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Above Ground Model 200iX/250iX Motorcycle Dynamometer Installation Guide

C

H A P T E R

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S

PECIFICATIONS

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PERATING

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EQUIREMENTS

Thank you for purchasing Dynojet’s Above Ground Model 200iX/250iX 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 Power Core software and a Dynojet dynamometer
will give you the professional results you are looking for.

This document provides instructions for installing the above ground motorcycle
dynamometer (dyno) along with the kart upgrade. This document will walk you
through operating requirements, installation, accessories, and basic dyno operation.
To ensure safety and accuracy in the procedures, perform the procedures as they are
described.

Document Part Number: 98200077

Version 2

Last Updated: 07-25-2016

This chapter is divided into the following categories:

• Introduction, page 1-2

• Dynamometer Specifications and Requirements, page 1-5

• DynoWare RT Electronics, page 1-11

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Summary of Contents for 200iX

Page 1: ......

Page 2: ...f 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...

Page 3: ...nd Drill Bit Requirements 1 9 Electrical Requirements 1 9 Environmental Requirements 1 9 Forklift Requirements 1 9 Ground Hook Requirements 1 9 Grounding Requirements 1 10 Phone and Internet Access 1...

Page 4: ...embly 2 45 Installing the Carriage Assembly 2 46 Monitor Support and Tray 2 49 Control Panel and Cable 2 50 Final Adjustments and Tests 2 53 Turning On the Dyno Power 2 53 High Pressure Blower Test 2...

Page 5: ...er 4 6 Using the Status Indicator 4 7 Using the Wheel Clamp 4 7 Power Distribution Assembly 4 9 Main Circuit Breaker 4 9 High Pressure Blower Circuit Breakers 4 9 Maintenance and Troubleshooting 4 10...

Page 6: ...he Building B 7 Appendix C EEC Kit Installation EEC Finger Guards Installation C 2 Removing the Drum Module Hood C 2 Installing the EEC Finger Guards C 3 Adjusting the EEC Finger Guards C 4 Door Safet...

Page 7: ...on 2 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Appendix F Torque Values Standard Bolt Torque Values F 2 Grade 5 F 2 Grade 8 F 3 Metric Bolt Torque Values F 4 Grade 8 8 F...

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Page 9: ...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 o...

Page 10: ...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 CAUTION Battery...

Page 11: ...d 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 u...

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Page 13: ...tools of Power Core software and a Dynojet dynamometer will give you the professional results you are looking for This document provides instructions for installing the above ground motorcycle dynamo...

Page 14: ...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...

Page 15: ...line shopping and press releases about our latest product lines example of convention description CAUTION The Caution icon indicates a potential hazard to the dynamometer equipment Follow all procedur...

Page 16: ...o 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...

Page 17: ...atteries This battery is not included with your dyno You will need to provide this battery For more information on installing the battery refer to Battery on page 2 13 CHASSIS SPECIFICATIONS descripti...

Page 18: ...C H A P T E R 1 Dynamometer Specifications and Requirements Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 1 6 Figure 1 1 Model 250iX Dyno Dimensions...

Page 19: ...amometer Installation Guide Figure 1 2 Model 250iX Dyno with Accessories iX Drum Module Eddy Current Brake High Pressure Blower Wheel Clamp Option Power Carriage Option Monitor Support and Tray Model...

Page 20: ...side diameter hose if no air brake is present 1 4 inch NPT pipe thread compressed air connector optional air regulator COMPUTER SPECIFICATIONS You will need to provide a computer system to run the Pow...

Page 21: ...n ENVIRONMENTAL REQUIREMENTS FORKLIFT REQUIREMENTS You will need to provide equipment capable of lifting a minimum of 2268 kg 5000 lb to lift the dyno off the crate and into position in your dyno room...

Page 22: ...le on page 5 8 CAUTION Always ground the vehicle to the dynamometer Never operate the dynamometer without properly grounding the vehicle to the dyno PHONE AND INTERNET ACCESS Dynojet recommends you ha...

Page 23: ...consists of a main module and a speed pickup Optional modules include the Air Fuel Ratio AFR module and the Eddy Current Brake ECB driver Use this section to identify the modules and connections More...

Page 24: ...ynos Communication I O Connect to auxiliary dyno electronics such as the pendant atmospheric module AFR module etc Emergency Stop Connects the dyno electronics to the emergency stop input on the 200i...

Page 25: ...network particularly a wireless network With DynoWare RT on a network you don t have to have one dedicated computer for the dyno Any computer on the network can connect and operate the dyno A wireles...

