING Risk of injury Be sure the wheel clamp is free and clear of any obstruction Do not operate the dyno if the wheel clamp indicator light is not on steady 46 A Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CONTROL PANEL INTERFACE OPERATION amp Basic CPI Operation CLOSING THE WHEEL CLAMP ATU Do not run into the edges of the wheel clamp pads with the bike tire Make sure the wheel clamp is sufficiently open before loading the motorcycle 1 Once the bike s front tire is fully seated in the clamp press and hold the close button left hand yellow square button
111. starter will not operate 1 Make sure the dyno brakes are not activated Verify the bike is in neutral or disengage the clutch Press and hold the green starter button until the drum reaches maximum speed Release the green starter button OA oY OQ N Use the momentum of the drum to start the bike Note Do not re engage the starter while the drum is turning 4 5 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 4 Zay jn y Basic CPI Operation USING THE STATUS INDICATOR The status indicator provides information on the status of the CPI control and the various inputs to the CPI Status Off indicates the CPI may not be receiving power due to the dyno being turned off or lack of power being applied to the dyno Status Steady On indicates all inputs into the CPI are okay for normal dyno operation and the CPI is receiving power e Status Blinking lIf the status indicator light is flashing with two short blinks on and a long pause off the Emergency Stop circuit is open This can be caused by the red button on the control panel being pressed or an external E Stop Emergency Stop condition is being fed to the CPI board The E Stop circuit must be closed to allow for normal dyno operation e Status Blinking lIf the status indicator light is blinking with equal on and off time the interlock signal into the CPI board is open This signal monitors the condition of optional
112. t 2 Turn the carriage screw handle or use the control panel to run the power carriage until the carriage is all the way out 3 Drive the vehicle onto the dyno and align the vehicle straight with the dyno 4 Stop the vehicle when the drive axle is centered on the drum 5 2 adjust carriage all the way out center drive axle on dyno drum Figure 5 1 Load the Vehicle Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 BASIC DYNO OPERATION Sx Loading the Vehicle N 5 When the vehicle is positioned properly on the dyno shut the engine off e Ifthe vehicle has an automatic transmission place it in park e Ifthe vehicle has a manual transmission place it in gear 6 Attach two tie down straps from the ground hooks to the rear of the vehicle 7 Attach two tie down straps from the ground hooks to the front of the vehicle Note If you are running an all wheel drive ATV use differential jacks to get the front wheels off the dyno Note When running an ATV you may need to increase the tire pressure so the tire does not come in contact with the decking 8 Tighten the four tie down straps evenly making sure the drive wheels remain centered on the drum WARNING PEN Never perform a dyno run if the tie down straps are not in place or they are damaged Q k T f O Co i o i Pr re BY 5 SS 6s 2 So ES Figure 5 2 Load the
113. t description The a parts are included in the Eddy Current Brake Assembly P N 63223700 side cover eddy current Zz brake i f P N 21226502 f IOON n 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 Z D ring bracket surface mount P N 10112 washer 3 8 splitlock steel 2 P N 36932100 2 8 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide anchor redhead 3 8 2 P N 37513200 washer 5 16 flat 2 P N DM150 002 007 bolt 3 8 16 x 1 hex 2 P N DM150 019 012 REMOVING THE DYNO FROM THE CRATE INSTALLATION Ss You will need to provide equipment capable of lifting a minimum of 2268 kg 5000 Ibs 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 2268 kg 5000 Ibs to attach to the dyno Dynojet recommends using a single loop style strap Be sure you record the dynamometer number on the inside cover of this manual 1 Remove the four lag bolts and washers securing the dyno to the crate base using a 9 16 inch socket open or box end wrench 2 The pickup card may be taped to the lifting eye Remove the pickup card and set it aside DC029 bolt and washer ee E
114. t 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 amp gt E guide body amp zip tube Ii ee cable wrap tool i p Q Figure 2 57 Secure the Cable s Into the Zip Tube p lt end of cables 2 63 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES 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 e Air Brake page 3 3 e Compressed Air Pump Assembly page 3 16 Extended Carriage page 3 17 e Power Carriage
