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98200049.06 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide98200049.06
©2014-2020 Dynojet Research, Inc. All Rights Reserved.
Installation Guide for Above Ground Model 250i Motorcycle
Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter
referred to as Dynojet, and all rights are reserved. This manual,
and the software described in it, 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.
#RECORD
i
TABLE OF CONTENTS
Chapter 1 Specifications and Operating Requirements Introduction .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 1-3 Technical Support . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 1-3 Your Dyno Room . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 1-4
Dynamometer Specifications and Requirements . . . . . . . . . . . .
. . . . . . . . . . . . . . 1-5 Battery Requirements . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 1-5 Chassis Specifications . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1-5 Compressed Air . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10 Computer Specifications . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 1-11 Environmental
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 1-11 Fire Suppression . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 1-11 Forklift Requirements . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 1-11 Grounding Requirements . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Ground Hook Requirements . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 1-12 Phone and Internet
Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 1-12 Tie-Down Straps . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 1-12 Tool Requirements . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 1-12
DynoWare RT Electronics . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 1-13 Main Module
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 1-14 Network Connections . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 1-15
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
Starter Installation . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Installing and Aligning the Starter . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 2-13 Wiring and Testing
the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 2-15 Moving the Starter Using Shims . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . 2-16 Moving the Drum . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-17
Battery Installation . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-18
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T A B L E O F C O N T E N T S
Above Ground Mode 250i Motorcycle Dynamometer Installation
Guide
ii
Pickup Card Installation . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 Eddy
Current Brake Installation . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 2-20
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 2-20 Installing the Eddy
Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 2-25 Installing the Load Cell . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 2-28
Secure the Dyno and Brake Module to the Floor . . . . . . . . . . .
. . . . . . . . . . . . . . 2-30 Support Arm and Monitor Tray
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2-31
Installing the Support Arm and Tray . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 2-31 Cable Routing . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 2-33
Identifying the Cables . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 Installing
the DynoWare RT Main Module . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 2-35 Routing the Cables . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 2-36 Connecting the Control Panel Cable . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 Routing
the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . .
. . . . . . . 2-42
Tire Carriage Installation . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 Side and
Top Cover Installation . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 2-48 Load Cell Calibration .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 2-51 Ramp Bracket . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 2-56 Ground Hook Installation . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 2-59 Zip Tube . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 2-60
Chapter 3 Accessories Main Dyno Power . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 3-2 Air Brake . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 3-3
Routing the Air Brake Cable and Air Hose . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 3-3 Installing the Emergency
Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 3-5 Air Brake Final Adjustments and Tests . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . 3-10 Adjusting the
Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 3-15
Air Fuel Ratio Module . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 Extended
Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 3-17
Installing the Extended Carriage Support Bracket . . . . . . . . .
. . . . . . . . . . . . . . . 3-19 Installing the Extended Carriage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 3-21
Folding Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Removing the Ramp from the Crate . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 3-25 Installing the Ramp on
the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 3-30
High Pressure Blower . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Installing the High Pressure Blowers . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 3-34
Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
Removing the Hand Wheel . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 3-37 Installing the
Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 3-38
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 3-42
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 3-42 Power Carriage
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 3-42 Wheel Clamp Final Adjustments and Tests . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
T A B L E O F C O N T E N T S
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Version 6 Above Ground Mode 250i Motorcycle Dynamometer
Installation Guide
Chapter 4 Control Panel Interface Operation Introduction . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 4-2 Basic Control Panel
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 4-3
Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . 4-4 Using the Emergency
Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 4-5 Using the High Pressure Blowers . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Understanding Interlocks . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Using 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 Breakers . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 4-9
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 4-10 Wheel Clamp . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 4-10 Replacing the Eddy Current
Brake Driver Fuses . . . . . . . . . . . . . . . . . . . . . . . .
