Dynojet 250i Installation Manual Download Page 4

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Above Ground Model 250i Motorcycle Dynamometer Installation Guide

T A B L E O F C O N T E N T S

Above Ground Model 250i Motorcycle Dynamometer Installation Guide

Chapter 2

Dyno Installation

Unpacking and Inspecting the Dyno

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Dyno Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Routing the Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Battery Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Pickup Card Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Eddy Current Brake Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-15
Installing the Eddy Current Brake  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-20
Installing the Load Cell  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  2-23

Secure the Dyno and Brake Module to the Floor

. . . . . . . . . . . . . . . . . . . . . . . . . 2-25

Support Arm and Monitor Tray Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Installing the Support Arm and Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Cable Routing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28

Tire Carriage Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38

Side and Top Cover Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42

Load Cell Calibration

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45

Ramp Bracket

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

Ground Hook Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53

Zip Tube

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

Chapter 3

Accessories

Main Dyno Power

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Air Brake

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Air Fuel Ratio Module

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Extended Carriage

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Installing the Extended Carriage Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Installing the Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Folding Ramp

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24

Removing the Ramp from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installing the Ramp on the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

High Pressure Blower

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Installing the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Summary of Contents for 250i

Page 1: ......

Page 2: ...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 tr...

Page 3: ...ery Requirements 1 5 Chassis Specifications 1 5 Compressed Air 1 8 Computer Specifications 1 8 Electrical Requirements 1 9 Environmental Requirements 1 9 Fire Suppression 1 9 Forklift Requirements 1 9...

Page 4: ...e Cables 2 28 Installing the DynoWare RT Main Module 2 30 Routing the Cables 2 30 Connecting the Control Panel Cable 2 33 Routing the Power Carriage and Wheel Clamp Cables 2 36 Tire Carriage Installat...

Page 5: ...the Power Carriage 4 6 Using the Starter 4 6 Using the Status Indicator 4 7 Using the Wheel Clamp 4 7 Power Distribution Assembly 4 9 Main Dyno Circuit Breaker 4 9 High Pressure Blower Circuit Breake...

Page 6: ...Wall Receptacle B 2 Testing for Correct Voltages B 3 Hard Wiring to the Building B 4 Excluding North America and Japan B 5 Installing the Wall Receptacle B 6 Testing for Correct Voltages B 7 Hard Wiri...

Page 7: ...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 8: ...to someone touch that person with your hand first then hand them the component Always carry circuit boards in anti static bags when the boards are exposed removed from the dynamometer Battery Fire and...

Page 9: ...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...

Page 10: ......

Page 11: ...ojet dynamometer will give you the professional results you require This document provides instructions for installing the Dynojet s Model 200i 250i Motorcycle Dynamometer dyno This document will walk...

Page 12: ...for installing the dyno ACCESSORIES This chapter lists each dyno accessory alphabetically and describes the procedures for installing and using this accessory CONTROL PANEL INTERFACE OPERATION This ch...

Page 13: ...on of this guide along with additional accessory guides software guides and the latest technical bulletins at www dynojet com downloads example of convention description The Caution icon indicates a p...

Page 14: ...ming 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 e...

Page 15: ...sions 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 mor...

Page 16: ...C H A P T E R 1 Dynamometer Specifications and Requirements Above Ground Model 250i Motorcycle Dynamometer Installation Guide 1 6 Figure 1 1 Model 200i Dimensions...

Page 17: ...CI FI CATI ON S A N D O PE R ATIN G RE QU I RE ME NT S Dynamometer Specifications and Requirements Version 4 Above Ground Model 250i Motorcycle Dynamometer Installation Guide Figure 1 2 Model 250i Dim...

Page 18: ...etter flow 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 Power Core software Refer to www dynoj...

Page 19: ...provide equipment capable of lifting a minimum of 1 133 98 kg 2 500 lbs 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 the...

Page 20: ...aps MUST pull the motorcycle forward Using the ground hooks as a pattern install the Red Head anchors using the hardware included with the ground hook kit Install the Red Head anchors according to the...

Page 21: ...nstallation Guide MODEL 200i MOTORCYCLE DYNAMOMETER Figure 1 3 Model 200i Dyno MC144 Air Connector Tire Carriage Tie down Loop used to secure the motorcycle to dyno Drum precision balanced and knurled...

Page 22: ...ER Figure 1 4 Model 250i With Optional Accessories MC157 High Pressure Blower cools the bike s engine Eddy Current Brake Module Air Brake Air Pump Assembly Power Carriage Monitor Tray supports the mon...

