98200024.03 Model SD12 Scooter Dynamometer Installation Guide
Contents
1. 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 Model SD12 Scooter Dynamometer Installation Guide e ons 3 7 Y CHAPTER 3 Y Pre Run Inspection BEFORE STARTING THE ENGINE Connect an exhaust hose or hoses if dual exhaust on the vehicle make sure the hose fits over the tail pipe is not plugged or kinked and the hose is vented correctly out of the dyno room WARNING PEN Engine exhaust contains poisonous carbon monoxide gas Breathing it could cause death Operate machine in well ventilated area ENGINE WARM UP Warm the 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 e 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 3 8 Maa 05 Model SD12 Scooter Dynamometer Installation Guide Version 3 BASIC DYNO OPERATION yu e Making a Test Run MAKING A TEST RUN Dyno runs provide safe reliable road2. RES EAR CH INSTALLATION GUIDE For Model SD12 Scooter Dynamometers P N 98200024 03 2010 2011 Dynojet Research Inc All Rights Reserved Installation Guide For Model SD12 Scooter 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 98200024 Version 3 05 2011 Dynamometer Number TABLE OF CONTENTS Warnings sro iaia i Chapter 1 Specifications and Operating Requirements INMOMUCHON 3a i RITT
3. warnings iii weight 1 4 wheel clamp 2 5 width 1 4 wiring breakout board jumpers 2 8 pickup card cable 2 8 Y your dyno room 1 3 equalizer box 1 3 exhaust extraction 1 3 fire suppression 1 3 intake air fan 1 3 noise control 1 3
4. D12 Scooter Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIREMENTS 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 98118103 9 pin hand held pendant system expansion connector RPM inductive pickup socket 25 pin socket atmospheric sensing module Fe RPM module Leg input output module e CPU module power 9 pin RS 232 socket 3 pin power plug Figure 1 3 The Dyno Electronics 1 7 Version 3 Model SD12 Scooter 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 e Unpacking the Dyno page 2 2 e Installation page 2 4 Fold and Move the Dyno page 2 10 e Accessories page 2 13 2 1 Model SD12 Scooter Dynamometer Installation Guide Y CHAPTER 2 r Unpacking the Dyno UNPACKING THE DYNO When you receive your dyno examine the exterior of the shipping container for any visible damage If damage is detected at this stage contact the shipper or Dynojet before proceeding with unpacking Use the following steps to
5. computer For more information on wiring the Breakout board refer to Wiring the Breakout Board on page 2 8 For more information on connecting cables to the dyno electronics refer to Dyno Electronics on page 1 7 breakout board pickup card cable 25 pin computer cable pickup card Figure 2 6 Routing Cables 2 7 Version 3 Model SD12 Scooter Dynamometer Installation Guide CHAPTER 2 Installation WIRING THE BREAKOUT BOARD 1 Attach the pickup card cable to the Breakout board The pickup card cable has four wires which connect to the wiring block labeled DRUM 1 Red wire connects to R1 Black wire connects to B1 e White wire connects to W1 Ground shield wire connects to S1 2 Attach the 25 pin RS232 computer cable to the Breakout board 3 Verify jumpers J1 and J2 are set for the digital brake as shown in Figure 2 7 25 pin computer cable SH ne P 4 Y ol m a pickup card e ea nati JZ Ji ES UN EN digital brake e di 63 si Y ET RESEARCH CB008 Figure 2 7 Wire the Breakout Board 2 8 yam Model D12 Scooter Dynamometer Installation Guide Version 3 INSTALLATION S e Installation I
6. area There is a carbon monoxide hazard with all internal combustion engines Engine exhaust contains poisonous carbon monoxide gas Breathing it could cause death Any dyno room design must incorporate sufficient exhaust extraction Always wear proper ear and eye protection when operating the dynamometer Never operate the dynamometer with the covers removed Never stand behind the dynamometer when in operation Never operate the dynamometer when there is excessive vibration or noise Resolve these problems before proceeding Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken Verify brake operation before beginning any dynamometer testing Verify the vehicle is properly secured to the dynamometer Never operate the blowers without the guards installed Exercise care with any dynamometer testing portions of the dynamometer and vehicle may become hot As with any equipment using electricity and having moving parts there are potential hazards To use this dynamometer safely the operator should become familiar with the instructions for operation of the dynamometer and always exercise care when using it Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically recommended in published user repair instructions that you understand and have the skills to carry out Version 3 Model SD12 Scooter Dynamometer Installation Guide SPECIFICATIONS AND OPERATING REQUIRE
