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1. control panel interface board Figure 4 4 CPI Fuses F3 F4 Th ES F1 F2 status light PD047 4 11 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION This chapter includes instructions for basic dyno operation For more detailed instructions refer to your 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 Motorcycle page 5 2 e Connecting the RPM Pickup page 5 5 Pre Run Inspection page 5 10 e Making a Test Run page 5 12 Preventative Maintenance page 5 13 5 1 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide x CHAPTER 5 F Loading the Motorcycle LOADING THE MOTORCYCLE Use the following steps to load a motorcycle on the dyno PSN WARNING Keep the motorcycle balanced while driving on and off the dyno PSN WARNING Risk of injury Always wear proper eye and ear protection when operating the dyno Load the motorcycle on the dyno Place the bike on the dyno so the front tire is in the tire stop 3 Strap the front wheel to the tire stop and tighten Note If you have the
2. PD047 blower circuit breakers right blower on top Figure 4 2 CPI Circuit Breakers 48 D In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 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 that the wheel is clamped If the wheel has been clamped and the wheel clamp indicator light is on steady then
3. left side installation right side installation looking from the bottom looking from the bottom Figure 2 41 Eddy Current Brake Cover for Left and Right Side Installations 2 48 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION S Pit Covers W 1 Remove the six 1 4 20 inch button head screws 1 4 inch flat washers and 1 4 20 inch lock nuts securing the two angle supports to the bottom of the eddy current brake cover and set aside PDO18 angle support aw ae nut ee ee T ii 1 i l 1 T i 1 fi i L T i 1 1 Ea T Figure 2 42 Right Side Eddy Current Brake Cover Angle Supports 2 Remove the four No 6 32 pan head screws securing the heat shield and insulation and set aside 3 Move the heat shield and insulation to other side of the cover as shown in Figure 2 41 and secure with the four No 6 32 pan head screws removed earlier PD019 heat shield i Figure 2 43 Right Side Eddy Current Brake Cover Heat Shield and Insulation 4 Move the two angle supports to the other side of the cover as shown in Figure 2 41 and secure with the six 1 4 20 inch button head screws 1 4 inch flat washers and 1 4 20 inch lock nuts removed earlier 5 Continue with the instructions for installing the pit covers 2 49 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTE
4. a ERLE ick up card H lcocPooofSsoch VEN load control A ld A as AT R e je N air brake ODYNOJET 03 18 9 YNOJET RESEARCH IN C only CB008 Figure 2 37 Wire the Breakout Board 2 43 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 ay Power Carriage Installation POWER CARRIAGE INSTALLATION You will need the following part e 82943001 Power Carriage Remove the four screws securing the power carriage cover and set aside Bring the power carriage cable two pin connector from the cable track over to the motor mount 3 Secure the strain relief to the side of the power carriage motor mounts 4 Place the power carriage motor assembly near the motor mount and plug the motor connector into the power carriage cable 5 Secure the power carriage cover using the four screws removed earlier 6 Verify the carriage moves without binding Refer to Final Adjustments and Tests on page 2 46 oa L Figure 2 38 Install the Power Carriage 2 44 A a In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide lt INSTALLATION s Tire Stop Installation TIRE STOP INSTALLATION If you ordered the optional wheel clamp refer to Wheel Clamp on page 3 17 for instructions
5. i SHR A Ky 15 24 cm 6 00 in PDOO1 7 62 cm 3 00 in gt lt Figure 2 3 Drum Module Placement in Pit Left Side Eddy Current Brake E ia Be we 15 24 cm 6 00 in PD024 7 62 cm gt q 3 00 in Figure 2 4 Drum Module Placement in Pit Right Side Eddy Current Brake 2 9 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 r Eddy Current Brake EDDY CURRENT BRAKE This section will walk you through removing the eddy current brake or retarder from the crate and attaching the brake to your dyno To route and wire the temperature sensor cable and the theta controller to the Breakout board refer to Routing the Eddy Current Brake Battery and Dyno Power Cables on page 2 38 and Wiring the Breakout Board on page 2 42 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 par
6. eddy current brake cable 2 38 Route the eddy current brake cable P N 66952005 from the eddy current brake through the designated power pit conduit and to the theta controller Route the battery cable P N 76950312 from the CPI through the same conduit and over to the battery Refer to the steps and Figure 2 34 on page 2 39 for instructions on connecting the battery and starter cables Note Be sure to keep the power and communications cables in different pit conduits Route the temperature sensor cable from the eddy current brake through the designated pit conduit and to the break out board see Figure 2 37 Route the dyno power cable from the CPI to your power source but do not plug it in at this time fad g a ye d theta f controller EN o OAS temperature 4 sensor cable battery cable starter cable battery SSSA T A PD169 route power cables starter in designated conduit Figure 2 33 Route the Eddy Current
7. 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 1 9 lt CHAPTER 1 b Dyno Electronics DYNO ELECTRONICS The standard dyno electronics package is comprised of four interconnected modules Atmospheric Sensing Module RPM Module Dynamometer Input Output Module and the CPU Module For more information refer to your WinPEP 7 User Guide P N 98128104 9 pin hand held pendant system expansion connector RPM inductive pickup socket 25 pin socket atmospheric sensing module 1a RPM module power 9 pin RS 232 socket 3 pin power plug Figure 1 3 The Dyno Electronics 1 10 A 7 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS Verify the Pit Dimensions VERIFY THE PIT DIMENSIONS Before placing the dyno in the pit take a moment to verify that the dimensions of the pit are correct Refer to the pit dimensions P N 98229102 y
8. 2 20 A 5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 INSTALLATION g A Blower and Monitor Support Installation BLOWER AND MONITOR SUPPORT INSTALLATION Use the following instructions to install the blower mounts monitor support and junction box along with the high pressure blower assemblies and monitor tray You will need the following parts 21221500 21228000 61329101 Blank Plate Junction Box Junction Box Base Monitor Tray The following parts are included in the Monitor Support P N 61329003 26215520 35521420 61329100 61329500P Washer 1 8 Poly 3 Cap Plug 4 Monitor Arm 2 Monitor Support The following parts are included in the Blower Assembly P N 76722005 21600015 26215220 26215520 26215521 35521420 35712991 37513200 61328101 61329601 63413001 DM150 002 007 DM150 019 012 Lower Blower Arm 2 Washer 3 8 Metal 2 Washer 1 8 Poly 4 Washer 1 4 Poly 4 Cap Plug 8 Clamp Lever 2 Anchor Redhead 3 8 8 Blower Housing Assembly 2 Blower Mount 2 Upper Blower Arm 2 Washer 5 16 Flat 8 Bolt 3 8 16 x 1 Hex 8 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 2 21 z9 CHAPTER 2 f Blower and Monitor Support Installation MARK AND DRILL BLOWER MOUNTS AND SUPPORT ARM MOUNTING HOLES 1 Using the carriage mounting plate and the dyno frame as reference position the support arm and opti
9. ACCESSORIES os 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 Use the red brake button on the pendant or the emergency stop button on the control panel to activate and deactivate the brake Listen for air leaks and double check all connections 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 3 9 CHAPTER 3 x9 Air Brake CHANGING THE BRAKE PADS PS WARNING To prevent possible injury disconnect the battery and unplug the dyno Open the CPI s front panel access and turn off the main breaker Unplug the dyno power cable Refer to page 3 2 Remove the eight button head screws se
10. 2 13 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide f straight edge 2 14 z9 CHAPTER 2 Eddy Current Brake 3 Remove the eight bolts washers and six nuts from the dyno frame where the connector plates will attach where the connector plate attaches to the starter brace there are only two nuts Refer to Figure 2 9 4 Remove the starter brace and set aside Only remove the starter brace when installing the eddy current brake on the left starter side of the dyno 5 Keeping the panels parallel slide the eddy current brake towards the dyno Slide the coupler over the key on the dyno shaft You will need to support the coupler as you slide it onto the dyno shaft 6 Continue sliding the eddy current brake towards the dyno until the uprights on the brake and dyno are flush 7 Loosely secure the connector plates to the dyno frame using the eight bolts washers and six nuts removed earlier Note Do not tighten the bolts 8 Verify the uprights on the drum and eddy current brake modules are flush with the top of the pit floor before you tighten the connector plates 8a Loosen all upright bolts 8b Place two straight edges across the drum module uprights as shown 8c With the upright tight against the straight edges tighten the connector plate bolts and nuts on the drum module Note You can use c clamps to attach the upright to the straight edges to make this quicker Tighten the c clamps until
11. RES EAR CH INSTALLATION GUIDE For In Ground Model 200iP and 250iP Motorcycle Dynamometers P N 98229103 04 2004 2011 Dynojet Research Inc All Rights Reserved Installation Guide For In Ground Model 200iP and 250iP 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 98229103 Version 4 03 2011 Dynamometer Number Eddy Current Brake Retarder Number TABLE OF CONTENTS WARNINGS s
12. 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 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide APPENDIX B r 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 ANT 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 measuring 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 In Ground Model 200iP 250iP 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 config
13. 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 47 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 2 ry Pit Covers PIT COVERS Before installing the covers be sure to install the battery pickup card eddy current brake air brake EEC Kit and any accessories you may have purchased with your dyno This section describes how to install the pit covers and drum guards You will need the following parts 21226104 21226105 21226106 21229111 21624103 36561045 36580434 DM150 020 005 Right Pit Cover Left Pit Cover Eddy Current Brake Pit Cover Drum Guard Side 2 Drum Guard Mounting Bracket Screw 1 4 20 x 5 8 Pan Head Torx 12 Bolt 3 8 16 x 1 2 Button Head Flange Allen 12 Nut crush 1 4 20 4 CHANGING THE EDDY CURRENT BRAKE COVER FOR RIGHT SIDE INSTALLATIONS This installation has been designed for the eddy current brake to be installed on the left side of the dyno Contact Dynojet for information regarding installation on the right If you ordered an eddy current brake retarder and plan to mount it on the right side you will need to change the eddy current brake cover PDO20
14. Suzuki White or Black Blue Triumph Brown Yellow Yellow Blue Green Black Black Green Yamaha Orange or Gray In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide oe 5 7 49 CHAPTER 5 Y Connecting the RPM Pickup CONNECTING THE SECONDARY INDUCTIVE PICKUP If the primary wire is not accessible connect a secondary inductive pickup to an available spark plug wire The secondary inductive pickup cannot be in contact with or it s connecting wire be crossing other engine electrical wires or stray RF interference may result You will need the following part e DE100 109S Secondary Inductive Pickup 2 1 Clip the secondary inductive pickup around one spark plug wire Route the inductive pickup cable to the RPM Module making sure the cable is clear of devices that produce electronic noise spark plug wires coil wire coil etc 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 Note When using one secondary pickup disconnect the other pickup from the dyno electronics connect secondary pickup to an available spark plug wire primary gt Secondary secondary firir Taraan from battery source ami
15. eee eee eee 4 8 Maintenance and Troubleshooting 2 00 eee eee eee eee 4 9 Maintaining and Troubleshooting the Wheel Clamp 4 9 Replacing the Theta Controller Fuses 0 0 00 eee eee eee 4 10 Troubleshooting CPI Fuses 2 ee eee eee ene 4 11 Basic Dyno Operation Loading the Motorcycle s s 2 ss guu koiw ead Save cag aty tote tule ttle 5 2 Connecting the RPM Pickup 4345434 cede dade ds Ga sntoke nese 5 5 RPM Pickup Descriptions 0 0 e eee eee eee eee 5 5 Connecting the Primary Inductive Pickup 22 00085 5 6 Connecting the Secondary Inductive Pickup 4 5 8 Pre run IMS PECtON S ai oo 3 ok fe NS nk hee i A Ae Ak did fe 5 10 Before Starting the Engine 0 ee eee ee ee eee 5 11 Engine Warm Upy cs csi eee eae eas aes eee ewe ee ele os ale ey 5 11 After Engine Warm Up 2 eee ee ee ee ene 5 11 Making a Test ROn 2 24 03 eee oe ueei idee ede keke es oe own ees 5 12 Preventative Maintenance oo cece ie ee kee eee ee esas 5 13 Red Head Anchor Installation WV ANNU Sesoitig Miao eae e it s eE Gad man ew waren ts A 1 Contact Information for ITW Ramset Red Head A 1 mistaa aes ada aa eer ea a aaa RR REE ts A 2 Power Requirements and Installation Locations Using 60 Hz Power North America and Japan B 2 Installing the Wall Receptacle 22 eee eee ee B 3 Testing for Correct Voltag