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Page 27: ...the Dyno page 2 2 Dyno Installation page 2 10 Battery page 2 13 Pickup Card page 2 14 Eddy Current Brake page 2 15 Secure the Drum and Brake Module to the Floor page 2 23 Remove the Dyno Covers page 2...

Page 28: ...e the crated dyno into position in your dyno room Refer to Forklift Requirements on page 1 9 for more information 1 Move the crated dyno to a clear area near your dyno room 2 Using a pry bar or a larg...

Page 29: ...he six 1 4 inch screws securing the center panel on the dyno and remove the center panel Note Dynojet recommends using a T30 Torx driver Snap On PFTx30E to remove the 1 4 inch screws 7 Remove the tire...

Page 30: ...llation Guide 2 4 8 Remove the eight screws securing the top drum cover to the dyno and set aside Remove the drum cover and set aside 9 Remove the two top screws securing each side drum cover to the d...

Page 31: ...overs and set aside Note For future reference note the three access holes in the drum bulkhead These access holes will be used to route cables when installing accessories once the top cover is back on...

Page 32: ...r 3 8 flat 4 P N 36923100 grounding kit P N 76100015 see list of parts below anchor redhead 3 8 4 P N 37513200 PCV CAN termination plug P N 76423025 installation tool redhead anchor P N 37518200 CAN t...

Page 33: ...3 cable e stop to CPI P N 76950549 monitor tray P N 61329101P cable load cell P N 76950573 optional accessory eddy current brake P N 62900005 cable CAN powersports P N 76950680 tire stop P N 63310902...

Page 34: ...power carriage P N 82943001 optional accessory see page 3 24 ramp bracket assembly P N 69100001 banner dynojet 2 P N D706 carriage assembly P N 71323002 or extended carriage assembly P N 78100003 hand...

Page 35: ...meter Installation Guide The following parts are included in the Ground Hook Kit P N 79190001 ground hook D ring 1 P N 10111 washer 5 16 flat 2 P N DM150 002 007 washer 3 8 splitlock steel 2 P N 36932...

Page 36: ...no room You will also need a pair of straps capable of supporting 1 133 98 kg 2 500 lbs to attach to the dyno Dynojet recommends using a single loop style strap RECORD Be sure you record the dynamomet...

Page 37: ...part of the dyno is interfering with the strap Do not place the strap around the cable routing bracket or any other part of the dyno Figure 2 6 Loop Strap Placement 4 Carefully lift the dyno off the...

Page 38: ...n the jam nut 4 Hand tighten the knurled nut 5 Gently lower the dyno into position Be sure the location you have chosen for your dyno has enough room in front of the dyno for the maximum extension of...

Page 39: ...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 CAUTION There is danger of explosion if the battery is inc...

Page 40: ...crews 3 Align the optical pickup card with the wheel on the dyno drum axle Be sure the wheel passes freely through the optical pickup You may need to loosen the bracket to help with alignment 4 Once a...

Page 41: ...kip this section and continue with the installation 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...

Page 42: ...20 x 5 8 pan head torx 2 P N 36561045 woodruff key P N 37620622 set screw 2 P N 36580404 cable controller P N 66952003 see page 2 32 washer 3 8 flat 2 P N 36923100 see page 2 23 cable IR temp sensor...

Page 43: ...cycle Dynamometer Installation Guide 3 Remove the four screws securing the top cover and set aside Remove the cover and set aside RECORD Be sure you record the eddy current brake number on the inside...

Page 44: ...6 Place the nylon loop strap through the lifting eyes on either side of the brake 7 Using a forklift lift the eddy current brake from the crate and place the brake near the dyno making sure the panel...

Page 45: ...eline assembly coupler already installed on the brake shaft Note Safety requirements of your local country may require that both the air brake and eddy current brake are installed Be sure to follow th...

Page 46: ...ke and dyno are flush 5 Secure the connector plate to the dyno frame using the four bolts washers and nuts removed earlier There is a connector plate on either side of the brake Refer to Figure 2 15 N...

Page 47: ...eddy current brake to the panels on the dyno using a 1 4 20 bolt Do this on each side Figure 2 16 Secure the Side Panels to the Dyno 9 Replace the existing set screws on the driveline with the thread...

Page 48: ...o bolts and nuts securing the existing bar on the eddy current brake and remove the bar Set the bolts and nuts aside 3 Verify the eyelets on the load cell are spaced the same as the bar removed earlie...

Page 49: ...following parts 36923100 Washer 3 8 Hardened Flat Steel 6 37513200 Anchor Redhead 3 8 6 37518200 Redhead Anchor Installation Tool DM150 019 012 Bolt 3 8 16 x 1 Hex 6 1 Using the dyno and brake module...