7. axle shaft axle shaft retaining ring ug Figure 2 3 Install the Axle Shaft and Retaining Rings Slide the wheel clamp onto the front support 5 Lift the spring plunger to slide the wheel clamp to a different position Release the spring plunger to lock the wheel clamp in the new position Note The wheel clamp may already be installed wheel clamp spring plunger Figure 2 4 Install the Wheel Clamp 2 5 Version 3 Model SD12 Scooter Dynamometer Installation Guide CHAPTER 2 f Installation 6 Route the control cable lever and control lever bracket from the drum along the inside of the front support Note The control cable is coiled up and secured to the drum 7 Secure the control lever bracket to the inside of the front support using two 1 4 20 x 5 8 inch pan head torx screws 8 Secure the control cable to the inside of the front support using two cable ties control lever control lever bracket control cable cable ties Figure 2 5 Install the Control Lever Bracket and Cable 2 6 A Model SD12 Scooter Dynamometer Installation Guide INSTALLATION Installation ROUTING CABLES 1 Route the pickup card cable to the Breakout board Note The pickup card is already installed and is located on the drum 2 Route the 25 pin RS232 computer cable from the Breakout board to the dyno electronics CPU Module 3 Route the 9 pin cable from the RS232 port on the dyno electronics to your
8. categories Loading the Vehicle page 3 2 Connecting the RPM Pickup page 3 4 Pre Run Inspection page 3 7 Making a Test Run page 3 9 e Preventative Maintenance page 3 10 3 1 Model SD12 Scooter Dynamometer Installation Guide Y CHAPTER 3 r Loading the Vehicle LOADING THE VEHICLE Use the following steps to load a vehicle on the dyno PSN WARNING Risk of injury Always wear proper eye and ear protection when operating the dyno 1 Verify your computer is running Verify the wheel clamp is at the front of the front support Lift the spring plunger to slide the wheel clamp to a different position Release the spring plunger to lock the wheel clamp in the new position 3 Drive the vehicle onto the dyno and align the vehicle straight with the dyno Stop the vehicle when the drive axle is centered on the drum 5 When the vehicle is positioned properly on the dyno shut the engine off e Ifthe vehicle has an automatic transmission apply the parking brake e Ifthe vehicle has a manual transmission place it in gear 6 Slide the wheel clamp up to the front tire of the vehicle Lift the spring plunger to slide the wheel clamp to a different position Release the spring plunger to lock the wheel clamp in the new position 7 Turn the wheel clamp handle until the front tire is held securely in the wheel clamp slide the wheel clamp ES a pe A center drive axle wheel clamp on dyno dru
9. two secondary pickups Attach one pickup on each spark plug system wire on the same coil and set the degrees between plug fires to 360 in WinPEP 7 Primary pickup Attach the primary wire pickup to the primary side of the coil Set the degrees between plug fires by taking 720 four cycle engines or 360 two cycle engines divided by the number of coils For example the number of degrees between plug fires on a four cylinder four cycle engine with dual coils where each coil fires two cylinders is 720 4 x 2 360 3 4 Puan Model D12 Scooter Dynamometer Installation Guide Version 3 BASIC DYNO OPERATION Connecting the RPM Pickup gt CONNECTING THE SECONDARY INDUCTIVE PICKUP 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 SOTO PEN The inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration Do not drop the inductive pickup or snap the pickup closed Use extreme care in handling and placement of the pickups 1 Clip the secondary inductive pickup around one spark plug wire Note On a wasted spark ignition system two secondary inductive pickup wires may be needed 2 Route the inductive pickup cable clear of devices that produce electronic noise spark plug wires coil wire coil etc to the dyno electronics RPM module Note Inductive pickup place