16. route power cables in designated conduit Version 4 lt INSTALLATION Routing Cables ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES The wheel clamp is an optional accessory If you did not order this accessory it is still necessary to route the cables to the junction box After you install the wheel clamp you can finish routing the cables refer to Wheel Clamp on page 3 17 for installation instructions 1 Route the power carriage cable P N 76950314 from the CPI through the designated power pit conduit through the pit and out of the pit as shown in Figure 2 32 2 Route the wheel clamp cable P N 76950313 from the CPI through the same conduit and along the same path as the power carriage cable Note Be sure to keep the power and communications cables in different pit conduits 3 From the pit route both cables through the junction box 4 Press each cable into the cable track cable track PD168 Figure 2 32 Route the Power Carriage and Wheel Clamp Cables 2 37 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 Routing Cables ROUTING THE EDDY CURRENT BRAKE BATTERY AND DYNO POWER CABLES 1 dyno power cable dyno electronics
17. 30 CHASSIS SPECIFICATIONS description specifications Length with standard carriage allow 304 80 cm 120 00 in with extended carriage allow 355 60 cm 140 00 in pit covers 137 16 cm 54 00 in Height from bottom of dyno to top of dyno 45 72 46 67 cm 18 00 18 38 in from top of pit to drum guard 5 40 cm 2 13 in from top of pit to top of tire carriage 50 64 cm 16 00 in Width dyno with eddy current brake 179 07 cm 70 50 in pit covers with eddy current brake 208 28 cm 82 00 in Weight model 200iP drum module crated dyno 725 kg 1600 pounds 817 kg 1800 pounds model 250iP retarder module crated dyno 953 kg 2100 pounds 1 043 kg 2300 pounds Drum diameter 45 72 cm 18 00 in width 50 80 cm 20 00 in Frame structural steel channel and angle Maximum Speed 322 KPH 200 MPH Maximum Motorcycle Length front of front wheel to center of rear wheel standard carriage 213 00 cm 84 00 in extended carriage 256 54 cm 101 00 in Remote Switches remote software control 1 5 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 1 6 CHAPTER 1 Dynamometer Specifications and Requirements standard carriage 304 80 cm 120 00 in extended carriage 355 60 cm 140 00 in 45 72 46 67 cm MONS Ee A eee oe 18 00 18 38 in Ny ll d4 a 208 28 cm 179 07 cm 82 00 in 70 50 in A a a cm 30 00 in Figure 1 1 Model 250iP Dyno Dimensions In Ground Model 200iP 250iP Mo
18. 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 recommended 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Ay APPENDIX A fy Installation INSTALLATION Use the table below to determine the catalog number drill
19. 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 In Ground Model 200iP 250iP 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 200iP 250iP dyno is designed to carry a group 24 deep cycle discharge series battery for operating the starter power carriage and optional wheel clamp The typical dimensions for this series of batteries are 27 cm long by 17 cm wide by 23 cm tall 10 625 inches by 6 75 inches by 9 125 inches The mounting is flexible so a battery that has dimensions close to this will work satisfactorily The built in battery cables are configured for top post batteries This battery is not included with your dyno You will need to provide this battery For more information on installing the battery refer to Installing the Battery on page 2
20. 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 PN 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CONTROL PANEL INTERFACE OPERATION amp Basic CPI Operation CLOSING THE WHEEL CLAMP AUT 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 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 a For proper and safe operation the wheel clamp must grip the wheel as well as the tire If the
21. before proceeding Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken Verify brake operation before beginning any dynamometer testing Verify the vehicle is properly secured to the dynamometer Never operate the blowers without the guards installed Exercise care with any dynamometer testing portions of the dynamometer and vehicle may become hot As with any equipment using electricity and having moving parts there are potential hazards To use this dynamometer safely the operator should become familiar with the instructions for operation of the dynamometer and always exercise care when using it Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically recommended in published user repair instructions that you understand and have the skills to carry out Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS Thank you for purchasing Dynojet s In Ground Model 200iP 250iP Motorcycle Dynamometer Dynojet s software and dynamometers will give you the power to get the maximum performance out of vehicles you evaluate Whether you are new to the benefits of a chassis dynamometer or an experienced performance leader the repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer will give you the professional results you are looking for This document provides instruction
22. 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 d GHo01 Figure A 1 Red Head Anchor Drill the Hole 2 Insert the anchor anchor GH002 Figure A 2 Red Head Anchor Insert the Anchor A 2 EEFAJ In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide RED HEAD ANCHOR INSTALLATION lt Installation 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 AN S N x N NANANA QQAA L NN GANN QQQAY NO AD Yj Uy LL YpyyyYY ss YL SS GH003 Head Anchor Drive the Anchor Flush om 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 installation setting tool GH004 Figure A 4 Red Head Anchor Expand the Anchor A 3 Version 4 In Groun
23. cable s into the cable holder e Pendant Cable e Control Panel Cable e RPM cable s e Additional cables if desired cable holder ee l a cable s KX guide body ee ie end of cables oo Figure 2 50 Insert Cable s Into Cable Holder 3 Rotate the cable holder closed 4 Insert the guide body into the zip tube Note Make sure you start the cable wrap tool close to the end of the cables This will make it easier to pull the tool along the length of the cables 5 Pull the cable wrap tool through the zip tube along the length of the cables cable wrap tool hy CIJ end of cables Figure 2 51 Securing Cable s Into the Zip Tube 2 56 eye In Ground Model 200iP 250iP 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 follo
24. components or wiring Disconnect all power cords before servicing electrical components for the greatest assurance of safety In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide P vi WARNINGS y AC Electrostatic Discharge Precautions Electrostatic Discharge Electrostatic Discharge ESD or static shock can damage electronic components within the dynamometer The damage may occur at the time of an ESD occurrence or the shock may degrade the component resulting in a premature component failure later To avoid ESD damage always practice good ESD control precautions when servicing the dynamometer Dynojet designs its 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 that person s energy is discharged directly to the electronics the electronics can be damaged Precautions To protect against ESD damage you must eliminate the difference of potential before the electronics are handled Touch the chassis of the dynamometer before touching any of the electronics By touching the chassis you discharge any static shocks to the chassis ins
25. 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 ATT Equipment Power Requirements The dynamometer has specific power requirements Connecting the dynamometer to the incorrect voltage will void the dynamometer warranty Installation may require a licensed electrician 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
26. eee 2 9 Eddy Current Brake lt cccdetcedecet tute bsuvevevivedess eeseeeeeas 2 10 Unpacking the Eddy Current Brake 20 e eee eee eee 2 11 Installing the Eddy Current Brake 2 2 0 2 eee eee eee 2 13 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide TABLE OF CONTENTS AR Chapter 3 Secure the Drum and Brake Module to the Pit Floor 2 16 PICKUP Cad ss000ssssi000s3seeereerve EEEE EEE GERERE 2 17 Carriage Plate and Tire Carriage ss ssecvevsedeeouweuanwend os 2 18 Installing the Carriage Plate 2 eee eee 2 18 Installing the Tire Carriage 2 eee eee eee 2 20 Blower and Monitor Support Installation 00 2 21 Mark and Drill Blower Mounts and Support Arm Mounting Holes 2 22 Installing the Monitor Support and Junction Box 2 23 Installing the Blower Assemblies 0 00 0 e ee eee eee eee 2 24 Installing the Monitor Arms and Monitor Tray 0 2 25 Cable Track INnstallghiOn 222ccccerescecasuuuuuedeeuwewetwowtens 2 26 Routing Cables sscevebeseseteccciccicigedegacead ehatesetecenss 2 28 Battery Requirements 0 0 cece eee eee eee 2 29 Installing the Battery 2 eee ene 2 30 Accessing the GPI isasssand ech ceeds creed etodoc read etaaoere 2 31 Routing the Control Panel and Pendant Cables 2 32 Routing the High Pressure Blower Cables 200005 2 36 Routi
27. 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 next bike to be loaded easily 4 7 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide a9 CHAPTER 4 r Power Distribution Assembly POWER DISTRIBUTION ASSEMBLY The Power Distribution Assembly inside the CPI has three circuit breake
28. instructions for North America and Japan The model 200iPX 250iPX 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 200iPX 250iPX 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 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 ANE 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 shou
29. 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 30 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 56 and skip the following steps Route the cable bundle along the support arms with service loops to allow movement as shown below In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Ss Routing Cables 13 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 install control pod spindle if you did not purchase the monitor tray dyno electronics Lo a o l Y j ae TN control panel place pendant here CPI PD166 Figure 2 30 Install the Control Panel 2 35 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 r Routing Cables ROUTING THE HIGH PRESSUR
30. 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 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 es PAN 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 Air Fuel Ratio Module Installation and User Guide for proper operating and maintenance procedures P N 98295110 Failure to follow proper procedures may result in inaccurate data or damage to the equipment This manual can be found on your WinPEP CD or at www dynojet com 4 3 In Ground Model 200iP 250iP Motorcycle Dynamometer Ins
31. on the wheel clamp with the holes on the carriage 3 Secure the wheel clamp to the carriage using four 3 8 16 x 1 inch bolts four 5 16 inch lock washers and four 5 16 inch flat washers Figure 3 20 Secure the Wheel Clamp to the Carriage 3 18 A 5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide ACCESSORIES 5 Wheel Clamp 4 Bring the wheel clamp cable three pin connector from the cable track over to the wheel clamp This cable was routed on page 2 37 5 Install the wheel clamp cable strain relief to the side of the wheel clamp 6 7 Replace the wheel clamp cover Plug the wheel clamp cable into the connector on the wheel clamp motor strain relief wheel clamp cable DY Vlg A i K 1 E ye Sh ca wheel clamp ig motor connector cable track Figure 3 21 Secure the Strain Relief and Cable 3 19 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 3 r Wheel Clamp 8 Place the wheel clamp cover on the wheel clamp 9 Secure the cable track to the wheel clamp as shown in Figure 3 22 using one 1 4 20 x 1 inch screw removed earlier 10 Secure the wheel clamp cover using the remaining five 1 4 20 x 1 inch screws removed earlier wheel clamp cover cable track screw Figure 3 22 Install the Cable Track WHEEL CLAMP FINAL ADJUSTMENTS AND TESTS 1 Place a stack of catalogs into the w
32. outlet 3 Turn on the main breaker inside the CPI door Note Use the main breaker to turn power on and off to the dyno power plug main breaker Figure 2 40 Turn on the Dyno Power 2 46 A 3 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Ss Final Adjustments and Tests HIGH PRESSURE BLOWER TEST Test the blowers by pressing the appropriate buttons on the control panel If the right hand blower turns on when the left hand blower button is pressed shut off the blowers and switch the cables at the junction box POWER CARRIAGE FINAL ADJUSTMENTS AND TESTS The power carriage allows you to easily adjust for various wheel bases distances with the press of a button Refer to Using the Power Carriage on page 4 5 for more information on using the power carriage To route the power carriage cables refer to Routing the Power Carriage and Wheel Clamp Cables on page 2 37 Using the Control Panel press the carriage forward and backward buttons and verify that the motor does turn WHEEL CLAMP FINAL ADJUSTMENTS AND TESTS The wheel clamp is an optional accessory To install the wheel clamp refer to Wheel Clamp on page 3 17 To route the wheel clamp cables refer to Routing the Power Carriage and Wheel Clamp Cables on page 2 37 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