. . 4-11 Troubleshooting CPI Fuses . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Chapter 5 Basic Dyno Operation Loading the Vehicle . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 5-2 Connecting the RPM Pickup . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 5-4
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 5-4 Connecting the
Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 5-5 Connecting the Secondary Inductive Pickup
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-7
Grounding the Vehicle . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 Pre-Run
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 5-10
Before Starting the Engine . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . 5-11 Engine Warm Up
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . 5-11 After Engine Warm Up . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 5-11
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Using the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Above Ground Mode 250i Motorcycle Dynamometer Installation
Guide
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T A B L E O F C O N T E N T S
Above Ground Mode 250i Motorcycle Dynamometer Installation
Guide
iv
Appendix A Red Head Anchor Installation Warnings . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . A-1 Contact Information for
ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . . . . .
. . . A-1 Installation . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . A-2
Appendix B Power Requirements and Installation North America,
Japan, and Locations Using 60 Hz Power . . . . . . . . . . . . . .
. . . B-2
Installing the 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 Wiring to the Building . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-7
Appendix C EEC Finger Guard and Door Safety Switch Installation EEC
Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Removing the Drum Module Hood . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . C-2 Installing the EEC Finger
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . C-4 Adjusting the EEC Finger Guards . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-5
Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Installing the Door Safety Switch . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . C-6
Appendix D Torque Values Standard Bolt Torque Values . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . D-2
Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-3
Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . D-4 Grade 8.8 .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . D-4 Grade 10.9 .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . D-4
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Index-i
WARNINGS
Disclaimers
Dynojet Research, Inc. (Dynojet) makes no representation or
warranties with respect to the contents hereof and specifically
disclaims any implied warranties of merchantability for any
particular purpose. Dynojet reserves the right to revise this
publication and to make changes from time to time in the content
hereof without obligation of Dynojet to notify any person of such
revision or changes. Dynojet is not responsible for false operation
due to unexpected dynamometer operation such as may be caused by
static, software bugs, hardware failure, etc. Dynojet is not
responsible for damage resulting from improper installation of the
dynamometer or from improper service rendered to the dynamometer.
Dynojet is not responsible for damage incurred due to alteration of
the dynamometer or components, use of unapproved parts, or abuse to
the dynamometer. Do not connect or disconnect cables or components
on the dynamometer with the power on. Always wear protective
clothing, ear protection, and eye protection (goggles, safety
glasses) when using and servicing the dynamometer.
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.
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.
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
vi
Electrostatic Discharge Precautions
Electrostatic Discharge Electrostatic Discharge (ESD), or static
shock, can damage electronic components within the dynamometer. The
damage may occur at the time of an ESD occurrence, or the shock may
degrade the component, resulting in a premature component failure
later. To avoid ESD damage, always practice good ESD control
precautions when servicing the dynamometer. Dynojet designs its
dynamometers to be very tolerant of static shocks by the users, but
the electronics are vulnerable when the electronics are exposed.
ESD occurs as a result of a difference of potential between two
objects when the two objects touch. Damage occurs as a result of
the energy released when the discharge (touch) occurs. The
difference of potential can accumulate by as simple an action as a
user moving across carpet or a seat. If that person’s energy is
discharged directly to the electronics, the electronics can be
damaged.
Precautions To protect against ESD damage, you must eliminate the
difference of potential before the electronics are handled. Touch
the chassis of the dynamometer before touching any of the
electronics. By touching the chassis, you discharge any static
shocks to the chassis 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
handling 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).
Battery Fire and Explosion Hazards
There is a danger of explosion if the battery is incorrectly
replaced. Replace only with the same or equivalent type recommended
by the manufacturer. Discard used batteries according to the
manufacturer’s instructions.
Automotive Batteries In operation, batteries generate and release
flammable hydrogen gas. They must always be assumed to contain this
gas which, if ignited by burning cigarette, naked flame or spark,
may cause battery explosion with dispersion of casing fragments and
corrosive liquid electrolyte. Carefully follow manufacturer's
instructions for installation and service. Keep away all sources of
gas ignition and do not allow metallic articles to simultaneously
contact the negative and positive terminals of a battery. Do not
allow the positive and negative terminals to short-circuit. The
dynamometer chassis is tied to the negative side of the battery. Do
not short between the positive battery terminal or the starter
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.
vii
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
W A R N I N G S
Grounding Requirements
Always ground the vehicle to the dynamometer. Never operate the
dynamometer without properly grounding the vehicle to the
dynamometer.