Page 50: ...nd side cover from the dyno Be sure to set the covers and screws aside these covers will be installed later on the iX upgrade 1 Remove the five screws securing the top cover to the dyno and set aside...

Page 51: ...into position in your dyno room Note If this is an iXW upgrade refer to Appendix E REMOVING THE ITEMS FROM CRATE 1 Move the crate to a clear area near your dyno room 2 Using a pry bar or a large flat...

Page 52: ...at support the top portion of the crate 5 Remove the four lag bolts and washers securing the drum to the crate base using a 9 16 inch socket open or box end wrench set screw 2 P N 36580404 cable blowe...

Page 53: ...e crate and place the drum module near the dyno with the stepped end of the shaft towards the dyno Make sure the panels on the drum module and the dyno are parallel 5 Remove the two existing screws fr...

Page 54: ...t be flush and parallel If these covers are not flush place shims between the floor and the drum module or the dyno until they are flush 13 Once aligned tighten all screws 14 Secure the side panels on...

Page 55: ...x 5 8 Ph Torx 16 61300007 Monitor Support Brace 76950053 Cable Fan Power Extension 1 Place the monitor support brace on the five studs on the front bulkhead 2 Secure the brace to the studs using five...

Page 56: ...ch the blower power extension cable to the existing blower cable disconnected earlier by matching up the colors 7 Attach the blower power extension cable to the fan socket Connect the brown wire to N...

Page 57: ...Installation Guide 9 Secure the dyno top cover to the bulkheads using the five screws removed earlier 10 Secure the drum side cover to the drum module using the eight 1 4 20 x 5 8 inch button head sc...

Page 58: ...extension cable connects the right blower cable from the CPI to the AC blower socket on the dyno chassis see page 2 30 E 76950201 primary RPM pick up cable 76950203 secondary pick up cable connects t...

Page 59: ...ory O 76950680 CAN powersports cable connects Dynojet Powersports products to the DynoWare RT PCV OBD2 P 76950791 CAN control cable 15 connects the eddy current brake driver to the DynoWare RT using t...

Page 60: ...le into the bracket assembly in the dyno Figure 2 27 Install the DynoWare RT Main Module T 76951501 control panel cable connects the control panel POD to J3 on the POD intercept board U 76423025 PCV C...

Page 61: ...ontrol panel cable and network cable and secure both cables in the other hole on the cable pass through cover The bushing should be around the cable protective wrap 7 Secure the cable pass through cov...

Page 62: ...on the CAN dyno user cable Q and route to the eddy current brake driver Attach the CAN control cable P to the eddy current brake driver 21 Attach the CAN dyno user cable R to the T on the CAN control...

Page 63: ...nation plug U from the front of the DynoWare RT module and save for use with the PCV module 23a Attach the PCV or OBD2 module using the CAN powersports cable O 23b Insert the PCV CAN termination plug...

Page 64: ...ructions refer to Power Carriage on page 3 24 and Wheel Clamp on page 3 27 for more information You will need the following part 43991080 Split Snap Bushing 2 1 Remove the two screws securing the cabl...

Page 65: ...into place in one hole on the cable pass through cover 5 Place a split snap bushing around the power carriage cable and secure into place in the other hole on the cable pass through cover 6 Secure the...

Page 66: ...the center panel be sure to route all your cables and air hoses and install any additional accessories you purchases Note If this is an iXW upgrade refer to Appendix E 1 Secure the eddy current brake...

Page 67: ...current brake six 1 4 20 x 5 8 inch screws removed earlier 3 Secure the drum top cover to the drum using the eight 1 4 20 x 5 8 inch screws removed earlier 4 Secure the center cover to the dyno using...

Page 68: ...wing parts 21200037 Center Cover iX 21200038 Drum Safety Cover 36561045 Screw 1 4 20 x 5 8 Ph Torx 6 1 Secure the drum top cover to the drum module using the six 1 4 20 x 5 8 inch screws removed earli...

Page 69: ...250iX Motorcycle Dynamometer Installation Guide 3 Place the drum safety cover over the drum This cover has two pins to keep it in place Risk of injury Never run a motorcycle on the dyno without this c...

Page 70: ...82034 Bolt 3 8 16 x 1 25 Button head Flange 8 61300009 Fan Arm Mount 2 1 Install the fan arm mount on the right side of the dyno using four 3 8 16 x 1 25 inch button head flange screws 2 Place the fan...