33. 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 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide y B 10 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 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 colors are brown gray black and green yellow 1 Connect 240VAC single phase power between the brown and the gray wire connection points 2 Connect the green yellow wire to the ground connection point Cut off the gray wire Q 4 Refer to the previous table for testing and probe the new connections as follows e black wire as location 1 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 wit
34. switches are the only adjustments 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide THETA CONTROLLER Ss 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
35. the Emergency Stop Sticker 0 0 00 02 eee eee 3 5 Air Brake Final Adjustments and Tests 0 0 0 eee eee eee 3 9 Changing the Brake Pads 0 cee eee eee nee 3 10 Adjusting the Brake Pad Clearance 0 0c eee eee eee 3 15 Compressed Air Pump Assembly sa ccvcedsiedeieded kd vee ewes 3 16 WEEN cca encees cohvegeas ca aenete Feces Cee Eee 3 17 Installing the Wheel Clamp 0 2 e eee eee eee eee eee 3 17 Wheel Clamp Final Adjustments and Tests 0 00000 3 20 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Chapter 4 Chapter 5 Appendix A Appendix B Version 4 TABLE OF CONTENTS Control Panel Interface Operation Basic CPI Operation 44634 o25 06 06 06 628s n cites tee dee wee ees ee es 4 2 Using the Air Fuel Ratio Air Pump 0 20 eee eee eee eee 4 3 Using the Emergency Stop Dyno Shutdown 006 4 4 Using the High Pressure Blowers 0 2 00 e eee ee eee eee 4 4 Understanding Interlocks 2 0 2 0 eee eee ee tenes 4 4 Using the Power Carriage 2 eee ee eee eens 4 5 Using the Starter 3 2 5 tats sea ese een tind es 4 5 Using the Status Indicator 2 2 eee eee 4 6 Using the Wheel Clamp 002 e eee 4 6 Power Distribution Assembly v 63 5 55 c5 50404540424ne wana cacedane 4 8 Main Circuit Breaker 2 0 1 eee eee nee 4 8 High Pressure Blower Circuit Breakers 0 000
36. 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 4 9 CHAPTER 4 Maintenance and Troubleshooting REPLACING THE THETA CONTROLLER FUSES NA Hazardous voltage To avoid risk of electrical shock disconnect the battery and unplug the dyno 1 Remove the Control Panel Interface CPI cover and set aside Refer to Accessing the CPI on page 2 31 2 Gently push the fuse holder slightly inward and rotate counterclockwise Remove the fuse holder Replace the fuse with a fuse type listed below 4 Replace the CPI cover using the eight button head screws removed earlier AWD For continued protection against risk of fire replace only with a fuse of the same type and having the same electrical rating Qe 240V Theta Controller Fuses 120V Theta Controller Fuses e Buss P N BAF 15 15A Fuse e Buss P N BAF 25 25A Fuse e Little Fuse KLK 15 e Fast Blow Dynojet P N 54212501 e Fast Blow Dynojet P N 54211501 theta controller fuses A MC133 Figure 4 3 Theta Controller Fuses 4 10 ayaa In Ground Model 200iP 250iP Motorcycle Dynamometer In
37. to manual S ys 6 N fefer to manu WHEEL CLAMP O Steady indicator light wheel i i secure WARNING OPEN AWARNI NG Risk of injury A F RATIO Eye and Ear protection required Cc A R R l A G EX EON J Read and follow all oa instructions and safety precautions STARTER FRONT WHEEL MUST BE SECURED AT ALL TIMES TIE DOWN STRAPS MUST BE USED TO STABILIZE THE MOTORCYCLE 97415160 03 Figure 4 1 Control Panel Features 4 2 In Ground Model 200iP 250iP 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 of 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
38. 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 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 number of cylinders For example the number of degrees between plug fires on a V 8 engine with a single coil is 720 8 90 degrees 5 5 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 49 CHAPTER 5 Y Connecting the RPM Pickup CONNECTING THE PRIMARY INDUCTIVE PICKUP The primary inductive pickup cannot be in co
39. 250iP Motorcycle Dynamometer Installation Guide 3 5 CHAPTER 3 r Air Brake 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 Unscrew the black switch body nut and remove the switch body Set the nut and switch body aside switch body D gt L CP033 Figure 3 6 Removing the Switch Body 3 6 Rape In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide ACCESSORIES 5 Air Brake 4 Place the emergency stop sticker over the dyno shutdown sticker place emergency F stop sticker here Q 97415160 OL co CP015 Figure 3 7 Placing the Emergency Stop Sticker 3 7 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 3 8 CHAPTER 3 Air Brake 5 Secure the switch body to the control panel using the switch body nut removed earlier switch body nut switch body i central panel 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4
40. 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 1 9 battery 1 5 chassis specifications 1 5 compressed air 1 8 computer specifications 1 8 drill and drill bit 1 8 environmental 1 8 forklift 1 8 phone internet access 1 9 power 50 Hz B 7 power 60 Hz B 2 tie downs 1 9 retarder see also eddy current brake right blower assembly installing 2 24 routing cables 2 28 2 41 25 pin 2 40 9 pin 2 40 air fuel sensor 2 41 air pump power 2 41 battery 2 38 2 39 blowers 2 36 control panel 2 32 dyno electronics 2 40 dyno electronics power 2 41 dyno power 2 38 eddy current brake 2 38 pendant 2 32 pickup card 2 40 power carriage 2 37 starter 2 39 Index iii In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INDEX wheel clamp 2 37 RPM pickup 5 5 5 9 connecting 5 5 5 9 primary inductive pickup 5 6 secondary inductive pickup 5 8 S secondary inductive pickup 5 8 setting tool A 3 specifications 1 5 1 9 starter routing cable 2 39 using 4 5 starter brace 2 14 status indicator 4 3 4 6 support arm anchor placement 2 22 installing 2 23 remove from crate 2 2 T technical support 1 3 temperature sensor cable routing wiring to breakout board 2 42 testing high pressure blowers 2 47 testing voltages 50 Hz B 9 60 Hz B 4 theta controller dip switches D 2 power adjustment D 2 power line freq
41. 8 using 4 4 brake pads 3 10 3 14 3 15 5 13 brake pressure 5 13 breakout board pickup card 2 40 2 42 breakout board wiring jumpers 2 42 temperature sensor 2 42 theta controller 2 42 C cable cover 2 55 cable track 2 27 cable track adapter bracket 2 45 cable track mounting bracket 2 27 cable wrap tool 2 56 cables blower 2 36 high pressure blower 2 36 routing air brake 3 3 carriage plate 2 18 2 19 anchor placement 2 19 installation 2 18 ce drum guards see EEC finger guards certification 1 3 chassis specifications 1 5 height 1 5 length 1 5 width 1 5 compliance testing 1 3 compressed air 1 8 compressed air pump 3 16 computer specifications 1 8 connecting power to the dyno 50 Hz B 11 60 Hz B 6 connector plate 2 11 control panel 4 2 air pump 4 3 Index i In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INDEX blowers 4 3 4 4 dyno shutdown 4 3 4 4 emergency stop 4 3 4 4 features 4 2 4 3 installing 2 34 power carriage 4 3 4 5 routing cables 2 32 starter 4 3 4 5 status indicator 4 3 wheel clamp 4 3 4 6 control panel interface basic operation 4 2 4 7 battery charger 2 29 removing the cover 2 31 conventions 1 3 coupler 2 14 set screws 2 15 CPI removing the cover 2 31 routing cables 2 32 CPU module 2 40 crate remove dyno 2 8 remove tire carriage 2 2 unpacking eddy current brake 2 11 D dimensions 1 6 dip switches D 2 disclaimers v document part number 1 1 door sa
42. ACK INSTALLATION You will need the following parts e 134260301 Nut 4 40 Hex 4 e 136206141 Screw 4 40 x 3 8 Flat Head 6 e 21228520 Cable Hole Cover Track Mount e 21626217 Cable Track Mounting Bracket e 43432150 Cable Track 1 Secure the cable hole cover track mount to the junction box using two 4 40 x 3 8 inch flat head screws PD162 cable hole cover track mount junction box Figure 2 21 Install the Cable Hole Cover Track Mount 2 26 ayn In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 INSTALLATION S Cable Track Installation Secure the cable track to the cable hole cover track mount on the junction box using two 4 40 x 3 8 inch screws and two 4 40 nuts Secure the cable track mounting bracket to the cable track using two 4 40 x 3 8 inch screws and two 4 40 nuts Figure 2 22 Install the Cable Track and Mounting Bracket In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 2 27 z9 CHAPTER 2 r Routing Cables ROUTING CABLES The CPI and dyno electronics must be placed near the conduits in the pit Be sure to keep the power and communications cables in different pit conduits For the following instructions we will designate the pit conduits as shown in Figure 2 23 cable track n ee fad 4 junction box g g EAS monitor support and tray A a route co
43. APTER 3 Air Brake 5 Route the air brake air hose through the access hole in the drum module upright and through the pit conduit 6 Connect your clean dry shop air supply 60 psi 415 kilopascal max constant line pressure to the air hose to 60 psi clean dry air pit conduit access hole air brake Figure 3 3 Connecting the Air Hose In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide PD179 Version 4 ACCESSORIES 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 1b 1c 1d le Remove the two nuts from the top of the cover and set aside Remove the screw on the top of the cover and set aside Remove the screw on the side of the cover and set aside Remove the four screws on the back of the cover and set aside Remove the control panel rear cover and set aside Figure 3 4 Remove the Control Panel Rear Cover In Ground Model 200iP
44. Brake Battery and Power Cables agama In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Ss Routing Cables 5 Connect the battery and starter cables Be sure to route the cables through the cable routing bracket Secure the cables to the bracket using cable ties 5a Attach the brown cable to the positive battery post 5b Attach the red battery cable to the positive battery post and to the large stud on the starter solenoid 5c Attach the blue and yellow cable to the negative battery post 5d Attach the black battery cable to the negative battery post and to the grounding location on the starter brace 5e Attach the blue cable to the starter solenoid brown cable blue yellow cable battery cable black cable battery cable routing bracket red cable starter brace blue cable starter solenoid Figure 2 34 Connect the Battery and Starter Cables 2 39 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 r Routing Cables ROUTING 1 pickup card 9 pin cable to computer dyno electronics THE PICKUP CARD AND DYNO ELECTRONICS CABLES Route the pickup card cable P N 66953002 from the CPI through the designated pit conduit and over to the pickup card Attach the cable to the pickup card Note Be sure to keep the power and communications cables in diff
45. 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 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 PN WARNING 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION J Pre run Inspection N 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 car
46. Cover and End Cap s JUNCTION BOX COVER CABLE COVER AND END CAP Before installing the junction box cover cable cover and end cap be sure to route all of your cables You will need the following parts e 21228517 Cable Routing Cover e 21228519 Cable Channel End Cap e 21228521 Junction Box Cover e 21626902 Cable Cover Pit to Junction Box e 36540643 Screw 8 32 x 3 8 Pan Head Phil 13 1 Secure the junction box cover to the junction box using two 8 32 x 3 8 inch pan head screws 2 Secure the end cap to the pit cover using two 8 32 x 3 8 inch pan head screws 3 Secure the cable cover to the end cap using four 8 32 x 3 8 inch pan head screws 4 Secure the cable cover to the junction box cover using one 8 32 x 3 8 inch pan head screw Note Verify the cables are placed inside the cable cover 5 Secure the cable routing cover to the right side pit cover using four 8 32 x 3 8 inch pan head screws junction box cover cable cover cable routing cover Figure 2 49 Install the Junction Box Cover End Cap and Cable Cover 2 55 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 2 pry 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 You will need the following part e 43400000 Cable Harness Wrap Kit 1 Rotate the cable holder to the open position 2 Insert the