Other Potential Hazards
The AC power outlet shall be installed near the equipment and it
shall be easily accessible to allow for disconnect before service.
The dynamometer should be located in a well ventilated area. There
is a carbon monoxide hazard with all internal combustion engines.
Engine exhaust contains poisonous carbon monoxide gas. Breathing it
could cause death. Any dynamometer 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. Verify the vehicle is properly
grounded 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.
1-1
CHAPTER 1
REQUIREMENTS
Thank you for purchasing Dynojet’s Model 200i/250i 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 require.
This document provides instructions for installing the Dynojet’s
Model 200i/250i Motorcycle Dynamometer (dyno). This document will
walk you through operating requirements, installation, accessories,
and basic dyno operation. To ensure safety and accuracy in the
procedures, perform the procedures as they are described.
Document Part Number: 98200049
• Introduction, page 1-2
• DynoWare RT Electronics, page 1-13
C H A P T E R 1
Introduction
1-2
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.
DYNO INSTALLATION
ACCESSORIES
This chapter lists each dyno accessory alphabetically and describes
the procedures for installing and using this accessory.
CONTROL PANEL INTERFACE OPERATION
This chapter describes the control panel interface (CPI) operating
procedures.
BASIC DYNO OPERATION
RED HEAD INSTALLATION
This appendix describes the procedures for installing the Red Head
anchors.
POWER REQUIREMENTS AND INSTALLATION
This appendix describes power requirements and installation
instructions.
EEC FINGER GUARD AND DOOR SAFETY SWITCH INSTALLATION
This appendix describes the procedures for installing the EEC
finger guards and door safety switch.
TORQUE VALUES
1-3
S P E C I F I C A T I O N S A N D O P E R A T I N G R E Q U I R E M
E N T S
Introduction
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
CONVENTIONS USED IN THIS MANUAL
The conventions used in this manual are designed to protect both
the user and the equipment.
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at
1-800-992-4993, or write to Dynojet at 2191 Mendenhall Drive, North
Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet
provides state of the art technical support, on-line shopping, and
press releases about our latest product lines. Try our remote
support assistance or watch one of our informative videos.
Access the electronic version 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 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 the dynamometer equipment.
#RECORD The Record # icon reminds you to record your dynamometer
and eddy current brake (retarder) serial number on the inside cover
of this manual.
Bold Highlights items you can select 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.”
Blue Highlights items you can click on directing you to a location
with additional information (electronic version).
Introduction
1-4
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:
• minimize noise
• 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 vehicle’s engine while supplying fresh oxygen for you and your
vehicle to breathe. It is a common misconception that you cannot
tune a vehicle without a large fan simulating exact road
conditions; however, a good cooling fan is the only requirement for
consistent diagnostics and tuning. The dyno room requires a minimum
of seven (7) air changes per minute (CFM). Use the formula Room
Volume × Air Changes Per Minute = CFM to calculate the CFM needed
for your dyno room. For example, if your room is 10 x 10 x 10 (room
volume is L×W×H), then 1000 × 7 = 7000 CFM. The CFM value is room
size dependent.
Equalizer Box—If the air flow rate coming into the dyno room is
greater than the air flow rate leaving the dyno room, the room will
become pressurized. A pressurized dyno room will make measured
power misleading. To compensate, you need an equalizer box. The
equalizer box is a baffled (to reduce noise) vent to the outside of
your dyno room. The size of the equalizer box is dependent on the
size of your dyno room and the size of your fans.
Exhaust Extraction—An exhaust fan is needed to remove exhaust
gasses, especially carbon monoxide, from the dyno room. Carbon
monoxide is potentially lethal to people if not removed from the
room and will affect engine power when mixed with fresh air.
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 Motorcycle Dynamometers P/N
98200081.