115. t the wheel is clamped If the wheel has been clamped and the wheel clamp indicator light is on steady then the dyno power is turned off or the E Stop activated the wheel clamp indicator light will go back to the blinking state as the clamp status is unknown Pressing the clamp button again will secure the clamp If the E Stop circuit is open or the Emergency Stop button is pressed the wheel clamp will not operate Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 4 9 xe CHAPTER 4 oy Maintenance and Troubleshooting REPLACING THE THETA CONTROLLER FUSES The theta controller has two fuses WARNING x Hazardous voltage To prevent possible injury open the CPI door and set the main breaker to the off position and unplug the dyno Refer to Figure 3 1 for breaker location 1 2 3 4 5 Open the Control Panel Interface CPI cover and set aside Remove the four screws securing the blanking plate and remove the plate Reach through this opening to access the fuses on the theta controller Gently push the fuse holder slightly inward and rotate counterclockwise Remove the fuse holder Replace the fuse with a fuse type listed below ATU For continued protection against risk of fire replace only with a fuse of the same type and having the same electrical rating 4 10 240V Theta Controller Fuses 120V Theta Controller Fuses Buss P N BAF 15 15A Fuse e Buss P N BAF
116. talling the battery refer to page 2 36 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 e Using the bolts from the battery terminals secure the ring connectors from the charger to the battery terminals e 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 AW 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 35 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 Routing Cables a 9 INSTALLING THE BATTERY Locate the red battery cable on the inside of the dyno 1 2 Place the battery in the battery carrier on the inside of the dyno s
117. ted 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 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS g 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 200iX 250iX 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 batterie
118. tion TURNING ON THE DYNO POWER 1 Plug the power plug into the power outlet 2 Turn on the main circuit breaker inside the CPI door Note Use the main circuit breaker to turn power on and off to the dyno s amp s S Ss S S S SS SS amp S amp S S s Ss S 8S SS SS S S S SS SS S SS S S S SS amp SS S SS SS AU SS SS SS SS SS SS SS SS SS SS SS SS SS SS sS SS SS DJ a WRI Ss Sss SSS SSS SS SSS SSS SssS Ss Sss SSS SSS SSS SSS SSS SSS gss gss S amp S a b LJ power plug main circuit breaker Figure 2 55 Turn on the Dyno Power 2 61 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 2 ny Final Adjustments and Tests HIGH PRESSURE BLOWER TEST Test the blowers by pressing the appropriate buttons on the control panel POWER CARRIAGE FINAL ADJUSTMENTS AND TESTS The power carriage is an optional accessory To install the power carriage refer to Power Carriage on page 3 20 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 40 Using the Control Panel press the carriage forward and backward buttons and verify that the motor does turn TRIKE CARRIAGE ADAPTER ASSEMBLY TEST 1 Using the supplied chain lube or grease lube the front
119. tion Guide control panel button sub assembly P N 66117001 wheel clamp P N 71329000 optional accessory blower assembly P N 76722005 optional accessory iX upgrade kit P N 77000003 shipped in a separate crate refer to page 2 26 standard carriage P N 71300002 or extended carriage P N 78100003 ground hook kit 2 P N 79190001 see list of parts below power carriage P N 82943001 optional accessory banner dynojet 2 P N D706 INSTALLATION amp Dyno Installation description part description monitor tray inductive secondary P N 61329101 pickup 2 P N DE100 109S Du TF a E monitor arm assembly inductive primary pickup P N 61329003 clip P N DE100 110L eddy current brake module 5 washer 5 16 flat 7 P N 63223700 A Ne P N DM150 002 007 VA tire stop bolt 3 8 16 x 1 hex 7 P N 63310902 P N DM150 019 012 not included if you ordered the optional wheel clamp on board compressed air air fuel ratio assembly P N 64100002 optional accessory The following parts are included in the Monitor Arm Assembly P N 61329003 Version 1 washer 1 87 x 1 25 ID x 12 THK 3 P N 26215520 monitor arm 2 P N 61329100 cap plug 1 75 x 1 2 4 P N 35521420 monitor support P N 61329500 2 7 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 2 Dyno Installation part description par
120. ts for various length motorcycles For more information on using the power carriage refer to Using the Power Carriage on page 4 6 You will need the following part e 82943001 Power Carriage AWM The power carriage motor is preset to be installed with the carriage screwed in all the way Do not run the motor prior to installing it on your dyno PN WARNING To prevent possible injury open the CPI door and set the main breaker to the off position and unplug the dyno Refer to Figure 3 1 for breaker location REMOVING THE HAND CRANK 1 Loosen the set screw on the hand crank and remove the hand crank 2 Using a 7 16 inch wrench remove the two bolts securing the flange bearing PC034 flange bearing bolt Pa hand crank wy Figure 3 22 Remove the Hand Crank 3 20 ayaa 5 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES amp Power Carriage INSTALLING THE POWER CARRIAGE Remove the four screws securing the power carriage cover and set aside Insert the coupler jaw on the carriage screw making sure the inside of the coupler jaw is flush with the end of the carriage screw Secure the coupler jaw with the set screw Secure the motor mount to the carriage using two 1 4 20 x 1 inch bolts and two 1 4 inch lock washers The motor mount is installed in front of the flange bearing If the motor mount is already installed skip this step and continue Note