47. Dynamometer Installation Guide CHAPTER 2 Z Dyno Drum Module Installation REMOVING THE DYNO FROM THE CRATE This section will walk you through removing the dyno from the crate and installing the dyno in your pit You will need to provide equipment capable of lifting a minimum of 1 089 kg 2400 1b to lift the dyno drum module off the crate and into position in your dyno room You will also need a pair of straps capable of supporting 1 089 kg 2400 lb to attach to the dyno Dynojet recommends using a single loop style strap SQN Be sure you record the dynamometer number on the inside cover of this manual 1 Remove the four lag bolts and washers securing the drum module to the crate base using a 9 16 inch socket open or box end wrench 2 Wrap the single loop straps around the drum module shaft 3 Lift the drum module off the crate and move into position in your pit dyno number stamped on frame not visible Figure 2 2 Remove the Dyno From the Crate Base 2 8 M In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Ss Dyno Drum Module Installation PLACING THE DYNO IN THE PIT Place the drum module in the pit as shown Note This installation has been designed for the eddy current brake to be installed on the left side of the dyno Contact Dynojet for information regarding installation on the right g e gt
48. E BLOWER CABLES The high pressure blowers are an optional accessory If you did not order the high pressure blowers it is still necessary to route the blower cables to the junction box 1 Route each blower cable P N 76950315 from the CPI through the designated power pit conduit through the pit and out of the pit as shown Note Be sure to keep the power and communications cables in different pit conduits 2 From the pit route both cables into the junction box 3 Attach the two blower connectors to the junction box using 4 40 screws Note The blower connectors are attached to the blower cables 4 Connect the cables from each blower to the connectors on the junction box Note There is an extension cable P N 76950317 for the blower furthest from the junction box Plug the power cord from this blower into the supplied blower extension cable and into the power source located at the junction box blower connectors in junction box mi A HP a extension dyno cable electronics J A US b i eS ON lo route power cables in designated conduit PD167 Figure 2 31 Route the High Pressure Blower Cables 2 36 aya In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide electronics dyno CPI
49. OR AND DYNO ELECTRONICS POWER CABLES 1 Route the air pump power cable P N 76950318 from the CPI to the air pump 2 Route the air fuel sensor cable P N 76950701 from the dyno electronics to the air pump 3 Route the dyno electronics power cable to your power source Refer to Dyno Electronics on page 1 10 for the dyno electronics power cable location E oe m a dyno electronics g power cable Ye i 1 dyno electronics a SA ON b ke CPI air fuel sensor cable PD171 air pump assembly air pump power cable Figure 2 36 Route the Air Pump Power Air Fuel Sensor and Dyno Electronics Power Cables 2 41 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 2 42 z9 CHAPTER 2 Routing Cables WIRING THE BREAKOUT BOARD 1 Attach the temperature sensor cable to the Breakout board The temperature sensor cable has five wires which connect to the wiring block labeled TEMP This cable was routed to the Breakout board on page 2 38 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 Attach the theta controller cable to t
50. R 2 f Pit Covers INSTALLING THE PIT COVERS 1 Place the eddy current brake cover over the brake module 2 Loosely secure the eddy current brake cover using four 3 8 16 x 1 2 inch button head flange screws Do not tighten gE lt 8 E Figure 2 44 Install the Eddy Current Brake Cover Note If this is a European dyno you will need to install the EEC finger guards Refer to Appendix C for EEC finger guard installation instructions 2 50 eye In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION gt Pit Covers W 3 Loosely attach the drum guard bracket to the left side drum cover using four 1 4 20 x 5 8 inch pan head torx screws Note Dynojet recommends using a T30 Torx driver Snap On PFTx30E to secure the 1 4 inch screws For dynos with serial numbers lower than 2030152 Dynojet recommends using a hardened 5 32 inch hex driver such as Snap On Fa5E to attach the 1 4 inch screws A standard allen key may round off in the shallow screw head ACAN T EE drum guard bracket Figure 2 45 Install the Drum Guard Bracket 2 51 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 2 ay Pit Covers Place the left side drum cover over the drum module 5 Verify all the cables are routed under the left drum cover and through the cable routing Opening 6 Loosely secure the left side drum cover using four 3 8 16 x 1 2 inch butt
51. adjusting the power carriage every five minutes Recharging from use of the built in dyno starter will take longer Do not add any external battery chargers to the car battery Note If you do not install the battery make sure the positive battery cable is insulated from the chassis as the charging circuit is always providing charging current whenever the dyno main power breaker is turned on The battery charging circuit is active anytime the main power on the dyno is turned on If the main breaker is turned off then the battery will not be charged Frequent use of the starter will quickly deplete the battery and it may need several hours of the internal charging to bring the battery back to a full charge For more information on installing the battery refer to page 2 30 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
52. apable of drilling holes in concrete Refer to Appendix A for more information on installing Red Head Anchors e drill bit size 1 2 inch minimum hole depth 1 5 8 inch 41 2 mm ELECTRICAL REQUIREMENTS The Model 200iP 250iP dynamometers require a 240V 30a single phase electrical circuit for reliable and precise operation No other loads should be plugged into these circuits and these circuits should be independent of the lighting in the dyno room Before you plug in your dyno you or your electrician must refer to Appendix B for detailed information ENVIRONMENTAL REQUIREMENTS description specifications 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide You will need to provide equipment capable of lifting a minimum of 1 043 kg 2300 1b to lift the dyno off the crate and into position in your dyno room You will also need a pair of straps capable of supporting 1 043 kg 2300 Ib to attach to the dyno Dynojet recommends using single loop style straps Version 4 SPECIFICATIONS AND OPERATING REQUIREMENTS ons Dynamometer Specifications and Requirements PHONE AND INTERNET ACCESS Dynojet recommends you have a phone close to the dyno to call for assistance in an emergency You may also wish to contact Dynojet to troubleshoot your dyno
53. ay 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION Les Locations Using 60 Hz Power North America and Japan 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
54. be mounted at the entry of the dyno room 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 door safety switch and the air brake will release and the status light will be on steady C 5 In Ground Model 200iP 250iP 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide y D 2 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 ANTA 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 ANTE The two dip
55. bon monoxide gas Breathing it could cause death Operate machine in well ventilated area ENGINE WARM UP Warm the vehicle 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 11 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide f 5 12 49 CHAPTER 5 Making a Test Run y 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 mph 4 Test the tachometer operation 4a Rev the engine The gauges on the computer screen should be mo
56. 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CONTROL PANEL INTERFACE OPERATION Basic CPI Operation USING THE POWER CARRIAGE This accessory requires the CPI and battery to operate Use the control panel to activate the power carriage allowing you to center the bike s rear tire on the dyno drum The power carriage and wheel clamp cannot be activated at the same time Note When operating the power carriage with a bike on the dyno make s
57. ce and troubleshooting information for the wheel clamp and CPI fuses To maintain proper dynamometer operation Dynojet recommends 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 Air Pump Filter clean the filter daily or more often depending on usage Change the filter when necessary 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 Dyno Bearing Grease Under steady use over 25 runs per day each bearing should receive 650z of a recommended grease every 2 months Under occasional use less than 25 runs per day each bearing should receive 650z of a recommended grease every six months Recommended Grease grease specification description thickener Lithium 12 Hydroxy Stearate oil Petroleum thickness NLGI 2 operating temperature 20 F to 200 F intermittent to 250 F EP additive yes examples Mobil Mobilith AW 2 5 13 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi Set II
58. cle Dynamometer Installation Guide junction box 2 23 junction box cover installing 2 55 K knurl 5 3 L layout dyno pit room 2 28 length 1 5 lifting eyes 2 12 load bike 5 2 5 4 M main circuit breaker 3 2 4 8 making a test run 5 12 manuals finding on WinPEP cd 3 1 monitor tray 2 25 P PDA see also power distribution assembly pendant cable 2 32 phone 1 9 pickup card installing 2 17 routing cable 2 40 wiring to breakout board 2 42 pit brake module placement 2 11 dimensions 1 11 drum module placement 2 9 pit covers 2 48 2 54 drum guards 2 54 EEC finger guards 2 50 retarder right side 2 48 pit room layout 2 28 power 50 Hz B 7 60 Hz B 2 cable 2 38 connecting the dyno 50 Hz B 11 connecting the dyno 60 Hz B 6 hard wiring 60 Hz B 5 hard wiring 50 Hz B 10 installation 50 Hz B 7 installation 60 Hz B 2 installing receptacle 60 Hz B 3 installing receptacle 50 Hz B 8 replacing power plug 50 Hz B 10 replacing power plug 60 Hz B 5 requirements 50 Hz B 7 requirements 60 Hz B 2 testing voltages 50 Hz B 9 Version 4 testing voltages 60 Hz B 4 verifying operation 50 Hz B 11 verifying operation 60 Hz B 6 power carriage routing cables 2 37 testing 2 47 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 10 5 11 preventative maintenance 5 13 primary inductive pickup
59. ctions to the chassis In addition make sure metal tools such as screw drivers wrenches and torque wrenches do not come in contact with the negative and positive terminals of the battery Short circuiting the terminals of the battery can cause burn injuries damage to the dynamometer or trigger explosions Charging Batteries being charged will generate and release flammable hydrogen gas Charging space should be ventilated Keep battery vent caps in position Prohibit smoking and avoid creation of flames and sparks nearby Wear protective clothing eye and face protection when charging or handling batteries In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide WARNINGS S C aa 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 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
60. curing the right drum cover and set aside Remove the right drum cover and set aside For safety apply the brake and disconnect the air supply Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor AUU KRW DN e outboard brake pad adjust castle nut remove hairpin cotter Figure 3 11 Loosen the Castle Nut 3 10 See In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide ACCESSORIES Ke Air Brake y 7 Using a 9 16 inch ratchet and wrench remove the bolt washer and nut securing the spring to the brake assembly The spring is located on the drum side of the brake assembly nut washer and spring nut washer and spring bolt Figure 3 12 Remove the Brake Spring ASA Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide QT CHAPTER 3 x9 Air Brake 8 Remove the two bolts and two washers securing the brake caliper stop to the brake bracket and remove the brake caliper stop brake caliper stop brake bracket ore ABO60 Figure 3 13 Remove the Brake Caliper Stop 9 Remove the hairpin cotter from the bottom clevis pin located on the front of the air brake assembly hairpin cotter bottom clevis pin Figure 3 14 Remove Bottom Hairpin Cotter B12 a O JEt In Ground Model 200iP 250iP Motorcycle D
61. current brake set up for right side installation installation Figure 2 5 Left or Right Side Brake Set Up apply force using hammer and punch shaft apply force using hammer and punch YW lt Figure 2 6 Removing the Key 2 11 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide SY CHAPTER 2_ 7 Eddy Current Brake 4 Place the ends of a nylon loop strap through the lifting eyes on either side of the brake and hook onto the shaft 5 Using a forklift lift the eddy current brake from the crate and place the brake in the pit near the drum module making sure not to hit the driveline assembly 6 Record the eddy current brake number on the inside cover of this manual SQN Be sure you record the eddy current brake number on the inside cover of this manual lifting eye eddy current brake number Figure 2 7 Record the Eddy Current Brake Number 2 12 Raye 3 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Ss Eddy Current Brake INSTALLING THE EDDY CURRENT BRAKE Safety requirements of your local country may require that both the air brake and the eddy current brake are installed Be sure to follow the safety requirements specific to your country 1 Insert the key into the keyway on the dyno drum module shaft 2 Usea c clamp to press the key in key key way on dyno shaft EBO69 Figure 2 8 Install the Key