Page 23: ...nsists 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 de...

Page 24: ...s 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 250...

Page 25: ...y a wireless network With DynoWare RT on a network a single dedicated computer for the dyno is no longer required Any computer on the network can connect and operate the dyno A wireless connection all...

Page 26: ......

Page 27: ...categories Unpacking and Inspecting the Dyno page 2 2 Dyno Installation page 2 10 Battery Installation page 2 13 Pickup Card Installation page 2 14 Eddy Current Brake Installation page 2 15 Secure the...

Page 28: ...133 98 kg 2 500 lbs to move the crated dyno into position in your dyno room Move the crated dyno to a clear area near your dyno room 1 Using a pry bar and a hammer remove the top and sides of the cra...

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 6 Remove the tire...

Page 30: ...ion Guide 2 4 7 Remove the eight screws securing the top drum cover to the dyno and set aside Remove the drum cover and set aside 8 Remove the two top screws securing each side drum cover to the dyno...

Page 31: ...vers 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: ...kit P N 76100015 see list of parts below washer 3 8 flat 4 P N 36923100 PCV CAN termination plug P N 76423025 anchor Red Head 3 8 4 P N 37513200 CAN termination plug P N 76423045 installation tool Red...

Page 33: ...cable e stop to CPI P N 76950549 monitor support and arm P N 61329003 cable IR temp sensor P N 76950569 monitor tray P N 61329101P cable load cell P N 76950573 optional accessory eddy current brake P...

Page 34: ...it P N 79100001 see list of parts below speed pick up P N 68300002 ground hook kit 6 P N 79190001 see list of parts below ramp bracket assembly P N 69100001 power carriage P N 82943001 optional access...

Page 35: ...n 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 36932100 bolt 3 8 16 x 1 hex 2 P N DM150 019 012 anchor Red Head...

Page 36: ...t the dyno off the crate and into position in your dyno room You will also need a pair of straps capable of supporting the same weight Dynojet recommends using a single loop style strap 1 Remove the f...

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: ...e 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 the...

Page 39: ...ou will need to provide this battery 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 There is dang...

Page 40: ...ing two No 8 screws 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 alig...

Page 41: ...e Dyno and Brake Module to the Floor on page 2 25 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 pa...

Page 42: ...P N 21227107 top cover P N 63200000 screw 1 4 20 x 5 8 pan head torx 2 P N 36561045 eddy current brake driver P N 66400012 washer 3 8 flat 2 P N 36923100 cable controller P N 66952003 anchor Red Head...

Page 43: ...Motorcycle 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 i...

Page 44: ...y 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 14 5b Move the retarder connector plates to the other sid...

Page 45: ...oop strap through the lifting eyes on either side of the brake 8 Using a forklift lift the eddy current brake from the crate and place the brake near the dyno making sure the panels on the brake and d...

Page 46: ...r brake is located on the right side of the dyno It is not necessary to remove the air brake regardless of which side of the dyno you are installing the eddy current brake right or left Note Safety re...

Page 47: ...5 Secure the retarder connector plate to the dyno frame using the four bolts washers and nuts removed earlier There is a retarder connector plate on either side of the brake Refer to Figure 2 17 Note...

Page 48: ...y current brake to the panels on the dyno using a 1 4 20 bolt Do this on each side Figure 2 18 Secure the Side Panels to the Dyno 9 Replace the existing set screws on the coupler with the thread lock...

Page 49: ...d cell If you did not purchase the load cell skip this section and continue with Secure the Dyno and Brake Module to the Floor on page 2 25 You will need the following part 1 Verify the main dyno powe...

Page 50: ...lock nut and turning the eyelet Figure 2 21 Verify Load Cell Spacing 4 Secure the load cell to the mounting bracket using the two bolts and nuts removed earlier Refer to Cable Routing on page 2 28 fo...

Page 51: ...following parts 36923100 Washer 3 8 Hardened Flat Steel 6 37513200 Anchor Red Head 3 8 6 37518200 Red Head Anchor Installation Tool DM150 019 012 Bolt 3 8 16 x 1 Hex 6 1 Using the dyno and brake modul...

Page 52: ...nitor tray may be installed on either side of your dyno 1 Remove the four 3 8 16 x 1 2 inch button head flange screws from the dyno where you plan to install the support arm 2 Using an allen wrench se...

Page 53: ...Monitor Tray Installation Version 4 Above Ground Model 250i Motorcycle Dynamometer Installation Guide Figure 2 24 Install the Support Arm and Monitor Tray MA021 second arm poly washer first arm monito...