10. unload your dyno You will need to provide equipment capable of lifting a minimum of 454 kg 1000 pounds to move the crated dyno into position in your dyno room Refer to Dynamometer Specifications and Requirements on page 1 4 for more information The following directions describe how to unpack and install your dyno Follow the directions in the order that they are presented UNPACKING THE DYNO 1 Move the crated dyno to a clear area near your dyno room 2 Using a pry bar or a large flat screwdriver and a hammer carefully remove the top and sides of the crate Note At this point you will want to inspect the exterior of the dyno for any indications of damage Report any damage immediately Be sure you record the dynamometer number on the inside cover of this manual 3 Remove the hardware boxes from the crate 4 Verify the contents of the hardware boxes and set aside description part description drum wheel clamp P N 71300003 front support dyno electronics P N 76199001 ramp inductive secondary pickup Di P N DE100 109S SIKA 1 2 2 Mapa 03 Model SD12 Scooter Dynamometer Installation Guide INSTALLATION Unpacking the Dyno part description part description axle shaft 2 inductive primary pickup P N 22100011 clip P N DE100 110L gt retaining ring 1 2 4 cable tie 4 2 gt P N 32800000 P N 197104130 screw 1 4 20 x 5 8 pan SN head torx 2 A P
11. 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 components or wiring Disconnect all power cords before servicing electrical components for the greatest assurance of safety Rene 0 iii Model D12 Scooter Dynamometer Installation Guide e Y WARNINGS y PSN WARNING 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 res
12. ER 1 2 Conventions Used In This Manual 1 2 Technical SUpport vaa ais ee ee ec EE 1 2 Your Dyno ROOM iii o ee a a 1 3 Dynamometer Specifications and Requirements 1 4 Chassis Specifications LL 1 4 Compressed Air Requirements 1 6 Computer Specifications 1 6 Environmental Requirements 1 6 Forklift Requirements LL 1 6 Phone and Internet Access 0 2 eee eee ee ee tenes 1 6 Tie Down Straps LL 1 6 DUNG FIGCIONICS opor sss Gees eee snake aaa aegis 1 7 Chapter 2 Installation Unpacking the Dyno rotors ilaele 2 2 Unpacking the Dyno LL 2 2 Removing the Drum from the Crate LL 2 3 Installation oes bcse eg sie ses obs bd ce dh ce che i iieiea aires 2 4 Installing the Front Support 2 4 ROUTING Cables cuco e a ini 2 7 Wiring the Breakout Board 2 8 Installing the Ramp o 2 9 Fold and Move the Dyno sergorarso ida 2 10 Folding the Dyno 1 2 2 eee eee eee nee 2 10 Moving the Dyno LL 2 11 Opening the DyN0 LL 2 12 ACCESSONES Soe G eae sane seed dies hens 2 13 Compressed Air Pump Assembly LL 2 13 Stand Alone Blowers LL 2 13 Model SD12 Scooter Dynamometer Installation Guide Y TABLE OF CONTENTS Chapter 3 Basic Dyno Operation Loading the Vehicle 2 45524 ode rra a iaia 3 2 Connecting the RPM Pickup errori terna 3 4 RPM Pickup Descriptions 0 0 eee eee eee nee 3 4 Connecting the Secondary Inductive Pickup LL 3 5 Connecting The Primary Inductive Pic
13. MENTS Thank you for purchasing Dynojet s Model SD12 Scooter Dynamometer Dynojet s software and dynamometers will give you the power to get the maximum performance out of vehicles you evaluate Whether you are new to the benefits of a chassis dynamometer or an experienced performance leader the repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer will give you the professional results you are looking for This document provides instructions for installing the scooter 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 98200024 Version 3 Last Updated 05 24 2011 This chapter is divided into the following categories Introduction page 1 2 e Dynamometer Specifications and Requirements page 1 4 e Dyno Electronics page 1 7 1 1 Model SD12 Scooter Dynamometer Installation Guide Y CHAPTER 1 f 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 I