62. d Model 200iP 250iP Motorcycle Dynamometer Installation Guide EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION amp FEC Finger Guards ADJUSTING THE EEC FINGER GUARDS Once the pit cover plates are installed and adjusted the EEC finger guards will need to be adjusted 1 Loosen the 1 4 20 x 5 8 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 P 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 0 25 inches FRONT OF DYNO PDO82 adjust screw adjust clearance Figure C 2 Adjust the EEC Finger Guard Clearance C 3 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide APPENDIX C r Door Safety Switch 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 dy
63. d Model 200iP 250iP 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 following 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 aya a3 B 1 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide y B 2 APPENDIX B 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 pag
64. d 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 f eee j PS j I im j 2 y PD149 e airau rl P7 on the Ea iiia CPI board i Ea a aias Ee CH H brake wiring block TB le ff el ages p a g on breakout board BSa E ir oe I lE l Bel I E Fi Wee i i va T ls i j EI d 3 a Ouse E 7 Figure 3 2 Routing the Air Brake Cable 3 3 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 3 4 CH
65. d cap P N 21228519 cable track P N 43432150 plug turnlok 30A 125 250V P N 43816430 receptacle turnlok 30A 125 250V P N 43826430 control pod spindle assembly P N 61329000 monitor tray P N 61329101 optional accessory monitor support P N 61329003 generic i dyno pit P N 62919003 eddy current brake retarder module pit P N 62919004 see parts list below 2 3 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 Dyno Drum Module Installation part description part description cable hole cover track tire stop mount P N 63310902 P N 21228520 junction box cover P N 21228521 drum guard side 2 P N 21229111 drum guard mounting bracket P N 21624103 cable track mounting bracket P N 21626217 cable track adapter bracket P N 21626218 cable cover pit to junction box P N 21626902 screw 8 32 x 3 8 pan head phil 13 P N 36540643 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide not included if you ordered the optional wheel clamp control panel button sub assembly P N 66117001 standard carriage P N 71323006 or extended carriage P N 71323007 see list of parts below wheel clamp P N 71329000 optional accessory control panel interface CPI P N 76129010 dyno electronics assembly P N 76199001P blower assembly P N 76722005 optional accessory see list of parts below ba
66. e For example select File gt 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 CONFIRMATION OF COMPLIANCE TESTING AND CERTIFICATION Dynojet Model 200iP 200iPX 250iP and 250iPX dynamometers have been tested to NFPA 79 2002 and UL 508 A standards and pass the requirements Certificate Number US72080032 01 In Ground Model 200iP 25 OiP Motorcycle Dynamometer Installation Guide 1 3 f 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 controlled 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 n
67. e B 7 The model 200iPX 250iPX 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 200iPX 250iPX 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 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 m
68. e the power distribution stand alone temperature probe assembly P N 76955001 washer 5 16 flat 2 P N DM150 002 007 bolt 3 8 16 x 1 hex 2 P N DM150 019 012 The following parts are included in both the Standard Carriage Assembly Pit P N 71323006 and the Extended Carriage Assembly Pit P N 71323007 2 6 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide anchor redhead 3 8 4 P N 37513200 power carriage P N 82943001 washer 5 16 flat 4 P N DM150 002 007 bolt 3 8 16 x 1 hex 4 P N DM150 019 012 part description part INSTALLATION S Dyno Drum Module Installation description The ae Tae are included in the Blower Assembly P N 76722005 S Version 4 lower blower arm 2 P N 21600015 washer 3 8 metal 2 P N 26215220 washer 1 8 poly 4 P N 26215520 washer 1 4 poly 4 P N 26215521 cap plug 1 75 x 1 2 Blk 8 P N 35521420 clamp lever 3 8 16 x 3 4 2 P N 35712991 anchor redhead 3 8 8 P N 37513200 Sn Bl B EI A AE F blower housing assembly 2 P N 61328101 blower mount 2 P N 61329601 upper blower arm 2 P N 63413001 cable high pressure blower blower to junction box 2 P N 76950301 cable fan power extension P N 76950317 washer 5 16 flat 8 P N DM150 002 007 bolt 3 8 16 x 1 hex 8 P N DM150 019 012 2 7 In Ground Model 200iP 250iP Motorcycle
69. edures 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 1 2 U a5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 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 AGUS PS 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 performing all procedures The Warning icon indicates potential harm to the person performing a procedure and or the dynamometer equipment The Record icon reminds you to record your 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 choic
70. eed 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 SOLENT PEN Engine exhaust contains poisonous carbon monoxide gas Breathing it could cause death Operate machine in well ventilated area Fire Suppression Always have adequate fire suppression or fire extinguishers in your dyno room Industrial Noise Control Inc Industrial Noise Control
71. emove the two nuts from the top of the cover and set aside 4b Remove the screw on the top of the cover and set aside 4c Remove the screw on the side of the cover and set aside 4d Remove the four screws on the back of the cover and set aside 4e Remove the control panel rear cover and set aside Figure 2 27 Remove the Control Panel Rear Cover 5 Route the control panel cable through the access hole on the side of the control panel box and through the cable tie 6 Attach the control panel cable to the Button board access hole button board control panel cable with cable harness wrap cable tie cPo30 Figure 2 28 Attach the Control Panel Cable to the Button Board 2 33 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 2 34 z9 CHAPTER 2 Routing Cables 10 11 12 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 9a Replace the four screws on the back of the cover removed earlier 9b Replace the screw on the top of the cover removed earlier 9c Replace the screw on the side of the cover removed earlier 9d Replace the two nuts removed from the top of the cover removed earlier Figure 2 29 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
72. erent pit conduits Route the 25 pin cable P N 42924251 from the dyno electronics input output module to the Breakout board Refer to Figure 2 37 for Breakout board location Refer to Dyno Electronics on page 1 10 for the 25 pin cable location Route the 9 pin serial cable P N 42967090 from the dyno electronics CPU Module to your computer Refer to Dyno Electronics on page 1 10 for the 9 pin serial cable location pickup card cable bpd Te 25 pin cable to breakout board CPI e e g g e o o o No 9 o Z f ils 7 a ile lo 25 pin cable to breakout board N _ ut Pepa J fl i PD170 ok ee XN e Figure 2 35 Route the Pickup Card and Dyno Electronics Cables 2 40 A as In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Ss Routing Cables ROUTING THE AIR PUMP POWER AIR FUEL SENS
73. ert the pin on the blower assembly into the upper arm AGU The blowers can run at any time once the cord is plugged into a power source right blower assembly upper blower arm lower blower arm 1 4 inch thick clamp lever poly washer aluminum washer Figure 2 19 Install the Blower Assemblies 2 24 ayaa In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION J ons Blower and Monitor Support Installation INSTALLING THE MONITOR ARMS AND MONITOR TRAY 1 Insert a plastic cap in both ends of each arm 2 Place a poly washer around the pin of the first arm and insert the pin into the support arm 3 Place a poly washer around the pin of the second arm and insert the pin into the first arm 4 Place a poly washer around the pin of the tray and insert the pin into the second arm Note The monitor tray is an optional accessory If you did not order a monitor tray skip this step 5 Check for clearance between the monitor arm and motorcycle walls ceiling etc Note Dynojet does not recommend placing the computer CPU on the monitor keyboard tray since vibration can cause damage to the computer tray washers arms washer monitor support Figure 2 20 Install the Monitor Arms and Monitor Tray 2 25 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 2 Van Cable Track Installation CABLE TR
74. es 2 2 eee eee ee eee B 4 Replacing the Power Plug 2 eee eee eee eee eee B 5 Hard Wiring to the Building 0 0 eee eee eee nee B 5 Connecting the Dyno seres erste eee eee eens B 6 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide kg s TABLE OF CONTENTS AR Locations Using 50 Hz Power Locations other than North America and Japan Installing the Wall Receptacle 2 2 ee eee ee Testing for Correct Voltages 2 eee ee ee eee Replacing the Power Plug 2 see e ee eee eee eee ee Hard Wiring to the Building 0 0 eee eee nee Connecting the Dyno 1 2 ee ee eee Appendix C EEC Finger Guard and Door Safety Switch Installation BEC Finger CURIOS lt 2sccicdcdeeec ease ceuySvyeiueueruewreeeres Installing the EEC Finger Guards 1 2 0 0 0 0 ee eee eee ee Adjusting the EEC Finger Guards 0 Door Safety Switch 55 ascee se doses s been eee eR w ows Installing the Door Safety Switch 0 0 0 0 eee eee Appendix D Theta Controller Power Adjustment 2 6 42 c6seee eevee eee etedeeeseceseseseeeees Accessing the Dip Switches 0 0 ee eee eee eee In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide WARNINGS Disclaimers Dynojet Research Inc Dynojet makes no representation or warranties with respect to the contents hereof and specifically
75. fety switch C 4 C 5 drill and drill bit requirements 1 8 dyno dimensions 1 6 height 1 5 length 1 5 weight 1 5 dyno bearing grease 5 13 dyno drum module contents 2 3 dyno electronics 1 10 power cable 2 41 routing cables 2 40 standard modules 1 10 dyno power cable 2 38 dyno room 1 4 equalizer box 1 4 exhaust extraction 1 4 fire suppression 1 4 intake air fan 1 4 layout 2 28 noise control 1 4 dyno shutdown 4 3 4 4 dyno shutdown sticker 3 7 Index ii E eddy current brake 2 10 2 16 connector plate 2 11 coupler 2 14 coupler set screws 2 15 installation 2 13 2 15 right side installation 2 11 routing cable 2 38 starter brace 2 14 theta controller fuses 4 10 unpacking 2 11 wiring breakout board 2 42 EEC finger guards 2 50 C 2 C 3 adjusting C 3 installing C 2 electrostatic discharge vi emergency stop 4 3 4 4 emergency stop sticker 3 5 end cap installing 2 55 environmental requirements 1 8 equalizer box 1 4 ESD precautions vi exhaust extration 1 4 F fire suppression 1 4 forklift requirements 1 8 fuses power distribution assembly 4 11 theta controller 4 10 H hard wiring power 50 Hz B 10 60 Hz B 5 hazards vii height 1 5 high pressure blowers circuit breakers 4 8 mounts 2 21 2 23 routing cables 2 36 testing 2 47 using 4 4 Industrial Noise Control Inc 1 4 installing power receptacle 50 Hz B 8 60 Hz B 3 intake air fan 1 4 interlocks 4 4 internet access 1 9 In Ground Model 200iP 250iP Motorcy
76. h 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 Qe Cut off the gray wire 4 Refer to the previous table for testing and probe the new connections as follows e black wire as location 1 e brown wire as location 3 e green yellow wire as location 2 POWER REQUIREMENTS AND INSTALLATION Locations Using 50 Hz Power Locations other than North America and Japan es CONNECTING THE DYNO 1 Turn off the main circuit breaker on the dyno The main breaker is located in the CPI door Off is the down position 2 Once you verify the voltages on the receptacle connect the dyno to the receptacle 3 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 NNW Test the control panel operations For more information refer to your dyno installation guide B 11 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION This appendix contains instructio
77. he 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 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 e Red wire connects to R1 Black wire connects to B1 e White wire connects to W1 Ground shield wire connects to S1 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 37 If you have an eddy current brake and air brake the air brake will only be activated when the dyno electronics power is turned off the E stop button is pressed or the optional door interlock is installed and activated In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Routing Cables N 5 Close the CPI front access panel Refer to page 2 31 e gt a E i ws a ae F ae i T Goo AS i 1 a il eee 2 Soe ok temp p j J2 J1 o H Sea H panio mar E eddy current brake only or a HTN i eddy current brake and air z o H U A F brake with control panel
78. heater etc 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 1 2 eo q 2 2 O N O To MC0004 Figure D 1 Theta Controller Dip Switch Settings D 3 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 25 pin cable 2 40 50 Hz power B 7 60 Hz power B 2 9 pin cable 2 40 A accessories air brake 3 3 3 15 eddy current brake 2 10 monitor tray 2 25 wheel clamp 3 17 3 20 air brake 3 3 3 15 adjustments and tests 3 9 3 15 brake pads 3 10 3 14 3 15 emergency stop sticker 3 5 routing cables 3 3 air fuel sensor cable 2 41 air pump assembly 3 16 air pump power cable 2 41 air pump using 4 3 anchor placement blower mounts 2 22 carriage plate 2 19 drum module 2 16 eddy current brake module 2 16 support arm 2 22 B battery 1 5 2 29 2 30 charger 2 29 dimensions 1 5 routing cable 2 38 2 39 type 1 5 battery hazards vi blower see also high pressure blowers blower cables 2 36 blower mounts anchor placement 2 22 installation 2 23 INDEX blowers circuit breakers 4