S P E C I F I C A T I O N S A N D O P E R A T I N G R E Q U I R E M
E N T S
Dynamometer Specifications and Requirements
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS
The following specifications and requirements will help you set up
your dyno area and verify you have the requirements necessary to
operate your dyno safely. For more information about dyno room
setup and layout, refer to the Pre-Installation Guide P/N
98200081.
BATTERY REQUIREMENTS
Your 200i/250i dyno is designed to carry a group 24 deep-cycle
discharge series battery for operating the starter, power carriage,
and optional wheel clamp. The typical dimensions for this series of
batteries are 27 cm long by 17 cm wide by 23 cm tall (10.625-inches
by 6.75-inches by 9.125-inches). The mounting is flexible so a
battery that has dimensions close to this will work satisfactorily.
The built-in battery cables are configured for top-post batteries.
This battery is not included with your dyno. You will need to
provide this battery. For more information on installing the
battery, refer to “Installing the Battery” on page 2-10.
CHASSIS SPECIFICATIONS
description specifications
Height
Width
Weight
model 200i dyno/crated dyno 725 kg (1,600 pounds)/771 kg (1,700
pounds)
model 250i dyno/crated dyno 1,077.28 kg (2,375 pounds)/1,133.98 kg
(2,500 pounds)
Drum
Frame structural steel channel and angle
Maximum Speed 322 KPH (200 MPH)
Maximum Motorcycle Length (front of front wheel to center of rear
wheel)
standard carriage 213.00 cm (84.00 inches)
extended carriage 256.00 cm (101.00 inches)
Remote Switches remote software control
Dynamometer Specifications and Requirements
1-6
1-7
S P E C I F I C A T I O N S A N D O P E R A T I N G R E Q U I R E M
E N T S
Dynamometer Specifications and Requirements
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
Figure 1-2: Model 250i Dimensions
C H A P T E R 1
Dynamometer Specifications and Requirements
1-8
MC144
motorcycle to dyno
Drum precision balanced
Power Cord
Control Panel Interface houses the main power breaker, eddy current
brake driver, and
battery disconnect
Tire Stop
Hand Wheel
1-9
S P E C I F I C A T I O N S A N D O P E R A T I N G R E Q U I R E M
E N T S
Dynamometer Specifications and Requirements
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
Figure 1-4: Model 250i With Optional Accessories
MC157
Eddy Current Brake Module
Power Carriage
Tire Carriage
motorcycle to dyno
Drum precision balanced
Dynamometer Specifications and Requirements
1-10
COMPRESSED AIR
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 dyno.
The following requirements are needed for the optional air
brake:
• regulator set to 65 psi max (450 kilopascal)
• air dryer
• gauge on the regulator
• 1/4-inch NPT pipe thread connector (to attach air to the
dyno)
The following requirements are needed for the optional Air Fuel
Ratio (AFR) module:
• Clean and dry air, 100 psi regulated (690 kpa), 5 CFM (.014
m3/min) or better 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.dynojet.com for the latest computer
requirements.
description minimum specifications recommended specifications
Operating System Windows 7 or later Windows 7 or later
Processor Dual Core Processor, 2GHz or faster
Intel Core i5 2.8GHz or faster
Memory 4GB System Ram 8GB System Ram or more
Hard Drive 100GB or larger (54MB required for program)
500GB or larger (54MB required for program)
Monitor/Graphics Card 1280x1024 (SXGA) resolution or higher
1600x900 resolution or higher
1 free 100Mbps RJ45 Port or Wireless
External Media CD-Rom Drive CD-Rom Drive
Printer Printer, if prints are needed Color printer, if prints are
needed
1-11
S P E C I F I C A T I O N S A N D O P E R A T I N G R E Q U I R E M
E N T S
Dynamometer Specifications and Requirements
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
ELECTRICAL REQUIREMENTS
The Model 200i/250i dynamometers require a 240V - 30a single-phase
electrical circuit for reliable and precise operation. No other
loads should be plugged into this circuit and this circuit should
be independent of the lighting in the dyno room. Before you plug in
your dyno, you or your electrician must refer to Appendix B for
detailed information.
ENVIRONMENTAL REQUIREMENTS
FIRE SUPPRESSION
Always have adequate fire suppression or fire extinguishers in your
dyno room.