Page 71: ...tton head 6 36500009 Screw 3 8 16UNC x 1 Button head 2 63310902 Tire Stop Assembly 71300002 Trike Carriage Adapter Assembly 71323002 Carriage Assembly INSTALLING THE TRIKE CARRIAGE ADAPTER ASSEMBLY 1...

Page 72: ...cle Dynamometer Installation Guide 2 46 INSTALLING THE CARRIAGE ASSEMBLY 1 Remove the four 1 4 x 20 inch button head screws securing the bearing bracket 2 Remove the bearing bracket and the carriage s...

Page 73: ...hand crank to the screw shaft by tightening the set screw using a 5 32 inch allen wrench 7 Using the hand crank or the control panel to run the power carriage run the carriage screw through the nut b...

Page 74: ...ire stop to the carriage using four 3 8 16 x 1 2 inch button head flange bolts 10 Secure the tire lock to the carriage using four 3 8 16 x 1 2 inch button head flange bolts Note If you purchased the w...

Page 75: ...head flange bolts Note Make sure the fan arm mount is sandwiched in between the dyno panel and the monitor support base 2 Place a 1 8 inch thick poly washer around the pin on the lower monitor arm 3...

Page 76: ...emove the two nuts from the top of the cover and set aside 1b Remove the screw on the top of the cover and set aside 1c Remove the screw on the side of the cover and set aside 1d Remove the four screw...

Page 77: ...panel to either side of the monitor tray using two 8 32 inch screws Note If you did not order a monitor tray you will need to install the control pod spindle on the bottom of your control panel using...

Page 78: ...Note You may want to route the RS232 connector to your computer part way up the support arm along with the control panel and pendant cables depending on where you your computer is located Figure 2 45...

Page 79: ...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 TURN...

Page 80: ...MBLY TEST 1 Using the supplied chain lube or grease lube the front and rear adapter slides unpainted part 2 Pull the pin up to slide the carriage until the pin locks into the next location Verify the...

Page 81: ...Cable Control Panel Cable RPM cable s Additional cables if desired Figure 2 47 Insert the Cable s Into the Cable Holder 3 Rotate the cable holder closed 4 Insert the guide body into the zip tube Note...

Page 82: ...teel 4 37513200 Anchor Redhead 3 8 4 DM150 002 007 Washer 5 16 Flat 4 DM150 019 012 Bolt 3 8 16 x 1 Hex 4 1 Mark the ground hook placement as shown in Figure 2 49 Two additional ground hooks are inclu...

Page 83: ...fy your ramp to secure it to the ramp bracket If you purchased the folding ramp option refer to Appendix D You will need the following part 21629203 Ramp Bracket 1 With the ramp upside down center the...

Page 84: ...3 8 inch bolts from the top of the ramp and secure using 3 8 inch washers and nuts Figure 2 51 Secure the Bolts to the Ramp 4 Remove the four 1 4 inch bolts from the rear of the drum cover 5 Secure th...

Page 85: ...Version 2 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 6 Place the ramp on the ramp bracket slipping the bolts on the ramp through the large holes on the ramp bracket Figur...

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Page 87: ...hased 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...

Page 88: ...your dyno you or your electrician must refer to Appendix B for detailed power instructions Always turn the power off when connecting and disconnecting cables 1 Use the main circuit breaker to turn po...

Page 89: ...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 a...

Page 90: ...ynoWare RT module to P7 on the CPI front panel 4 Attach the two pin connector to the DynoWare RT module 5 Attach the flat four pin connector to P7 on the CPI board 6 Route the air hose from the air br...

Page 91: ...the brake and stops the drum Installing the emergency stop sticker indicates the added functionality applied to the dyno shutdown button 1 Remove the control panel rear cover 1a Remove the two nuts f...

Page 92: ...four screws securing the Button board to the control panel and set aside 2b Remove the Button board and set aside Figure 3 5 Removing the Button Board 3 Unscrew the black switch body nut and remove th...

Page 93: ...ve Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 4 Place the emergency stop sticker over the dyno shutdown sticker Figure 3 7 Placing the Emergency Stop Sticker CP015 97415160 S H...

Page 94: ...switch body to the control panel using the switch body nut removed earlier Figure 3 8 Replacing the Emergency Stop Button 6 Secure the Button board to the control panel using the four screws removed e...

Page 95: ...ADJUSTMENTS AND TESTS 1 Verify the dyno is set up properly the dyno electronics is powered up and operational and the air supply is connected properly 2 Use the red brake button on the pendant or the...

Page 96: ...unplug the dyno Refer to Main Dyno Power on page 3 2 for breaker location 1 Remove the top and right side covers from the dyno 2 For safety apply the brake and disconnect the air supply at the front...