121. ump Assembly page 2 13 Eddy Current Brake page 2 17 e Remove Dyno Covers page 2 25 iX Drum Module Installation page 2 26 e Routing Cables page 2 34 Side and Top Cover Installation page 2 42 Trike Carriage Adapter and Carriage Assembly page 2 47 e Tie Down Installation page 2 51 e Monitor Support Tray and Control Panel page 2 52 e High Pressure Blowers page 2 58 e Ground Hook Installation page 2 60 Final Adjustments and Tests page 2 61 e Zip Tube page 2 63 2 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ne CHAPTER 2 Dyno Installation DYNO 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 2268 kg 5000 Ibs to move the crated dyno into position in your dyno room Refer to Dynamometer Specifications and Requirements on page 1 4 for more information The following directions describe how to unpack and install your dyno Follow the directions in the order that they are presented 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
122. ver motor assembly PC 039 Figure 3 25 Assemble the Power Carriage 3 23 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide xy CHAPTER 3 vy Wheel Clamp WHEEL CLAMP The wheel clamp allows you to easily adjust for various wheel thicknesses with the press of a button Refer to Using the Wheel Clamp on page 4 6 for more information on using the wheel clamp You will need the following parts e 71329000 Wheel Clamp Assembly e DM150 002 004 Washer 5 16 Lock 4 e DM150 002 007 Washer 5 16 Flat 4 e DM150 019 012 Bolt 3 8 16 x 1 Hex 4 1 Remove the six 1 4 20 x 1 inch screws securing the wheel clamp cover Remove the cover and set the cover and screws aside cover Figure 3 26 Remove the Wheel Clamp Cover 3 24 ayaa aS Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide ACCESSORIES Sx Wheel Clamp N 2 Place the wheel clamp on the carriage Align the four holes on the wheel clamp with the holes on the carriage 3 Secure the wheel clamp to the carriage using four 3 8 16 x 1 2 inch bolts lock washers and flat washers wheel clamp WC 013 Figure 3 27 Secure the Wheel Clamp to the Carriage 3 25 Version 1 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Ay CHAPTER 3 F amp Wheel Clamp 4 Bring the wheel clamp cable three pin connector from the front of the dyno over to the wheel clamp This cable was r
123. with the new lower blower arms as shown in Figure 2 53 Place the new lower blower arm over the pin Place an aluminum washer between the clamp lever and the lower bower arm Secure the lower blower arm to the tie down pin using the clamp lever included in the upgrade Place a 1 8 inch thick poly washer around the pin on the upper blower arm Insert the pin on the upper blower arm into the lower blower arm Place a 1 8 inch thick poly washer around the pin on the blower Insert the pin on the blower into the upper blower arm Plug the power cord from the blower into the power source located on the dyno chassis Note To allow full extension of the right blower use the blower extension cord P N 76950317 This extension cord is only used with the blower mounted on the right side of the dyno Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Version 1 INSTALLATION Sx High Pressure Blowers N ACE The blowers can run at any time once the cord is plugged into a power source MM Va LL clamp lever upper blower arm aluminum washer rei lower 1 4 inch thick poly washer OWS atm plug power cord from use two on non monitor blower into dyno chassis arm side Figure 2 53 Installing the Blowers 2 59 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide CHAPTER 2 Zay vy Ground Hook Installation GROUND HOOK INSTALLATION Use the following instructi
124. yellow wire as location 3 HARD WIRING TO THE BUILDING Use the following instructions to wire the dyno directly to the building The dyno must connect to a two pole disconnect switch to allow the removal of all power to the dyno for servicing This box may contain fusing circuit breakers or the circuit protection may be upstream in the building power system The circuit must be protected to 30A with slow blow fuses or time delayed circuit breakers The power cord that attaches to the dyno has four conductors internally and their colors are brown blue black and green yellow 1 Remove the dyno power plug and connect 240VAC single phase between the brown and the blue wires through the disconnect switch 2 Connect the green yellow wire to the ground connection 3 Wrap the black wire with white tape to denote that it is a neutral connection and connect it to the neutral connection 4 Refer to the previous table for testing and probe the new connections as follows e blue wire as location 2 e brown wire as location 4 e black wire as location 1 e green yellow wire as location 3 B 5 aed r B 6 APPENDIX B y Locations Using 60 Hz Power North America and Japan CONNECTING THE DYNO 1 N AUA Turn off the main circuit breaker on the dyno The main breaker is located in the CPI door Off is the down position Once you verify the voltages on the receptacle connect the dyno to the receptacle Connect the high pressure blow

Above Ground Model 200iX/250iX Installation Guide

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