14. Move the Dyno OPENING THE DYNO 1 Lift the spring plunger and slide the wheel clamp forward Release the spring plunger to lock the wheel clamp in position 2 Lower the ramp to the floor 3 Squeeze the control lever to release the front support 4 Lower the front support to the floor slide wheel clamp forward control lever lower ramp Figure 2 11 Opening the Dyno 2 12 yma 05 Model SD12 Scooter Dynamometer Installation Guide INSTALLATION va Accessories ACCESSORIES This section describes the various optional accessories that are available for the scooter dyno to meet your individual needs For more information about these accessories please contact Dynojet s Product Specialists at 1 800 992 3525 for pricing and availability Complete installation instruction manuals may also be found by browsing the Manuals folder on your WinPEP installation CD COMPRESSED AIR PUMP ASSEMBLY Refer to the Compressed Air Air Fuel Ratio Module Installation and User Guide P N 98200006 for proper operating and maintenance procedures Refer to the Flow Meter User Guide P N 98129104 to test your air pump for accuracy Failure to follow proper procedures may result in inaccurate data or damage to the equipment These manuals can be found on your WinPEP CD or at www dynojet com PN WARNING The sensor and the copper sample tube are hot Before touching the sensor or the sample tube make sure it has cooled Leaded r
15. N 36561045 REMOVING THE DRUM FROM THE CRATE You will need to provide a 5 8 inch x 3 foot steel bar to lift the drum off the crate and into position in your dyno room Lifting the drum will require two people 5 RECORD_ Be sure you record the dynamometer number on the inside cover of this manual 1 Remove the lag bolts and washers securing the drum to the crate base using a 9 16 inch socket open or box end wrench 2 Insert the 5 8 inch x 3 foot steel bar into the shaft hole 3 Using two people carefully lift the drum off the crate and move into position in your dyno room shaft hole steel bar Figure 2 1 Insert the Steel Bar and Lift the Drum off the Crate 2 3 Version 3 Model SD12 Scooter Dynamometer Installation Guide CHAPTER 2 fy Installation INSTALLATION Use the following steps to install the scooter dyno You will need the following parts e Drum e Front Support e Ramp e 197104130 Cable Tie 4 2 e 22100011 Axle Shaft 2 e 32800000 Retaining Ring 1 2 4 e 36561045 Screw 1 4 20 x 5 8 Pan head Torx 2 e 71300003 Wheel Clamp INSTALLING THE FRONT SUPPORT 1 Place the front support on the drum front support Figure 2 2 Place Front Support on the Drum 2 4 Model D12 Scooter Dynamometer Installation Guide INSTALLATION amp i Set Installation 2 Install the front support axle shaft 3 Secure the shaft in place using two retaining rings
16. NSTALLATION This chapter describes the procedures for installing the dyno BASIC DYNO OPERATION This chapter describes basic dyno operating procedures 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 AGE ANTA b RECORD 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 choice For example select File Open means select the File menu then select the Open choice on the File menu For assistance please contact Dynojet Technical Support at 1 800 992 3525 or write to Dynojet at 2191 Mendenhall Drive North Las Vegas NV 89081 Visit us on the World Wide Web at www dynojet com and www winpep com where Dynojet provides state of the art technical support on line shopping 3D visualizations and press releases about our latest product lines 1 2 Mo
17. NSTALLING THE RAMP 1 Place the ramp on the drum 2 Install the ramp axle shaft 3 Secure the shaft in place using two retaining rings ramp Y axle shaft retaining ring Figure 2 8 Install the Ramp Model SD12 Scooter Dynamometer Installation Guide 2 9 Y CHAPTER 2 ay Fold and Move the Dyno FOLD AND MOVE THE DYNO Use the following instructions to fold and move the scooter dyno FOLDING THE DYNO 1 Lift the front support up until it clicks and locks into place 2 Lift the spring plunger and slide the wheel clamp forward on the front support Release the spring plunger to lock the wheel clamp in position 3 Raise the ramp until it comes in contact with the front support 4 Lift the spring plunger and slide the wheel clamp until it locks the ramp in place Release the spring plunger slide wheel slide wheel clamp to clamp forward N lock ramp in place raise ramp lock front support in place Figure 2 9 Folding the Dyno 2 10 aya Model SD12 Scooter Dynamometer Installation Guide INSTALLATION S Fold and Move the Dyno MOVING THE DYNO 1 With the scooter dyno in the folded position grab the front support leg brace 2 Tilt the dyno towards you 3 Roll the dyno to the desired position front support leg brace front support leg brace Figure 2 10 Moving the Dyno 2 11 Version 3 Model SD12 Scooter Dynamometer Installation Guide Y CHAPTER 2 ay Fold and