79. heel 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 20 aya 5 In Ground Model 200iP 250iP 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 e Basic Operation page 4 2 e Power Distribution Assembly page 4 8 e Maintenance and Troubleshooting page 4 9 4 1 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 4 E i Basic CPI Operation BASIC CPI OPERATION The control panel may be mounted to either side of the tray for easy access by the dyno user while seated on the bike The graphics on the control panel are grouped together according to function and color coded for ease of identification A description of the functions and displays follows STATUS On Ok gt status indicator light J Flashing Error refer
80. iage plate carriage plate carriage screw nut block bearing plate E screws Figure 2 13 Remove the Carriage From the Carriage Plate 2 18 yam 5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION S Carriage Plate and Tire Carriage 2 Use the carriage plate to mark and drill mounting holes as shown in Figure 2 14 2a Using the carriage plate as a template mark and drill four 1 2 inch holes 2b Install the Red Head anchors Refer to Appendix A for installation instructions lt lt _ _ gt 40 32 cm 15 875 in 66 04 cm 26 0 in C032A Figure 2 14 Carriage Plate Mounting Dimensions 3 Secure the carriage plate to the floor using four 3 8 x 1 inch bolts and 5 16 inch washers Figure 2 15 Install the Carriage Plate 2 19 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 49 CHAPTER 2 r Carriage Plate and Tire Carriage INSTALLING THE TIRE CARRIAGE 1 Starting from the back of the dyno slide the carriage under the carriage clamps 2 Slide the carriage screw and the bearing bracket toward the nut block until the carriage screw is touching the nut block 3 Secure the bearing bracket to the carriage using four 1 4 20 x 5 8 inch pan head torx bolts removed earlier bearing bracket carriage carriage clamp nut block carriage screw Figure 2 16 Install the Tire Carriage
81. ipping company or Dynojet before proceeding with unpacking Since this manual ships inside the packing crate you must have already cut the bands around the crate removed the remove by customer only boards and lifted the pallet containing the pit covers from the top of the crate and set it aside in order to remove the top of the crate It is important to follow the remaining steps carefully UNPACKING THE DYNO 1 Remove the crate braces and sides Note At this point you will want to inspect the exterior of the dyno for any indications of damage Report any damage immediately 2 Remove the tire carriage and support arm and set aside The tire carriage and support arm are fastened to the bottom of the crate 3 Remove the following parts hardware boxes the control panel interface and accessories from the crate and set aside support arm tire carriage Figure 2 1 Uncrate the Dyno 2 2 aya In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 4 Verify the contents of the hardware boxes and set aside description part INSTALLATION amp Dyno Drum Module Installation description Version 4 nut 4 40 hex 4 P N 134260301 screw 4 40 x 3 8 flat head 6 P N 136206141 blank plate junction box P N 21221500 pit cover right P N 21226104 pit cover left P N 21226105 cable junction box base P N 21228000 cable routing cover P N 21228517 cable channel en
82. ld 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 B 7 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide APPENDIX B r 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 correct 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 pome L terminal IN J Se oe A N terminal i ground terminal white green AA Figure B 2 Wire the Wall Receptacle B 8 EEFAJ In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION 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
83. 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 P WARNING 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 29 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 r Routing Cables INSTALLING THE BATTERY 1 Secure the battery to the tray with the battery hold down 2 Refer to page 2 38 for instructions on routing and connecting the battery cable battery PD184 Figure 2 24 Installing the Battery 2 30 DA In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 INSTALLATION S Routing Cables ACCESSING THE CPI The CPI comes wired and ready to install Should you need to re route the cables so they come out a different side of the box use the following instructions to access the CPI box 1 Turn off the power to the dyno Refer to Main Dyno Power on page 3 2 for more information 2 Remove the eight button head
84. mmunications AL d cables in designated conduit o aS A oO A ry i i P a control panel dyno o C electronics 4 control panel interface CPI route power cables in designated conduit PD164 Figure 2 23 Pit Dyno Room Layout 2 28 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 INSTALLATION J ons Routing Cables BATTERY REQUIREMENTS The model 200iP 250iP dyno is designed to carry a group 24 deep cycle discharge series battery for operating the starter optional power carriage and optional wheel clamp The typical dimensions for this series of batteries are 10 5 8 inches long by 6 3 4 inches wide by 9 1 8 inches tall The mounting is flexible so a battery that has dimensions close to this will work satisfactorily The built in battery cables are configured for top post batteries This battery is not included with your dyno You will need to provide this battery The battery provides the necessary energy to run the starter optional power carriage and optional wheel clamp The CPI has a built in battery charging circuit to keep the battery charged Each time the starter power carriage or wheel clamp is used this built in charging circuit will recharge the battery The charging rate is sufficient to keep up with loading a bike operating the wheel clamp and
85. mnnut Figure 5 4 Tachometer Pickup Secondary Inductive 5 8 A In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION Ss Connecting the RPM Pickup Erratic tachometer operation can be caused by Electro Magnetic Interference EMI The following are some steps that the user can take to clean up the signal if an EMI situation occurs e Ground the computer case to a good earth ground like the receptacle box Keep the computer as far away from the dyno as possible e Try attaching one secondary inductive cable to one wire and attach a second inductive cable to the first in a piggy back fashion The first inductive cable acts as a filter e Using a jumper wire ground the metal case of the inductive clip to the motorcycle chassis Rout the inductive wire s 90 degrees perpendicular away from the motorcycle When laid alongside parallel to the motorcycle they can act as an antenna 5 9 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 5 10 49 CHAPTER 5 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
86. namometer 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 INSTALLING THE DOOR SAFETY SWITCH 1 Open the CPI front panel access and turn off the main breaker 2 Unplug the dyno power cable 3 Remove the eight button head screws securing the CPI cover and set aside 4 Remove the cover and set aside cover front panel access Figure C 3 Access the CPI C4 Fo fene In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION he Door Safety Switch N Loosen the screws that hold the jumper wires in place and remove the wire Route the black and yellow wire from the door 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 remove jumper wire yellow wire to 1A on J2 connector on J4 connector F S black wire to 6B 10 11 12 13 14 Version 4 Figure C 4 Wire the Door Safety Switch Replace the CPI cover using the screws removed earlier The door safety switch needs to
87. ng the Power Carriage and Wheel Clamp Cables 2 37 Routing the Eddy Current Brake Battery and Dyno Power Cables 2 38 Routing the Pickup Card and Dyno Electronics Cables 2 40 Routing the Air Pump Power Air Fuel Sensor and Dyno Electronics Power Cables cc ees ba eae Sad vo Hee ok TESTES EENE ee E E 2 41 Wiring the Breakout Board 00 cece eee eee 2 42 Power Carriage Installation 2 0 cee eee eee 2 44 Tike Stop Installation 2 2044 0040445354es10drdureiereeeeowieenees 2 45 Final Adjustments and Tests 22224242222 ssscs seseensenvencades 2 46 Turning On the Dyno Power 0 e eee eee 2 46 High Pressure Blower Test 0 0c eee eee eee eee 2 47 Power Carriage Final Adjustments and Tests 005 2 47 Wheel Clamp Final Adjustments and Tests 0 0000 2 47 PIV COVEDS t4 90 lt i3eeaucnataeave EEEE EErEE EEEE TEE E E E EEEE RA 2 48 Changing the Eddy Current Brake Cover for Right Side Installations 2 48 Installing the Pit Covers 0 0 cee ec eee eee nee 2 50 Junction Box Cover Cable Cover and End Cap 2 55 Zip TUDE o os cow iedgis ncarode see PEER er EERCeORELeey GaSe Se Te Ses S 2 56 Accessories Main Dyno POWER etek ecueee bei el pr ee e ee ae oe eS 3 2 PIP Brake a vislidetesatanensedecedeteddure ashes bee eat a beset ie 3 3 Routing the Air Brake Cable and Air Hose 1 2 2 2 0 0 eee eee 3 3 Installing
88. nner dynojet 2 P N D706 part description part INSTALLATION S Dyno Drum Module Installation description screw 1 4 20 x 5 8 pan head torx 13 P N 36561045 5 bolt 3 8 16 x 1 2 button CUS head flange allen 12 P N 36580434 anchor redhead 3 8 4 P N 37513200 installation tool redhead anchor P N 37518200 cable harness wrap kit P N 43400000 cable clamp 5 8 7 DA P N 43428232 LEA inductive secondary pickup 2 P N DE100 109S inductive primary pickup clip P N DE100 110L washer 5 16 flat 4 P N DM150 002 007 bolt 3 8 16 x 1 hex 4 P N DM150 019 012 nut crush 1 4 20 4 P N DM150 020 005 The following parts are included in the Monitor Support P N 61329003 A washer 1 87 x 1 25 ID x 12 SAN THK 3 P N 26215520 P N 35521420 Version 4 cap plug 1 75 x 1 2 Blk 4 monitor arm 2 P N 61329100 monitor support P N 61329500P 2 5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 2 r Dyno Drum Module Installation part description description The following parts are included in the Retarder Module Pit P N 62919004 pit cover plate retarder P N 21226106 anchor redhead 3 8 2 P N 37513200 woodruff key 3 8 x 1 3 8 2 P N 37620622 retarder driveline assembly P N 62240070 theta 2 controller 240V P N 66411003 insid
89. ns for installing the EEC Kit to the in ground model 200iP 250iP motorcycle dynamometers 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide APPENDIX C ay EEC Finger Guards EEC FINGER GUARDS The European model 200iP 250iP 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 3 for instructions on adjusting the gap INSTALLING THE EEC FINGER GUARDS 1 Secure each EEC finger guard to the drum guard mount using two 1 4 20 x 5 8 inch pan head screws 2 Continue with installing the pit covers on page 2 48 an or x drum guard mount left pit cover plate finger guard Figure C 1 Install the EEC Finger Guards C 2 ayaa In Groun
90. ntact with or it s connecting wire be crossing other engine electrical wires or stray RF interference may result You will need the following part e DE100 110L Primary Inductive Pickup 1 Clip the primary inductive pickup to the primary wire of the coil opposite the battery source 2 Route the primary wire cable to the RPM Module making sure the cable is clear of devices that produce electronic noise spark plug wires coil wire coil etc Note You must ground the vehicle to the dyno for the electronics to function properly connect the primary pickup opposite the battery sources ignition box primary secondary igus coil ra from battery source Strry grat Urerpgaae Hirtt Figure 5 3 Tachometer Pickup Primary Inductive 5 6 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 BASIC DYNO OPERATION Connecting the RPM Pickup Depending on accessibility the user can make a primary wire hookup from the coil or the ignition module Ignition modules can be found usually under the seats or side covers Refer to the following table to determine the wire color when hooking up the inductive tack lead to the primary side of the ignition make wire color BMW R Models Black BMW K Models Black Blue Black Red BMW Triplets Black Green Buell Pink Ducati Gray or Green Brown EFI Green or Violet Yellow Harley Blue or Pink Honda Yellow or Yellow Blue Kawasaki Green
91. o Figure 3 13 19 Secure the spring using the bolt washer and nut you removed earlier Refer to Figure 3 12 20 Tighten the castle nut and replace the hair pin cotter Refer to Figure 3 11 21 Adjust the brake pad clearance Refer to page 3 15 for complete instructions 22 Replace the right drum cover using the eight button head screws remove earlier 23 Connect your shop air 24 Turn the dyno power on using the main breaker Refer to page 3 2 3 14 ape In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 ACCESSORIES Ss Air Brake amp ADJUSTING THE BRAKE PAD CLEARANCE There should be equal pad clearance on both sides of the rotor If the pads touch the rotor during a run the information provided by the dyno will be inaccurate Use the following steps to adjust the clearance 1 2 nn Loosen the brake caliper stop bolts Insert the brake adjusting shim between the inboard brake pad and the brake rotor Refer to Figure 3 18 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 Tighten the brake caliper stop bolts Loosen the castle nut and remove the shim 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 Replace the hair pin cotte