Page 97: ...on Guide 4 Using a 9 16 inch ratchet and wrench remove the bolt washer and nut securing the spring to the brake assembly The spring is located on the drum side of the brake assembly Note For clarity t...

Page 98: ...o the brake bracket and remove the brake caliper stop Note For clarity the drum and parts of the dyno frame are not shown Figure 3 13 Remove the Brake Caliper Stop 6 Remove the hairpin cotter from the...

Page 99: ...f the assembly drum side You do not need to remove the pin completely 8 Remove the hairpin cotter from the top clevis pin located on the drum side of the air brake assembly Figure 3 15 Remove the Bott...

Page 100: ...assembly back on the brake bracket Refer to Figure 3 17 14 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 1...

Page 101: ...the castle nut on the caliper assembly to clamp the brake pads against the rotor and shim Refer to Figure 3 11 for hairpin and castle nut location 4 Tighten the brake caliper stop bolts 5 Loosen the...

Page 102: ...service life The sensor is not covered by a warranty Be sure to read and understand the Air Fuel Ratio Module Installation and User manual Before turning the pump on verify there is no water in the h...

Page 103: ...61300057 screw 5 16 UNC x 1 button head 5 P N 36500008 extended carriage assembly includes the following P N 21224114 P N 32522100 P N 36561045 6 P N 36561670 2 P N 36580434 4 P N 36912100 2 P N 61124...

Page 104: ...the extension support brace mount using two 3 8 x 1 inch hex bolts and two 3 8 16 nylock nuts each 2 Secure each leveling mount using two 3 8 inch nuts Figure 3 19 Assembling the Extension Support Br...

Page 105: ...h button head flange bolts 4 Secure the extension support brace to the extension support and the dyno using two 3 8 x 1 2 inch button head flange bolts 5 Use the leveling mounts to make the support br...

Page 106: ...button head bolts as shown in Figure 3 21 8 Secure the trike carriage adapter assembly to the dyno and the extended support using two 3 8 x 1 inch button head bolts as shown in Figure 3 21 9 Lube the...

Page 107: ...the hand crank or the control panel to run the power carriage run the carriage screw through the nut block until the screw is all the way in the nut block 4 Starting from the back of the dyno slide t...

Page 108: ...Place an aluminum washer between the clamp lever and the lower bower arm 5 Secure the lower blower arm to the fan arm mount pin using the clamp lever 6 Place a 1 8 inch thick poly washer around the p...

Page 109: ...Motorcycle Dynamometer Installation Guide CAUTION The blowers can run at any time once the cord is plugged into a power source Figure 3 23 Installing the Blowers upper blower arm new lower blower arm...

Page 110: ...ycles For more information on using the power carriage refer to Using the Power Carriage on page 4 6 You will need the following part 82943001 Power Carriage CAUTION The power carriage motor is preset...

Page 111: ...the coupler jaw with the set screw 4 Secure the motor mount to the carriage using two 1 4 20 x 1 inch bolts and two 1 4 inch lock washers The motor mount is installed in front of the flange bearing If...

Page 112: ...r spider on the carriage screw half of the coupler 8 Place the power carriage motor assembly near the motor mount and plug the motor connector into the power carriage cable 9 Turn the carriage screw t...

Page 113: ...tton Refer to Using the Wheel Clamp on page 4 6 for more information on using the wheel clamp You will need the following parts 71329000 Wheel Clamp Assembly DM150 002 004 Washer 5 16 Lock 4 DM150 002...

Page 114: ...uide 3 28 2 Place the wheel clamp on the carriage Align the four holes on the wheel clamp with the holes on the carriage 3 Secure the wheel clamp to the carriage using four 3 8 16 x 1 2 inch bolts loc...

Page 115: ...he wheel clamp Refer to Routing the Power Carriage and Wheel Clamp Cables on page 2 38 5 Install the wheel clamp cable strain relief to the side of the wheel clamp 6 Plug the wheel clamp cable into th...

Page 116: ...de the CPI door 2 Plug the power plug into the power outlet 3 Replace the CPI cover if it was removed Note Use the main breaker to turn power on and off to the dyno POWER CARRIAGE FINAL ADJUSTMENTS AN...

Page 117: ...rating 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...

Page 118: ...e door on the dyno or door on the external box The user interface is through the control panel which is normally mounted on the side of the monitor tray The control panel allows the user to control th...

Page 119: ...ification A description of the functions and displays follows Figure 4 1 Control Panel Features FORWARD BACK STATUS Flashing Error refer to manual WHEEL CLAMP CLOSE OPEN CAUTION FRONT WHEEL MUST BE SE...