18. acing fuels and two stroke applications will contaminate the sensor and dramatically shorten its service life The sensor is not covered by a warranty Be sure to read and understand the Compressed Air Air Fuel Ratio Module Installation and User manual Before turning the pump on verify there is no water in the hose Warm up the vehicle before placing the copper sample tube in the exhaust to avoid drawing excess water through the pump assembly Keep the air pump assembly upright Tipping the pump assembly may result in damage to the sensor Leaks in the system will result in erroneous readings Verify there are no cracks or holes in the hose Verify the sensor is seated properly in the sensor block To ensure accurate readings pump maintenance should be performed every six months or sooner depending on usage Refer to the Compressed Air Air Fuel Ratio Module Installation and User Guide for more information STAND ALONE BLOWERS Refer to the High Pressure Blower Installation Guide P N 98220105 for proper installation and operating procedures These manuals can be found on your WinPEP CD or at www dynojet com 2 13 Version 3 Model SD12 Scooter Dynamometer Installation Guide BASIC DYNO OPERATION This chapter includes instructions for basic dyno operation For more detailed instructions refer to the WinPEP 7 User Guide This manual can be found on your WinPEP CD or at www dynojet com This chapter is divided into the following
19. better flow e Fittings to hook your air system to a 3 8 inch inside diameter hose if no air brake is present optional air regulator COMPUTER SPECIFICATIONS You will need to provide a computer system to run the WinPEP software WinPEP 7 includes complete documentation in online Help From the WinPEP 7 menu bar choose Help 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 ENVIRONMENTAL REQUIREMENTS description specifications Temperature operating min max 10 C 50 C 50 F 122 F storage min max 0 C 60 C 32 F 140 F Humidity 0 to 95 non condensing FORKLIFT REQUIREMENTS You will need to provide equipment capable of lifting a minimum of 454 kg 1000 Ib to lift and move the crated dyno You will need to provide a 5 8 inch x 3 foot steel bar to lift the drum off the crate PHONE AND INTERNET ACCESS Dynojet recommends you have a phone close to the dyno to call for assistance in an emergency You may also wish to contact Dynojet to troubleshoot your dyno Internet access on your computer is desirable for contacting Dynojet and downloading new information and updates TiE DOWN STRAPS Dynojet recommends using motorcycle tie down straps for securing the bike on the dyno You will need to provide the tie down straps 1 6 pam Model
20. del D12 Scooter Dynamometer Installation Guide Version 3 SPECIFICATIONS AND OPERATING REQUIREMENTS six 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 be designed with safety in mind Intake Air Fan After building your dyno room you will need to supply an intake air fan The intake air fan supplies air to cool the bike s engine while supplying fresh oxygen for you and your bike to breathe It is a common misconception that you cannot tune a bike without a large fan simulating exact road conditions however a good cooling fan is the only requirement for consistent diagnostics and tuning The installed fan should be 5200 CFM Equalizer Box If the air flow rate coming into the dyno room is greater than the air flow rate leaving the dyno room the room will become pressurized A pressurized dyno room will make measured power misleading To compensate you need an equalizer box The equalizer box is a baffled to reduce noise vent to the outside of your dyno ro
21. kup 3 6 Pre Run Inspection 305560535 RA A 3 7 Before Starting the Engine LL 3 8 Engine Warm Up rss eevee mamata ia 3 8 After Engine Warm Up 3 8 Making a Test Run lt si0s aa eta eda 3 9 Preventative Maintenance 32 lt 2 22020 3 10 Adjusting the Brake 3 10 Adjusting the Brake Tension LL 3 11 Index Sot ee Eee Ee e as ae data Index i Model SD12 Scooter Dynamometer Installation Guide WARNINGS Disclaimers Dynojet Research Inc Dynojet makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability for any particular purpose Dynojet reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation of Dynojet to notify any person of such revision or changes Dynojet is not responsible for false operation due to unexpected dynamometer operation such as may be caused by static software bugs hardware failure etc Dynojet is not responsible for damage resulting from improper installation of the dynamometer or from improper service rendered to the dynamometer Dynojet is not responsible for damage incurred due to alteration of the dynamometer or components use of unapproved parts or abuse to the dynamometer Do not connect or disconnect cables or components on the dynamometer with the power on Always wear protective clothing ear protection and eye protection goggles safety glasses