Page 54: ...RPM pick up cable 76950203 secondary pick up cable connects to the DynoWare RT D 76950307 wheel clamp cable assembly connects to the wheel clamp E 76950308 power carriage cable assembly connects to t...

Page 55: ...15 connects the air fuel module to the DynoWare RT using the CAN adapter cable or CAN network cable chain optional accessory N 76950807 CAN control cable adapter 2 connects the DynoWare RT to the CAN...

Page 56: ...control panel O cable from the intercept board through the cable pass through closest to the monitor support and attach to the control panel Refer to Connecting the Control Panel Cable on page 2 33 5...

Page 57: ...and or AFR assembly insert the CAN termination plug S at the end of your CAN network cable chain Figure 2 26 CAN Network Cable Configuration 16 Route the e stop cable G from P7 on the front panel of...

Page 58: ...C H A P T E R 2 Cable Routing Above Ground Model 250i Motorcycle Dynamometer Installation Guide 2 32 Figure 2 27 Routing the Cables...

Page 59: ...arate container inside the dyno 1a Remove the two nuts from the top of the cover and set aside 1b Remove the screw on the top of the cover and set aside 1c Remove the screw on the side of the cover an...

Page 60: ...29 Attach the Control Panel Cable to the Button Board 4 Secure the rear cover to the control panel 4a Replace the four screws on the back of the cover removed earlier 4b Replace the screw on the top o...

Page 61: ...ray is shown in Figure 2 31 6 Place the pendant in the slot provided on the control panel and route the cable bundle along the support arms with service loops to allow movement 7 If you plan to route...

Page 62: ...ccessories For installation instructions refer to Power Carriage on page 3 35 and Wheel Clamp on page 3 39 for more information 1 Remove the two screws securing the cable pass through cover on the fro...

Page 63: ...ne 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 cable pass thr...

Page 64: ...ed 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 Note Before replacing the center panel and installing the tire carriage i...

Page 65: ...mps and spacers using two 5 16 inch bolts and washers each 3 Install the nut block and spacer using two 5 16 inch bolts and washers Figure 2 34 Install the Carriage Clamps and Nut Block 4 Remove the f...

Page 66: ...he carriage screw is touching the nut block 10 Using the hand wheel screw the carriage through the nut block and into the screw support bracket Note If you ordered the power carriage accessory you wil...

Page 67: ...p to the carriage using four 3 8 16 x 1 2 inch button head flange bolts Note If you purchased the wheel clamp accessory refer to Wheel Clamp on page 3 39 for installation instructions 13 Secure the ti...

Page 68: ...y pickup card eddy current brake and any accessories you may have purchased with your dyno Refer to Chapter 3 for accessory installation instructions 1 Secure the drum side cover to the dyno using six...

Page 69: ...ation Guide 3 Secure the top of the side covers with the screws you removed earlier 4 Refer to Appendix C and install and adjust the finger guards if they are required in your location 5 Secure the to...

Page 70: ...llation Above Ground Model 250i Motorcycle Dynamometer Installation Guide 2 44 6 Secure the eddy current brake top cover with the screws you removed earlier Figure 2 40 Replace the Eddy Current Brake...

Page 71: ...n page 1 3 2 Double click the Power Core program icon 3 Click Dyno Control from the Application Launcher 4 Verify you are connected to the DynoWare RT main module Note For more information on connecti...

Page 72: ...number stamped near the bolt pattern at the end of the calibration arm in the Mass box If you do not have enough room to use the bolt pattern closest to the end of the calibration arm use the number s...

Page 73: ...in the center of the arm Refer to Figure 2 45 11a Secure the calibration arm to the eddy current brake by tightening the bolt using the handle 11b Gently place the weights on the calibration arm Note...

Page 74: ...ot have enough room to use the bolt pattern closest to the end of the calibration arm use the bolt pattern in the center of the arm as shown in Figure 2 45 Figure 2 45 Install the Calibration Arm and...

Page 75: ...namometer Installation Guide 12 With the calibration arm and weights secured click Next to calibrate 13 Remove the calibration arm and weights and click Finish Figure 2 46 Finish Calibration Window 14...

Page 76: ...to modify your ramp to secure it to the ramp bracket You will need the following part 1 With the ramp upside down center the ramp bracket under the lip at the top of the ramp 2 Using the larger holes...