92. 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 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 4 ay Basic CPI Operation 4 6 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 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
93. on head flange screws Do not tighten cable routing opening Figure 2 46 Install the Left Side Drum Cover 2 52 yee In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 10 11 INSTALLATION S Pit Covers W Place the right side drum cover over the drum module Loosely secure the right side drum cover to the drum guard bracket using four 1 4 20 x 5 8 inch pan head torx screws Loosely secure the right side drum cover using four 3 8 16 x 1 2 inch button head flange screws Do not tighten Center the drum guard mounting bracket over the drum Verify the drum does not contact the mounting bracket Tighten all screws Figure 2 47 Install the Right Side Drum Cover In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 2 53 CHAPTER 2 vy Pit Covers 12 Install each drum guard to the drum guard mounting bracket using two 1 4 20 x 5 8 inch pan head torx screws and two 1 4 20 inch crush nuts Note Verify the drum guards do not contact the drum Note If you installed the EEC finger guards you will need to adjust them now Refer to Adjusting the EEC Finger Guards on page C 3 for detailed instructions drum guards BE Figure 2 48 Install the Drum Guards 2 54 ayaa In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION J Junction Box Cover Cable
94. on securing the cable track and connecting the wheel clamp cable If you did not order the wheel clamp the wheel clamp cable will hang from the cable track You will need the following parts e 21626218 Cable Track Adapter Bracket e 36561045 Screw 1 4 20 x 5 8 Pan Head Torx e 63310902 Tire Stop includes 36580434 Bolt 3 8 16 x 1 2 Button Head Flange Allen 4 1 Secure the tire stop to the carriage using three 3 8 16 x 1 2 inch button head flange bolts 2 Secure the cable track adapter bracket to the tire stop and carriage using the remaining 3 8 16 x 1 2 inch button head flange bolt 3 Secure the cable track to the adapter bracket using one 1 4 20 x 5 8 inch pan head torx screw cable track adapter bracket Figure 2 39 Install the Cable Track Adapter Bracket 2 45 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 r Final Adjustments and Tests FINAL ADJUSTMENTS AND TESTS After you have installed all of your additional accessories and routed all necessary cables perform the following procedures to ensure the safe and effective operation of your dyno Note Before you plug in your dyno you or your electrician must refer to Appendix B for detailed power information Always turn the power off when connecting and disconnecting cables TURNING ON THE DYNO POWER 1 Replace the CPI cover if it was removed Refer to page 2 31 for more information 2 Plug the power plug into the power
95. onal blower mounts as shown Note The high pressure blowers are an optional accessory If you did not order high pressure blowers you will not need to install the blower mounts 2 Using the mounting plates as a template mark and drill the four 1 2 inch holes needed to secure the blower mounts and support arm to the floor 3 Install the Red Head anchors Refer to Appendix A for installation instructions 24 13 cm d i 7 24 13 cm 9 50 in NTL A 9 50 in lt gt lt gt A A 5 jo o 111 76 cm 111 76 cm 44 00 in 44 00 in PD158 Figure 2 17 Blower Mounts and Support Arm Placement 2 22 yma 5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Ss Blower and Monitor Support Installation INSTALLING THE MONITOR SUPPORT AND JUNCTION BOX The high pressure blowers are an optional accessory If you did not order high pressure blowers you will not need to install the blower mounting plates Refer page 2 21 to for high pressure blower installation instructions 1 Secure the blower mount monitor support arm and junction box to the pit floor using four 3 8 x 1 inch bolts and four 5 16 inch washers Note The left blower mount is secured under the support arm 2 Secure the right blower m
96. orosiane eee E S v Chapter 1 Specifications and Operating Requirements IntrodUCtON setseseccsccactoeenees kietoo oenen a o eee 1 2 Conventions Used In This Manual 0 0 0 eee eee eee 1 3 Technical Support 2 eee teen eee 1 3 Confirmation of Compliance Testing and Certification 1 3 Your Dyna ROOM 2222 24 2682 F880 2 obs e eee eee ee ea eR 1 4 Dynamometer Specifications and Requirements 1 5 Battery Requirements 0 cee cee ee eee ee 1 5 Chassis Specifications 0 0 0 eee r 1 5 Compressed Air Requirements 0 0 eee eee ee eens 1 8 Computer Specifications 2 ee eens 1 8 Drill and Drill Bit Requirements 0 0 0 cee eee eee eee 1 8 Electrical Requirements 2 0 eee eee eee eee eens 1 8 Environmental Requirements 20 eee eee ee eee eee 1 8 Forklift Requirements 0 0 0 eee eee eee 1 8 Phone and Internet Access 0 cece eee ee eens 1 9 Tle DOWN Straps 6 fei cere see ee 6 6 ese ee ait wate wheeler alert 1 9 Dyno Electronics 24 5 o10505a5 508 ee ee ee RES ODES RESALE rnrn 1 10 Verify the Pit Dimensions ecre nea cea ne ease ekenene ce eeeee sa 1 11 Chapter 2 Installation Dyno Drum Module Installation 2 asccn eiserao de adeedwwwewwelia 2 2 Unpacking the Dyno 2 eee ee ee eens 2 2 Removing the Dyno from the Crate 0 cee eee eee 2 8 Placing the Dyno inthe Pit eee ee ee
97. ou received from your salesman for more detailed specifications e pit depth 45 00 cm 18 00 in e pit length 193 00 cm 76 00 in e pit width 121 00 cm 48 00 in Q k Q OR A 121 00 cm 48 00 in y 193 00 cm i 76 00 in PD155 Figure 1 4 Verify the Pit Dimensions 1 11 Version 4 In Ground Model 200iP 250iP 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 Drum Module Installation page 2 2 Eddy Current Brake page 2 10 Secure the Drum and Brake Module to the Pit Floor page 2 16 Pickup Card page 2 17 Carriage Plate and Tire Carriage page 2 18 Blower and Monitor Support Installation page 2 21 Cable Track Installation page 2 26 Routing Cables page 2 28 Power Carriage Installation page 2 44 Tire Stop Installation page 2 45 Final Adjustments and Tests page 2 46 Pit Covers page 2 48 Junction Box Cover Cable Cover and End Cap page 2 55 Zip Tube page 2 56 2 1 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 b Dyno Drum Module Installation DYNO DRUM MODULE INSTALLATION When you receive your dyno examine the exterior of the shipping container for any visible damage If damage is detected at this stage contact the sh
98. ount to the pit floor using four 3 8 x 1 inch bolts and four 5 16 inch washers The high pressure blowers are an optional accessory If you did not order high pressure blowers you will not need to install the blower mounting plates 3 Verify the blank plate is secured to the junction box as shown in Figure 2 18 support arm junction box blower mount Figure 2 18 Install the Monitor Support Arm and Junction Box 2 23 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide z9 CHAPTER 2 f Blower and Monitor Support Installation INSTALLING THE BLOWER ASSEMBLIES The high pressure blowers are an optional accessory If you did not order high pressure blowers skip these steps Use the following instructions to install both the left and right blower assemblies Note Tire carriage not shown for clarity 1 Insert a plastic cap in both ends of each arm Place two 1 4 inch thick poly washers around the pin on the blower mount Note Use only one 1 4 inch thick poly washer around the pin on the left blower mount Place the lower blower arm over the blower mount pin Place a 3 8 inch thick metal washer on top of the lower blower arm Secure the lower blower arm using the clamp lever Place a 1 8 inch thick poly washer around the pin on the upper blower arm Insert the pin on the upper arm into the lower arm Place a 1 8 inch thick poly washer around the pin on the blower assembly SO AN WAH KR WwW Ins
99. r 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 rotor inboard brake pad brake caliper stop bolts ABO76 Figure 3 18 Adjust the Brake Pad Clearance 3 15 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 49 CHAPTER 3 J j Compressed Air Pump Assembly COMPRESSED AIR PUMP ASSEMBLY Refer to the Air Fuel Ratio Module and AFR 4 Pump Assembly Installation and User Guide P N 98200006 for proper operating and maintenance procedures Refer to the Flow Meter User Guide P N 98129104 to test your air pump for accuracy Failure to follow proper procedures may result in inaccurate data or damage to the equipment These manuals can be found on your WinPEP CD or at www dynojet com 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 Air Fuel Ratio Module and AFR 4 Pump Assembly 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
100. rd 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 Once aligned tighten the screws to secure the pickup card in place 5 Refer to page page 2 40 for instructions on routing and connecting the pickup card cable AGU The optical pickup is very delicate Be careful not to damage the optical pickup during alignment tab on dyno optical pickup pickup card top view of pickup card optical pickup and tab on dyno pickup card bracket PDOO3 tab on dyno pickup card Figure 2 12 Install the Pickup Card 2 17 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 49 CHAPTER 2 ay Carriage Plate and Tire Carriage CARRIAGE PLATE AND TIRE CARRIAGE Use the following instructions to install the standard carriage or optional extended carriage The tire carriage is fastened to the bottom of the crate next to the dyno Refer to page 2 2 for instructions on removing the tire carriage from the crate You will need the following parts e 37513200 Anchor Redhead 3 8 4 e 37518200 Installation Tool Redhead Anchor e 71323006 Standard Carriage 71323007 Extended Carriage e DM150 002 007 Washer 5 16 Flat 4 e DM150 019 012 Bolt 3 8 16 x 1 Hex 4 INSTALLING THE CARRIAGE PLATE 1 Remove the four bearing plate screws and slide the carriage from the carr
101. rs 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 the left blower circuit These breakers do not provide a manual disconnect main dyno circuit breaker and disconnect
102. s for installing the in ground motorcycle dynamometer dyno This document will walk you through operating requirements installation accessories and basic dyno operation To ensure safety and accuracy in the procedures perform the procedures as they are described Document Part Number 98229103 Version 4 Last Updated 03 16 11 This chapter is divided into the following categories Introduction page 1 2 Dynamometer Specifications and Requirements page 1 5 Dyno Electronics page 1 10 e Verify the Pit Dimensions page 1 11 1 1 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 1 IM j Introduction INTRODUCTION Before installing your dyno please take a moment to read this guide for installation instructions dyno features and other important information This guide is designed to be a reference tool in your everyday work and includes the following chapters and information SPECIFICATIONS AND OPERATING REQUIREMENTS This chapter describes the requirements and specifications for the dyno INSTALLATION This chapter describes the procedures for installing the dyno ACCESSORIES This chapter lists each dyno accessory alphabetically and describes the procedures for installing and using the accessory CONTROL PANEL INTERFACE OPERATION This chapter describes the Control Panel Interface CPI operating procedures BASIC DYNO OPERATION This chapter describes basic dyno operating proc
103. screws securing the cover and set aside Remove the cover and set aside Qe 4 Open the front panel to access the breakers and Breakout board ij i cover i 1 i 1 a PeSas caus soso ssa La front panel access e X N PD027 Figure 2 25 Accessing the CPI In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 2 31 z9 CHAPTER 2 r Routing Cables ROUTING THE CONTROL PANEL AND PENDANT CABLES 1 Route the control panel cable P N 76951502 from the CPI through the designated communications pit conduit through the pit and out of the pit as shown 2 Route the pendant cable from the dyno electronics input output module through the same conduit and along the same path as the control panel cable Refer to Dyno Electronics on page 1 10 Note Be sure to keep the power and communications cables in different pit conduits 3 From the pit route the cables through the junction box route communications cables in designated conduit dyno electronics CPI route power cables in designated conduit Figure 2 26 Route the Control Panel and Pendant Cables 2 32 A D In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide PD185 INSTALLATION Ss Routing Cables 4 Remove the control panel rear cover 4a R
104. stallation Guide Version 4 CONTROL PANEL INTERFACE OPERATION 2 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 Replace 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