22. m handle Figure 3 1 Load the Vehicle 3 2 pent Model SD12 Scooter Dynamometer Installation Guide BASIC DYNO OPERATION Loading the Vehicle 8 Extend the tie down outriggers 8a Remove the spring pins 8b Slide out the tie down outriggers 8c Replace the spring pins tie down outrigger spring pin Figure 3 2 Extend the Tie Down Outriggers 9 Attach two tie down straps from the tie downs on the dyno to the frame or luggage rack of the vehicle 10 Tighten the tie down straps evenly making sure the drive wheel remains centered on the drum PN WARNING Never perform a dyno run if the tie down straps are not in place or they are damaged Figure 3 3 Attach the Tie Downs e _____ __ _ __ _ __ ___ mm 3 3 Version 3 Model SD12 Scooter Dynamometer Installation Guide Y CHAPTER 3 dy 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 o
23. ment is important Position the inductive pickup so that it is not making contact with any other spark plug wires Separate the spark plug wire from the spark plug wire bundle for proper operation Note You must ground the vehicle to the dyno for the electronics to function properly coil connect secondary inductive pickup on o the coil wire connect secondary inductive pickup on the coil wires O vr coil D Figure 3 4 Connect the Secondary Inductive Pickup 3 5 Model SD12 Scooter Dynamometer Installation Guide Y CHAPTER 3 dy Connecting the RPM Pickup CONNECTING THE PRIMARY INDUCTIVE PICKUP The primary inductive pickup cannot be in contact with or it s connecting wire be crossing other engine electrical wires or stray RF interference may result ATENTA The inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration Do not drop the inductive pickup or snap the pickup closed Use extreme care in handling and placement of the pickups 1 2 Clip the primary inductive pickup around the wire to the primary side of the coil Route the primary wire cable clear of devices that produce electronic noise to the dyno electronics RPM module Note You must ground the vehicle to the dyno for the electronics to function properly coil connect primary inductive pickup on A the negative side of i the coil x d Xx i E E i E Figure 3 5 C
24. naked flame or spark may cause battery explosion with dispersion of casing fragments and corrosive liquid electrolyte Carefully follow manufacturer s instructions for installation and service Keep away all sources of gas ignition and do not allow metallic articles to simultaneously contact the negative and positive terminals of a battery Do not allow the positive and negative terminals to short circuit The dynamometer chassis is tied to the negative side of the battery Do not short between the positive battery terminal or the starter connections to the chassis In addition make sure metal tools such as screw drivers wrenches and torque wrenches do not come in contact with the negative and positive terminals of the battery Short circuiting the terminals of the battery can cause burn injuries damage to the dynamometer or trigger explosions Charging Batteries being charged will generate and release flammable hydrogen gas Charging space should be ventilated Keep battery vent caps in position Prohibit smoking and avoid creation of flames and sparks nearby Wear protective clothing eye and face protection when charging or handling batteries Model D12 Scooter Dynamometer Installation Guide WARNINGS 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
25. ne 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 ACUTE Inductive pickups are very fragile The ferrite core can easily be damaged and is not covered under warranty Dropping snapping vibration and heat can all damage the ferrite core The dyno electronics RPM module contains the electronics that sense the RPM pulses An auto gain circuit looks at only the peak voltage of the vehicles 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