Page 77: ...3 8 inch bolts from the top of the ramp and secure using 3 8 inch washers and nuts Figure 2 48 Secure the Bolts to the Ramp 4 Remove the four 1 4 inch bolts from the rear of the drum cover 5 Secure t...

Page 78: ...Above Ground Model 250i Motorcycle Dynamometer Installation Guide 2 52 6 Place the ramp on the ramp bracket slipping the bolts on the ramp through the large holes on the ramp bracket Figure 2 50 Place...

Page 79: ...3200 Anchor Red Head 3 8 4 DM150 019 012 Bolt 3 8 16 x 1 Hex 4 1 Locate each ground hook approximately 96 5 cm 38 inches from the front of the dyno and approximately 20 cm 8 inches from the side of th...

Page 80: ...ble holder Pendant Cable Control Panel Cable RPM cable s Additional cables if desired Figure 2 52 Insert the Cable s Into the Cable Holder 3 Rotate the cable holder closed 4 Insert the guide body into...

Page 81: ...ut these accessories please contact Dynojet s Product Specialist s at 1 800 992 3525 for pricing and availability or visit www dynojet com Installation instructions for some of these options can be fo...

Page 82: ...ug 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...

Page 83: ...to use For detailed installation instructions refer to the Air Brake and EEC Kit Installation Guide P N 98200079 ROUTING THE AIR BRAKE CABLE AND AIR HOSE 1 Open the CPI front panel 2 Route the white...

Page 84: ...ugh the access hole in the drum module upright under the carriage frame brace and connect to the bulkhead fitting at the front of the dyno 8 You will need to provide an air hose nipple 1 4 inch NPT to...

Page 85: ...he drum Installing the emergency stop sticker indicates the added functionality applied to the dyno shutdown button 1 Remove the control panel rear cover 1a Remove the two nuts from the top of the cov...

Page 86: ...the four screws securing the Button board to the control panel and set aside 2b Remove the Button board and set aside Figure 3 5 Remove the Button Board 3 Unscrew the black switch body nut and remove...

Page 87: ...4 Above Ground Model 250i Motorcycle Dynamometer Installation Guide 4 Place the emergency stop sticker over the dyno shutdown sticker Figure 3 7 Place the Emergency Stop Sticker CP015 97415160 S H UTD...

Page 88: ...the switch body to the control panel using the switch body nut removed earlier Figure 3 8 Replace the Emergency Stop Button 6 Secure the Button board to the control panel using the four screws removed...

Page 89: ...ESTS 1 Verify the dyno is set up properly the dyno electronics is powered up and operational and the air supply is connected properly 2 Use the red brake button on the pendant or the emergency stop bu...

Page 90: ...Dyno Power on page 3 2 for breaker location 1 Remove the top and right side covers from the dyno Refer to page 2 4 and page 2 5 for more information 2 For safety apply the brake and disconnect the ai...

Page 91: ...uide 4 Using a 9 16 inch ratchet and wrench remove the bolt washer and nut securing the spring to the brake assembly The spring is located on the drum side of the brake assembly Note For clarity the d...

Page 92: ...e 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 bot...

Page 93: ...e 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 Bottom P...

Page 94: ...k 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 15 Using two...

Page 95: ...e 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 cas...

Page 96: ...hing the sensor or the sample tube make sure it has cooled Leaded racing fuels and two stroke applications will contaminate the sensor and dramatically shorten its service life The sensor is not cover...

Page 97: ...6 6 P N DM150 002 008 bolt 3 8 16 x 1 2 button head flange allen 10 P N 36580434 bolt 5 16 18 x 1 hex 4 P N DM150 053 tire lock assembly P N 63310901 extended carriage support bracket P N EXT100 207 w...

Page 98: ...nt of the dyno using six 3 8 16 x 1 2 inch button head flange allen bolts 2 Using a straight edge line the top of the support bracket with the top of the dyno chassis Tighten all six screws Figure 3 1...

Page 99: ...wo 5 16 x 1 inch bolts and two 5 16 inch lock washers 4 Secure the strap to the support bracket using two 5 16 x 1 inch bolts two 5 16 inch lock washers two 5 16 inch flat washers and two 5 16 inch nu...

Page 100: ...riage support bracket using two 5 16 18 x 1 5 inch bolts two 5 16 inch lock washers two 5 16 inch flat washers and two 5 16 inch nuts Figure 3 21 Install the Nut Block and Front Carriage Clamp INSTALL...