105. tallation Guide CHAPTER 4 ay Basic CPI Operation 4 4 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 of the dyno are designed to only work with Dynojet provided blowers Connecting other electrical loads or other blowers to the outlets on the dyno may damage the dyno and void the warranty If the blower indicator light on the control panel is on
106. tead 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 N Battery Fire and Explosion Hazards There is a danger of explosion if the battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Discard used batteries according to the manufacturer s instructions Automotive Batteries In operation batteries generate and release flammable hydrogen gas They must always be assumed to contain this gas which if ignited by burning cigarette naked flame or spark may cause battery explosion with dispersion of casing fragments and corrosive liquid electrolyte Carefully follow manufacturer s instructions for installation and service Keep away all sources of gas ignition and do not allow metallic articles to simultaneously contact the negative and positive terminals of a battery Do not allow the positive and negative terminals to short circuit The dynamometer chassis is tied to the negative side of the battery Do not short between the positive battery terminal or the starter conne
107. the neutral connection 4 Refer to the previous table for testing and probe the new connections as follows e black wire as location 2 brown wire as location 4 e gray wire as location 1 e green yellow wire as location 3 B 5 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Locations Using 60 Hz Power North America and Japan ny APPENDIX B B 6 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide POWER REQUIREMENTS AND INSTALLATION J WAR 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
108. the uprights are flush with the pit floor 8d Tighten the upright bolts and nuts on the drum module 8e Repeat this for the eddy current brake module uprights 9 Secure the starter brace to the starter using the washer and nut removed earlier 10 Remove the straight edges drum module upright loosen bolts securing uprights c clamp starter brace connector plate bolts eddy current brake module upright loosen bolts _ securing uprights not visible loosen bolts securing uprights bonnete pe plate bolts loosen bolts loosen bolts 7 securing securing uprights uprights not visible front of Ta yo wf PD183 dyno Figure 2 9 Secure the Uprights In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION Sx Eddy Current Brake N 11 Replace the existing set screws on the driveline with the thread lock set screws provided 12 Tighten the driveline set screws brake shaft dyno shaft set screw Figure 2 10 Tighten the Set Screws COC CCC 2 15 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 2 r Secure the Drum and Brake Module to the Pit Floor SECURE THE DRUM AND BRAKE MODULE TO THE PIT FLOOR Dynojet recommends you secure your drum and brake modules to the pit floor in your d
109. tical force to the bike PSN WARNING Never perform a dyno run if the tie down straps are not in place or they are damaged tie down tie down strap Figure 5 2 Attach the Tie down Straps Se JEE In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION oe 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 ATU Inductive pickups are very fragile The ferrite core can easily be damaged and is not covered under
110. torcycle Dynamometer Installation Guide PD153 Fa tft SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements Monitor Support Control Panel and Tray Wheel Clamp Option Power Carriage not visible Control Panel Interface houses all electronics not shown PD154 High Pressure Blower Eddy Current Air Brake Option Brake Module not shown Air Pump Option yiio Module not shown Figure 1 2 Model 250iP Dyno with Accessories 1 7 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 1 8 CHAPTER 1 ay Dynamometer Specifications and Requirements COMPRESSED AIR REQUIREMENTS Comp 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 UTER 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 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 c
111. ts e 62919004 Eddy Current Brake e 37620622 Woodruff Key 3 8 x 1 3 8 2 e 62240070 Driveline Assembly 2 10 ayn In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide Version 4 INSTALLATION Ss Eddy Current Brake UNPACKING THE EDDY CURRENT BRAKE 1 Remove the four bolts securing the brake to the crate 2 Remove the retarder connector plates if present 3 Determine if the brake is to be mounted on the left or right side of your dyno Note This installation has been designed for the eddy current brake to be installed on the left side of the dyno Contact Dynojet for information regarding installation on the right Make the following adjustments to the eddy current brake only if you want to mount the brake on the opposite side of the dyno that it is currently set up for e Move the coupler and key to the other side of the brake To remove the key use a punch and a hammer to apply pressure in the direction of the arrows shown in Figure 2 6 e The retarder connector plates removed in step 2 will need to be moved to the other side of the brake once the brake is installed in the pit e Move the temperature sensor to the other side of the brake connector plate bs temperature sensor wai driveline ae P Roo d a connector plate EB22 eddy current brake set up for left side eddy
112. 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 Air Fuel Ratio Module and AFR 4 Pump Assembly Installation and User Guide for more information 3 16 A 5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide ACCESSORIES Ss 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 part e 71329000 Wheel Clamp includes DM150 002 004 Washer 5 16 Lock 4 DM150 002 007 Washer 5 16 Flat 4 DM150 019 012 Bolt 3 8 16 x 1 Hex 4 INSTALLING THE WHEEL CLAMP 1 Remove the six 1 4 20 x 1 inch screws securing the wheel clamp cover Remove the cover and set the cover and screws aside Figure 3 19 Remove the Wheel Clamp Cover 3 17 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 3 b Wheel Clamp 2 Place the wheel clamp on the carriage Align the four holes
113. uency D 2 power line voltage D 3 replace fuses 4 10 wiring to breakout board 2 42 tie down straps 1 9 tie downs 5 4 tire carriage 2 18 2 20 5 2 carriage plate 2 18 installing 2 20 remove from crate 2 2 tire stop 2 45 cable track adapter bracket 2 45 TUV certification 1 3 Index iv Ww warnings V weight 1 5 wheel clamp closing 4 7 installing 3 17 3 19 maintenance 4 9 opening 4 7 routing cable 2 37 testing 2 47 3 20 troubleshooting 4 9 using 4 6 width 1 5 WinPEP finding manuals on 3 1 wiring breakout board jumpers 2 42 pickup card cable 2 42 temperature sensor cable 2 42 theta controller cable 2 42 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 56 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide
114. uration 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 gray black and green yellow 1 Connect 240VAC single phase power between the brown and the black wire connection points 2 Connect the green yellow wire to the ground connection point 3 Connect the gray wire to the neutral connection point 4 Refer to the previous table for testing and probe the new connections as follows e black wire as location 2 e brown wire as location 4 e gray wire as location 1 e green 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
115. ure 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 WARNING 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 29 for more information on the battery If the E Stop button is pressed the starter will not engage If the interlock circuit is open the starter will not operate 1 Make sure the dyno brakes are not activated 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
116. ving If the tachometer is moving but not registering the correct RPM values the number of degrees of revolution of the crank shaft the plug fires number is incorrect 4b 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 AGU 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 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION ox Preventative Maintenance PREVENTATIVE MAINTENANCE This section contains basic preventative maintenan
117. wheel clamp use the control panel to secure the front wheel NA Never perform a dyno run if the tire strap is not in place or is damaged 4 Use the control panel to run the power carriage until the rear axle is aligned with the center of the drum 52 TG In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide BASIC DYNO OPERATION Sx Loading the Motorcycle N 5 With the motorcycle in neutral align the wheel in the center of the knurl If you have a battery installed you may align the wheel by pressing the dyno starter switch tire stop tire strap center drive axle on dyno drum adjust carriage to align rear axle with drum Figure 5 1 Align the Wheel and Axle A3 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 5 Z Loading the Motorcycle 6 Attach the tie down straps from a solid place on the bike to the tie downs on the dyno or the ground hook locations Position the straps to allow proper clearance for the brake pedal the shift lever and the exhaust pipes For best results hook the straps at the rear of the bike so they pull down and forward 7 Siton the bike with your feet on the pegs Remove the slack from the straps Gently shift your weight from side to side while tightening the straps being careful to not overtighten the straps The straps are used to stabilize the bike They should not add any additional ver
118. wing categories e Main Dyno Power page 3 2 e Air Brake page 3 3 e Compressed Air Pump Assembly page 3 16 Wheel Clamp page 3 17 3 1 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide 3 2 49 CHAPTER 3 Main Dyno Power MAIN DYNO POWER Many instructions in this guide will require you to connect or disconnect the power to the dyno as part of the installation process Use the following steps to connect and disconnect power to the dyno Note Before you plug in your dyno you or your electrician must refer to Appendix B for detailed power instructions Always turn the power off when connecting and disconnecting cables 1 Use the main breaker to turn power on and off to the dyno The main breaker is located inside the CPI door When the handle is in the down position all power into the dyno is turned off 2 Disconnect the power plug to ensure all power has been removed from the dyno before performing certain installation procedures power plug main breaker breakout board LH Figure 3 1 Main Dyno Power In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide ACCESSORIES g 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 connecte
119. ynamometer Installation Guide ACCESSORIES 5 Air Brake 10 Push the bottom clevis pin towards the back of the assembly drum side You do not need to remove the pin completely 11 Remove the hairpin cotter from the top clevis pin located on the drum side of the air brake assembly top hairpin cotter top clevis pin bottom clevis pin AB062 Figure 3 15 Remove Bottom Pin and Top Hairpin Cotter 12 Remove the top clevis pin top clevis pin AB063 gl al Figure 3 16 Remove the Top Clevis Pin 3 13 Version 4 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide CHAPTER 3 r Air Brake 13 Lift the air brake assembly up and away from the dyno air brake assembly a Figure 3 17 Remove the Brake Assembly 14 Remove the brake pad retaining springs and slide the pads out Note You will need to use pliers to remove the spring securing the outside pad closest to the castle nut 15 Install the new brake pads and secure the pads with new springs 16 Place the air brake assembly back on the brake bracket Refer to Figure 3 17 17 Replace the top and bottom clevis pins and secure with the hairpin cotters removed earlier Refer to Figure 3 14 Figure 3 15 and Figure 3 16 18 Using two bolts and two washers secure the brake caliper stop to the brake bracket Refer t
120. yno room using concrete anchors You will want to drill the holes and secure the dyno before placing the covers on your dyno Note You may wish to drill the holes for the carriage mounting plate and blower mounts at this time Refer to page 2 18 for carriage plate instructions and page 2 22 for blower mounts and support arm instructions You will need the following parts e 37513200 Anchor Redhead 3 8 6 e 37518200 Installation Tool Redhead Anchor e DM150 002 007 Washer 5 16 Flat 6 e DM150 019 012 Bolt 3 8 16 x 1 Hex 6 1 Markand drill each hole needed as shown in Figure 2 11 to secure the drum and brake modules to the pit floor 2 Install the Red Head anchors Refer to Appendix A for installation instructions drill holes drill holes drill holes PDO14 Figure 2 11 Secure the Drum and Brake Module to Pit Floor 2 16 ayaa 5 In Ground Model 200iP 250iP Motorcycle Dynamometer Installation Guide INSTALLATION S Pickup Card S PICKUP CARD The pickup card is an electronic circuit board that accurately senses each drum revolution 1 Locate the pickup card bracket on the starter side of the dyno just ahead of the drum 2 Install the pickup card to the bracket using two No 8 screws Do not tighten the card must be aligned first Note If your dyno is equipped with an air brake you will need to attach compressed air and power to your dyno before you can turn the drum 3 Align the optical pickup ca

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