26. o operate your dyno safely CHASSIS SPECIFICATIONS description specifications Length dyno 218 70 cm 86 10 in with ramp 335 92 cm 131 25 in Height to top of dyno to top of wheel clamp Width of dyno of dyno with tie downs Weight dyno crated dyno Drum diameter width Frame Maximum Speed Maximum Scooter Length front of front wheel to center of rear wheel Remote Switches Model D12 Scooter Dynamometer Installation Guide 31 00 cm 12 21 in 61 10 cm 24 05 in 48 21 cm 18 98 in 86 36 cm 34 00 in 272 kg 600 pounds 30 50 cm 12 00 in 35 56 cm 14 00 in structural steel 175 KPH 109 MPH 188 27 cm 74 125 in remote software control SPECIFICATIONS AND OPERATING REQUIREMENTS g Dynamometer Specifications and Requirements gt 48 21 cm 18 98 in ae 86 36 cm 34 00 in 335 92 cm 131 25 in SD001 86 10 in 61 10 cm 24 05 in 31 00 cm 12 21 in Figure 1 1 Model SD12 Dyno Dimensions Folding Ramp Tie Down Front Support Wheel Clamp Air Pump Option not shown Stand Alone Blowers Option not shown Drum Module Brake Release Figure 1 2 Model D12 Dyno 1 5 Version 3 Model SD12 Scooter Dynamometer Installation Guide Y CHAPTER 1 ay Dynamometer Specifications and Requirements COMPRESSED AIR REQUIREMENTS The following requirements are needed for optional compressed air pump assembly e Clean and dry air 100 psi or greater 5 CFM or
27. om 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 NN WARNING PAN Engine exhaust contains poisonous carbon monoxide gas Breathing it could cause death Operate machine in well ventilated area Fire Suppression Always have adequate fire suppression or fire extinguishers in your dyno room Industrial Noise Control Inc Industrial Noise Control Inc offers a zinc coated steel room custom built to your specifications This room meets all dyno room requirements The dyno room must be clean and dry with a comfortable room air temperature above 32 degrees Fahrenheit 0 degrees Celsius and have some system of exhaust extraction For more information on a dyno room refer to your Pre Installation Guide For Model 200i 250i 200iB and 250iP Motorcycle Dynamometers P N 98129103 1 3 Model SD12 Scooter Dynamometer Installation Guide 1 4 Y CHAPTER 1 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 t
28. onnect the Primary Inductive Pickup 3 6 Mana 03 Model D12 Scooter Dynamometer Installation Guide Version 3 BASIC DYNO OPERATION 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 scooters equipped with a drive chain check the chain and the chain master link Make sure it is lubricated and adjusted to the proper tension Check the tire pressure and tire speed rating Improperly inflated tires or exceeding the maximum speed rating can result in premature wear or severe tire damage Make sure the tire has no major deficiencies cracks in sidewalls tread life etc 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
29. ontrol 1 3 E electrostatic discharge iv environmental requirements 1 6 equalizer box 1 3 ESD precautions iv exhaust extraction 1 3 eyebolt 3 11 F fire suppression 1 3 folding the dyno 2 10 forklift requirements 1 6 front support axle shaft 2 5 control cable 2 6 installing 2 4 wheel clamp 2 5 Index i Model D12 Scooter Dynamometer Installation Guide Y INDEX H hazards v height 1 4 Industrial Noise Control Inc 1 3 inspection 3 7 intake air fan 1 3 jumpers 2 8 L length 1 4 lifting bar 1 6 2 3 loading the vehicle 3 2 M maintenance 3 10 making arun 3 9 moving the dyno 2 11 O opening the dyno 2 12 P phone internet access 1 6 pickup card wiring to breakout board 2 8 pickup card cable 2 7 pre run inspection 3 7 preventative maintenance 3 10 primary inductive pickup 3 6 R ramp 2 9 requirements 1 4 chassis specifications 1 4 compressed air 1 6 computer specifications 1 6 environmental 1 6 forklift 1 6 phone internet access 1 6 tie down straps 1 6 routing cables pickup card 2 7 2 8 RS232 2 7 2 8 RPM pickup connecting 3 4 primary inductive pickup 3 6 secondary inductive pickup 3 5 RS232 cable 2 7 Index ii Model SD12 Scooter Dynamometer Installation Guide S secondary inductive pickup 3 5 specifications 1 4 stand alone blowers 2 13 I technical support 1 2 testing dyno test run 3 9 tie down straps 1 6 3 3 U unpacking dyno 2 2 using the dyno 3 9 W