Page 101: ...til it is halfway through the nut block Note If you ordered the power carriage accessory you will not have the hand wheel Carefully turn the carriage screw using pliers 7 Secure the bearing bracket to...

Page 102: ...ing the hand wheel move the carriage forward until the holes for the rear carriage clamps are accessible 10 Install the two rear carriage clamps and spacers using two 5 16 18 x 1 5 inch bolts and two...

Page 103: ...he carriage using four 3 8 16 x 1 2 inch button head flange bolts Note If you purchased the wheel clamp accessory refer to Wheel Clamp on page 3 39 for installation instructions 12 Secure the tire loc...

Page 104: ...nd safely load motorcycles onto the dyno This section will walk you through removing the ramp from the crate and installing the ramp on model 200i and 250i motorcycle dynos To ensure safety and accura...

Page 105: ...Version 4 Above Ground Model 250i Motorcycle Dynamometer Installation Guide 2 Remove the crate braces Figure 3 27 Remove the Crate Braces 3 Remove the 2x2 brace securing the ramp down Figure 3 28 Remo...

Page 106: ...ove Ground Model 250i Motorcycle Dynamometer Installation Guide 3 26 4 Fold the ramp up 5 Remove the front crate panel 6 Remove the braces Figure 3 29 Fold Ramp Up and Remove Front Crate Panel fold ra...

Page 107: ...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 3 30 Remove the Bolts and Washers Securing...

Page 108: ...round Model 250i Motorcycle Dynamometer Installation Guide 3 28 8 Remove the ramp by sliding it from the front of the crate Dynojet recommends using two people to remove the ramp from the crate Figure...

Page 109: ...O 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 lowering the ramp t...

Page 110: ...Dynamometer Installation Guide 3 30 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 3 33 Remove the...

Page 111: ...ide 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 head bolts removed...

Page 112: ...hrough the blower installation procedures You will need the following parts part description part description washer 1 87 x 1 25 ID x 12 thick poly 4 P N 26215520 upper blower arm assembly P N 6340000...

Page 113: ...nto the lower blower arm 6 Secure the upper blower arm to the lower blower arm using a 3 8 16 x 3 4 inch clamp lever 7 Place a 1 8 inch thick poly washer around the pin on the blower assembly 8 Insert...

Page 114: ...3 35 Install the High Pressure Blowers blower assembly 1 8 inch thick poly washer motor facing out intake facing in 1 4 inch thick poly washer upper blower arm assembly power cord from blower lower ar...

Page 115: ...at are recessed where the hand wheel is difficult to access The power carriage will also reduce the time spent making adjustments for various length motorcycles For more information on using the power...

Page 116: ...y open the CPI door and set the main breaker to the off position and unplug the dyno Refer to Main Dyno Power on page 3 2 for breaker location 1 Loosen the set screw on the hand wheel and remove the h...

Page 117: ...ecure the motor mount to the carriage using two 1 4 20 x 5 8 inch bolts and two 1 4 inch lock washers The motor mount is installed in front of the flange bearing If the motor mount is already installe...

Page 118: ...plastic coupler spider on the carriage screw half of the coupler 7 Place the power carriage motor assembly near the motor mount and plug the motor connector into the power carriage cable 8 Turn the ca...

Page 119: ...formation on using the wheel clamp refer to page 4 7 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 39 Remove the W...

Page 120: ...heel clamp Refer to Cable Routing on page 2 28 for more information 5 Install the wheel clamp cable strain relief to the side of the wheel clamp 6 Plug the wheel clamp cable into the connector on the...

Page 121: ...r outlet 2 Turn on the main breaker inside the CPI door Refer to Main Dyno Power on page 3 2 3 Close the CPI door Note Use the main breaker to turn power on and off to the dyno POWER CARRIAGE FINAL AD...

Page 122: ......

Page 123: ...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 chapt...

Page 124: ...oor 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 the f...

Page 125: ...OL PANEL 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 accordin...

Page 126: ...air fuel ratio sampling system Emergency Stop Dyno Shutdown 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...

Page 127: ...ight on the control panel is on but the blower is not running perform the following steps 1 Verify the switch on the blower is on 2 Verify the blower power plug is firmly plugged into the dyno 3 Verif...

Page 128: ...e 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 all...

Page 129: ...g 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 attac...

Page 130: ...e 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...

Page 131: ...le is in the down position all power into the dyno is turned off Refer to Figure 4 2 on page 4 9 Even if this breaker is turned off there is still the potential for lethal voltages to be present in th...

Page 132: ...or 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 in...