Page 120: ...e description Air Fuel Ratio Air Pump This optional accessory allows control of the internal air pump of the air fuel ratio sampling system Refer to page 4 4 for more information Emergency Stop Dyno S...

Page 121: ...lower will not operate even if the CPI output is on CAUTION The blower outlets on the front of the dyno are designed to only work with Dynojet provided blowers Connecting other electrical loads or oth...

Page 122: ...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...

Page 123: ...If 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 attach...

Page 124: ...ure 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 curre...

Page 125: ...When the handle is in the down position all power into the dyno is turned off Even if this breaker is turned off there is still the potential for lethal voltages to be present in the CPI Always discon...

Page 126: ...I 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...

Page 127: ...nnect the battery and unplug the dyno 1 Open the Control Panel Interface CPI door 2 Gently push the fuse holder slightly inward and rotate counterclockwise Remove the fuse holder 3 Replace the fuse wi...

Page 128: ...r 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 th...

Page 129: ...eds to make quick and accurate evaluations of engine performance and drive train problems This chapter includes instructions for basic dyno operation For more detailed instructions refer to the Power...

Page 130: ...ear proper eye and ear protection when operating the dyno 1 Verify your computer is running Set the dyno brake on by pressing the red button on the hand held pendant 2 Turn the carriage screw handle o...

Page 131: ...round hooks to the rear of the vehicle 7 Attach two tie down straps from the ground hooks to the front of the vehicle Note If you are running an all wheel drive ATV use differential jacks to get the f...

Page 132: ...age the ferrite core The DynoWare RT 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 r...

Page 133: ...ensitive 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 primary inductive pickup around th...

Page 134: ...d 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...

Page 135: ...e computer case to a good earth ground like the receptacle box Keep the computer as far away from the dyno as possible Try attaching one secondary inductive cable to one wire and attach a second induc...

Page 136: ...rate the dynamometer without first grounding the vehicle to the dyno You will need the following parts 21600084 Grounding Bracket 36560834 Screw 1 4 20 x 1 2 76950788 Vehicle Grounding Cable 1 Choose...

Page 137: ...sidewalls tread life etc Note When running an ATV you may need to increase the tire pressure so the tire does not come in contact with the decking Visually inspect the vehicle Make sure it is in safe...

Page 138: ...hine 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 A...

Page 139: ...ure the motorcycle is in neutral or the clutch is in 2 Press and hold the starter button to spin the drum Hold the starter button until the drum reaches maximum speed then release the starter button 3...

Page 140: ...umber is incorrect 5b Select Run File Information to enter vehicle information 6 Place the vehicle in a low gear and release the dyno brake using the hand held pendant 7 Slowly accelerate the vehicle...

Page 141: ...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 the...

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Page 143: ...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 ma...

Page 144: ...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 Figure A 1 Red H...

Page 145: ...crete or below the surface if the hole depth exceeds minimum embedment Figure A 3 Red Head Anchor Drive the Anchor Flush 4 Using a hammer expand the anchor with the setting tool The anchor is properly...

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Page 147: ...edures as they are described Be sure to read and understand the warnings included in this appendix Note The following instructions are intended as a guide to aide in the electrical installation of you...

Page 148: ...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 dyno will be reduced In no case shall all thr...

Page 149: ...e 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 w...

Page 150: ...cuit 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 atta...

Page 151: ...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 T...

Page 152: ...ptacle may be different from the image shown in Figure B 2 however the installation instructions are the same The cable carrying the power to this receptacle should be 4 0 mm2 ten gauge or larger Chec...

Page 153: ...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 s...

Page 154: ......

Page 155: ...added safety measure by automatically activating the dyno s air brake when it is triggered This appendix provides instructions for installing the EEC Kit to the model 200iX 250iX motorcycle dyno This...

Page 156: ...ds using a T30 Torx driver Snap On PFTx30E to remove the 1 4 inch screws For dynos with serial numbers lower than 2030152 Dynojet recommends using a hardened 5 32 inch hex driver such as Snap On FA5E...

Page 157: ...re the EEC Finger Guards 200i 250i and 200iX 250iX 2 Secure the drum module hood with the EEC finger guards to the dyno using the eight screws removed earlier 3 Secure the iX drum module hood with the...

Page 158: ...module 1 Loosen the 1 4 20 inch pan head screws and adjust the EEC finger guards so they are 0 16 cm to 0 64 cm 0625 in to 25 in from the drum Tighten the screws 2 Check the EEC finger guards regularl...