30. osition turn the 1 4 20 nut on the eyebolt clockwise to increase the spring tension until the drum can no longer be turned by hand 3 Verify the brake releases when the pedal is fully depressed Note The eyebolt can be adjusted until it touches the lever on the release shaft mechanism If the eyebolt makes contact when the brake release pedal is fully depressed then the eyebolt has been adjusted too far Back off the eyebolt nut until it no longer contacts the lever eyebolt adjust brake tension here brake release pedal Figure 3 7 Adjust the Brake Tension Model SD12 Scooter Dynamometer Installation Guide 3 11 A accessories 1 5 compressed air pump 2 13 stand alone blowers 2 13 air pump assembly 2 13 axle shaft 2 5 B battery hazards iv blowers 2 13 brake tension adjusting 3 11 brake adjusting 3 10 breakout board jumpers 2 8 pickup card 2 8 C cables pickup card 2 8 RS232 2 8 chassis specifications 1 4 height 1 4 length 1 4 weight 1 4 width 1 4 compressed air 1 6 compressed air pump 2 13 computer specifications 1 6 control cable 2 6 conventions 1 2 CPU module 2 7 crate remove dyno 2 3 INDEX D dimensions 1 5 disclaimers iii document part number 1 1 dyno contents 2 2 height 1 4 installing 2 2 length 1 4 unpacking 2 2 weight 1 4 width 1 4 dyno electronics 1 7 dyno room 1 3 equalizer box 1 3 exhaust extraction 1 3 fire suppression 1 3 intake air fan 1 3 noise c
31. r 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 Model SD12 Scooter Dynamometer Installation Guide 3 9 Y CHAPTER 3 o Preventative Maintenance PREVENTATIVE MAINTENANCE This section contains basic preventative maintenance and troubleshooting information 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 e Carriage Slide keep the carriage slide clean and lightly lubricated ADJUSTING THE BRAKE Use the following instructions to prevent the brake from dragging 1 A oy Ww N Remove any vehicles from the dyno Push the brake pedal until it stops Using your hand turn the drum Verify the brake is not dragging If the brake is dragging adjust the brake Using a 7 16 open end wrench adjust the brake stop bolt until there is no brake drag Note Adjusting the bolt too loose or too tight can cause brake drag 3 10 Model SD12 Scooter Dynamometer Installation Guide Figure 3 6 Adjust the Brake Version 3 BASIC DYNO OPERATION yu 6 Preventative Maintenance eS ADJUSTING THE BRAKE TENSION Use the following instructions to adjust the brake tension 1 Locate the eyebolt brake tension adjuster 2 With the brake release pedal in the up p
32. 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 2 3 4 5 Verify the vehicle is secured properly Release the dyno brake by pressing the brake pedal Slowly accelerate the vehicle to 20 m p h Test the tachometer operation 4a Rev the engine The gauges on the computer screen should be moving If the tachometer is moving but not registering the correct RPM values the number of degrees of revolution of the 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 Step off the brake pedal to apply 100 braking and slow down the vehicle ACE Using the vehicles own brakes to slow or stop the drum at speeds over 30 m p h can severely over heat the brake parts The vehicles brakes should be used in an emergency stop situation only 6 Shut the engine off and put the vehicle in gear manual transmission or apply the parking brake automatic transmission Set the vehicle s parking brake and leave the dyno brake on 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 othe
33. ult of the energy released when the discharge touch occurs The difference of potential can accumulate by as simple an action as a user moving across carpet or a seat If that person s energy is discharged directly to the electronics the electronics can be damaged Precautions To protect against ESD damage you must eliminate the difference of potential before the electronics are handled Touch the chassis of the dynamometer before touching any of the electronics By touching the chassis you discharge any static shocks to the chassis instead of to the electronics If you are holding a circuit board or dynamometer component in your hand when you approach the machine touch the chassis of the dynamometer with your hand before installing the circuit board or component When handing a circuit board or component to someone touch that person with your hand first then hand them the component Always carry circuit boards in anti static bags when the boards are exposed removed from the dynamometer AG 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
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