Page 133: ...en the CPI door and set the main breaker to the off position and unplug the dyno Refer to Main Dyno Power on page 3 2 for breaker location 1 Open the Control Panel Interface CPI cover and set aside 2...

Page 134: ...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 pr...

Page 135: ...to make quick and accurate evaluations of engine performance and drivetrain problems This chapter includes instructions for basic dyno operation For more detailed instructions refer to the Power Core...

Page 136: ...on the dyno 2 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 Never perform a dyno run if the tire strap is not in place or is da...

Page 137: ...and the exhaust pipes For best results hook the straps at the rear of the bike so they pull down and forward 7 Sit on the bike with your feet on the pegs Remove the slack from the straps Gently shift...

Page 138: ...d and is not covered under warranty Dropping snapping vibration and heat can all damage the ferrite core The DynoWare RT contains the electronics that sense the RPM pulses An auto gain circuit looks a...

Page 139: ...e 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 primary inductive...

Page 140: ...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 B...

Page 141: ...sed Use extreme care in handling and placement of the pickups 1 Clip the secondary inductive pickup around one spark plug wire 2 Route the inductive pickup cable clear of devices that produce electron...

Page 142: ...e 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 inductive cable to...

Page 143: ...thout 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 any location on your dy...

Page 144: ...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 be...

Page 145: ...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 ENGIN...

Page 146: ...ycle 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 Use the momen...

Page 147: ...g fires number 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...

Page 148: ...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 Carriage Slide keep the carriage...

Page 149: ...e 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 manufactu...

Page 150: ...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 Head...

Page 151: ...e 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 exp...

Page 152: ......

Page 153: ...res 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 your d...

Page 154: ...08 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 three phase lines be connected to the receptacle Installatio...

Page 155: ...ensed 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...

Page 156: ...ircuit 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 t...

Page 157: ...s 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 t...

Page 158: ...t 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 Check with local building...

Page 159: ...t 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 mus...

Page 160: ......

Page 161: ...afety 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 200i 250i motorcycle dyno This appendix...

Page 162: ...e following parts REMOVING THE DRUM MODULE HOOD Before installing the EEC finger guards the drum module hood must be removed Never operate the dynamometer with the drum module hood removed Dynojet rec...

Page 163: ...AC power cord from its power source refer to Main Dyno Power on page 3 2 2 Remove the eight 1 4 20 x 5 8 inch pan head screws securing the drum module hood to the dyno and set aside 3 Remove the drum...

Page 164: ...the EEC Finger Guards to the Drum Module Hood 2 Secure the drum module hood with the EEC finger guards to the dyno using the eight 1 4 20 x 5 8 inch pan head torx screws removed earlier Refer to Figu...

Page 165: ...finger guards so they are 0 16 cm to 0 64 cm 0 0625 in to 0 25 in from the drum Tighten the screws 2 Check the EEC finger guards regularly to verify the clearance has not changed Note For clarity the...

Page 166: ...nts 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 se...

Page 167: ...B position on the J4 connector Figure C 5 Wire the Safety Switch 9 Replace the CPI cover using the screws removed earlier 10 The door safety switch needs to be mounted at the entry of the dyno room 11...

Page 168: ......

Page 169: ...50i Motorcycle Dynamometer Installation Guide APPENDIX D TORQUE VALUES This appendix contains tables for standard and metric torque values Use these values when specified values are not given in other...

Page 170: ...uidelines 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 76 6 9...

Page 171: ...45 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 154...

Page 172: ...idelines 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 96 8 1...

Page 173: ...cable 2 29 CAN dyno user cable 2 29 CAN powersports cable 2 29 carriage clamp 2 39 3 20 ce drum guards adjusting C 5 compressed air requirements 1 8 computer specifications 1 8 control panel air pump...

Page 174: ...ounding requirements 1 10 H hand wheel 2 40 hazards vii height 1 5 hex bit socket 1 10 high pressure blower 3 32 circuit breakers 4 9 installing arms 3 33 installing blowers 3 33 power cable 3 33 usin...

Page 175: ...Ware RT 2 29 e stop 2 28 identifying cables 2 28 IR temp sensor 2 28 load cell 2 28 network 2 29 PCV CAN termination plug 2 29 pendant 2 28 power 2 12 power carriage 2 28 2 37 remote atmos 2 28 RPM pi...

Page 176: ...bove Ground Model 250i Motorcycle Dynamometer Installation Guide Index iv 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...

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Dynojet 250i, Installation Manual

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Summary of Contents for 250i

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