Page 159: ...ck This prevents the dyno from being used when the door is open Components attached to and within the dynamometer operate with potentially lethal voltages To provide the greatest assurance of safety t...

Page 160: ...e 6B position on the J4 connector Figure C 5 Wire the Safety Switch 8 Replace the CPI cover using the screws removed earlier 9 The door safety switch needs to be mounted at the entry of the dyno room...

Page 161: ...he model 200i 250i folding ramp assembly P N 82944001 and the model iX folding ramp assembly P N 82900000 to the Dynojet motorcycle dynamometer dyno To ensure safety and accuracy in the procedures per...

Page 162: ...ION DYNO The folding ramp P N 82944001 allows you to easily and safely load motorcycles onto the dyno This section will walk you through removing the ramp from the crate and installing the ramp on mod...

Page 163: ...on Dyno Version 2 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 2 Remove the crate braces Figure D 2 Remove the Crate Braces 3 Remove the 2x2 brace securing the ramp down Fi...

Page 164: ...Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide D 4 4 Fold the ramp up 5 Remove the front crate panel 6 Remove the braces Figure D 4 Fold Ramp Up and Remove Front Crate Panel...

Page 165: ...cle Dynamometer Installation Guide 7 Remove the two bolts and washers securing the ramp assembly to the crate Only one bolt and washer will be visible from this view Figure D 5 Remove the Bolts and Wa...

Page 166: ...e Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide D 6 8 Remove the ramp by sliding it from the front of the crate Dynojet recommends using two people to remove the ramp from the cra...

Page 167: ...RAMP ON THE DYNO 1 Lower the ramp by pressing on the ramp release with your foot and using the hand knob to gently lower the ramp to the floor Be sure to have someone hold the ramp assembly while lowe...

Page 168: ...Motorcycle Dynamometer Installation Guide D 8 2 Remove the four 1 4 inch button head bolts from the top of the dyno 3 Remove the two 3 8 inch button head bolts from the back of the dyno Figure D 8 Rem...

Page 169: ...tion Guide 4 Slide the ramp up to the dyno 5 Secure the top of the ramp to the dyno using the four button head bolts removed earlier 6 Secure the sides of the ramp to the dyno using the two button hea...

Page 170: ...Refer to Ramp Installation Dyno on page D 2 You will need the following parts 21200029 Tie Down Hook Plate 21200039 Ramp Top Cover 21200047 Ramp Panel 36561045 Screw 1 4 20 x 5 8 PH Torx 8 61300011 F...

Page 171: ...he ramp panel to the iX ramp using four 1 4 20 x 5 8 inch pan head torx screws and four 1 4 20 nuts 6 Secure the ramp panel to the dyno ramp using four 1 4 20 x 5 8 inch pan head torx screws and four...

Page 172: ...crews from the iX ramp as shown in Figure D 12 9 Secure the ramp tie down to the dyno ramp using the four screws removed earlier 10 Secure the ramp tie down to the iX ramp using the two screws removed...

Page 173: ...handle UTV s ATV s karts trikes and motorcycles This chapter will walk you through unpacking and installing the above ground iXW drum module and related items To ensure safety and accuracy in the proc...

Page 174: ...carriage allow 272 00 cm 107 00 in with extended carriage allow 323 00 cm 127 00 in Height to top of dyno cover 46 00 cm 18 00 in Width model 200iXW 231 00 cm 91 00 in model 250iXW 305 00 cm 120 00 i...

Page 175: ...OU N D I XW IN STALL ATI ON Dynamometer Specifications Above Ground iXW Dyno Version 2 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide Figure E 1 Model 250i Dyno with iXW Upg...

Page 176: ...er Installation Guide E 4 Figure E 2 Model 250i Dyno with iXW Upgrade and Accessories iXW Upgrade Module Eddy Current Brake High Pressure Blower Wheel Clamp Option Power Carriage Monitor Support and T...

Page 177: ...to move the crated drum into position in your dyno room REMOVING THE ITEMS FROM CRATE 1 Move the crate to a clear area near your dyno room 2 Using a pry bar or a large flat screwdriver and a hammer ca...

Page 178: ...22 nut 1 4 20 nylock 5 P N 36468100 trike carriage adapter assembly P N 71300002 see page 2 45 screw 5 16 UNC x 1 button head 6 P N 36500008 see page 2 45 cable high pressure blower power extension P...

Page 179: ...f the crate 5 Remove the four lag bolts and washers securing the drum to the crate base using a 9 16 inch socket open or box end wrench The following parts are included in each Ground Hook Kit P N 791...

Page 180: ...iXW drum side cover and set aside Remove the cover and set aside RECORD Be sure you record the iXW drum module number on the inside cover of this manual 4 Place the nylon loop strap around the shaft...

Page 181: ...m module towards the dyno Slide the driveline over the key on the dyno shaft You will need to support the driveline as you slide it onto the dyno shaft 11 Continue sliding the drum module towards the...

Page 182: ...llel If these covers are not flush place shims between the floor and the drum module or the dyno until they are flush 14 Once you have verified the panels are flush and parallel tighten all the screws...

Page 183: ...1045 Screw 1 4 20 x 5 8 Ph Torx 16 61300007 Monitor Support Brace 76950053 Cable Fan Power Extension 1 Place the monitor support brace on the five studs on the front bulkhead 2 Secure the brace to the...

Page 184: ...e blower power extension cable to the existing blower cable disconnected earlier by matching up the colors 7 Attach the blower power extension cable to the fan socket Connect the brown wire to N Conne...

Page 185: ...e the dyno top cover to the bulkheads using the five screws removed earlier 10 Secure the drum side cover to the drum module using the eight 1 4 20 x 5 8 inch button head screws removed earlier Figure...

Page 186: ...O Before replacing the center panel be sure to route all your cables and air hoses and install any additional accessories you purchases Refer to Cable Routing on page 2 32 and Chapter 3 Accessories 1...

Page 187: ...ke top cover to the eddy current brake six 1 4 20 x 5 8 inch screws removed earlier 3 Secure the drum top cover to the drum using the eight 1 4 20 x 5 8 inch screws removed earlier 4 Secure the center...

Page 188: ...r iXW 21200206 Right Cover iXW 36561045 Screw 1 4 20 x 5 8 Ph Torx 8 71300004 Drum Top Cover 1 Secure the drum top cover to the iXW drum module using the eight 1 4 20 x 5 8 inch screws removed earlier...

Page 189: ...r Installation Guide 4 Place the drum safety cover over the drum This cover has two pins to keep it in place Risk of injury Never run a motorcycle on the dyno without this cover in place Figure E 11 I...

Page 190: ...u will need the following parts 10111 Ground Hook D Ring 4 36932100 Washer 3 8 Splitlock Steel 8 37513200 Anchor Redhead 3 8 8 DM150 002 007 Washer 5 16 Flat 8 DM150 019 012 Bolt 3 8 16 x 1 Hex 8 1 Us...

Page 191: ...250iX Motorcycle Dynamometer Installation Guide APPENDIX F TORQUE VALUES This appendix contains tables for standard and metric torque values Use these values when specified values are not given in ot...

Page 192: ...ed as guidelines for Dynojet product torque values only Always use caution when torquing fasteners GRADE 5 size torque plain torque plated in threads in in lb ft lb N m in lb ft lb N m 1 4 20 101 8 11...

Page 193: ...37 245 20 28 3 8 16 523 44 59 392 33 44 3 8 24 593 49 67 444 37 50 7 16 14 837 70 95 628 52 71 7 16 20 935 78 106 701 58 79 1 2 13 1277 106 144 958 80 108 1 2 20 1439 120 163 1079 90 122 9 16 12 1843...

Page 194: ...d as guidelines for Dynojet product torque values only Always use caution when torquing fasteners GRADE 8 8 GRADE 10 9 size torque plain torque plated mm x pitch in lb ft lb N m in lb ft lb N m M6 X 1...

Page 195: ...cable 2 32 power extension cable 2 32 testing 2 54 using 4 5 brake cable 2 32 brake pads 3 10 5 13 brake pressure 5 13 bulkheads blower power extension cable 2 30 E 12 front 2 29 E 11 installing 2 29...

Page 196: ...er dyno 2 24 dyno power 2 53 3 2 main circuit breaker 2 53 3 2 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 dyno shutdown 4 4 4 5 dy...

Page 197: ...2 53 3 2 4 9 making a test run 5 12 metric torque values grade 10 9 F 4 grade 8 8 F 4 middle bulkhead 2 29 E 11 monitor support brace 2 29 E 11 fan arm mount 2 49 installing 2 49 monitor tray 2 49 mo...

Page 198: ...ety switch C 5 secondary inductive pickup 5 6 setting tool A 3 side cover drum 2 31 E 13 dyno 2 24 2 30 E 12 specifications 1 5 1 10 speed pick up cable 2 32 standard torque values grade 5 F 2 grade 8...

Page 199: ...rsion 2 Above Ground Model 200iX 250iX Motorcycle Dynamometer Installation Guide 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...

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