FORKLIFT REQUIREMENTS
You will need to 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 uncrated dyno. Dynojet recommends using
single loop style straps. Using lift straps with bare forks is not
OSHA compliant.
description specifications
Frequency 50 or 60 Hz
Voltage
Current 30 amps
end twist-lock plug or three-pin IEC plug
wall receptacle (included with dyno) twist-lock four wire grounded
30A NEMA L14-30 or three-pin IEC grounded 30A
Full Load Amperage (FLA) 30A
description specifications
Humidity 0 to 95% non-condensing
C H A P T E R 1
Dynamometer Specifications and Requirements
1-12
GROUNDING REQUIREMENTS
You will need to ground the vehicle to the dynamometer before every
run using the vehicle grounding kit P/N 76100015. Never operate the
dynamometer without first grounding the vehicle to the dyno. Refer
to “Grounding the Vehicle” on page 5-9.
Never operate the dyno without properly grounding the vehicle to
the dyno.
GROUND HOOK REQUIREMENTS
You may wish to install additional ground hooks (included with your
dyno) for securing the motorcycle. The tie-down loops on the pit
covers should work for most motorcycles. If you are running
motorcycles that require a different tie-down location, mount the
ground hooks accordingly.
Note: Tie-down straps MUST pull the motorcycle forward.
Using the ground hooks as a pattern, install the Red Head anchors
using the hardware included with the ground hook kit. Install the
Red Head anchors according to the instructions in Appendix A.
PHONE AND INTERNET ACCESS
Dynojet recommends you have a phone close to the dyno to call for
assistance in an emergency. You may also wish to contact Dynojet to
troubleshoot your dyno.
Internet access on your computer is desirable for contacting
Dynojet and downloading new information and updates.
TIE-DOWN STRAPS
Dynojet recommends using motorcycle tie-down straps for securing
the bike on the dyno. You will need to provide the tie-down
straps.
TOOL REQUIREMENTS
Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to
remove the 1/4-inch screws.
You will need to provide a drill and drill bit capable of drilling
holes in concrete. Refer to Appendix A for more information on
installing Red Head Anchors.
• drill bit size: ½-inch
1-13
S P E C I F I C A T I O N S A N D O P E R A T I N G R E Q U I R E M
E N T S
DynoWare RT Electronics
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
DYNOWARE RT ELECTRONICS
The DynoWare RT electronics 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 detailed information for
configuring the DynoWare RT electronics can be found in the Power
Core Help.
Figure 1-5: DynoWare RT Electronics
air fuel ratio module
eddy current brake driver
DynoWare RT main module
DynoWare RT Electronics
1-14
A description of the main module symbols and connections
follows.
use this port to use this port to
RPM Inputs Connect inductive and optical RPM inputs.
Auxiliary Temperature
Connect to an auxiliary input for an infrared temperature
sensor.
Communication I/O Connect to auxiliary Dynojet products such as the
Power Commander, Wideband 2, etc.
Auxiliary Switch Connect to the brake air pressure switch on 248
and older 224 dynos.
Communication I/O Connect to auxiliary dyno electronics such as the
pendant, atmospheric module, etc.
Emergency Stop Connects the dyno electronics to the emergency stop
input on the 200i/250i dynos.
Communication I/O Connect to internal dyno electronics and
controllers such as the ECB controller and AFR module.
Network Connection
Connects the dyno electronics to your computer or computer
network.
Drum Connect to the drum 1 and drum 2 speed inputs and digital
brake outputs.
Refer to Instructions
Do not press this button unless instructed to do so by a Dynojet
Technician. This button may need to be pressed to update the
device.
1 2
1 2
1 2
N. Las Vegas, NV 89081 100-240 VAC
50-60 Hz 1.0 A
Analog
Status
BA
A
B !
C
1-15
S P E C I F I C A T I O N S A N D O P E R A T I N G R E Q U I R E M
E N T S
DynoWare RT Electronics
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
NETWORK CONNECTIONS
The Dynojet DynoWare RT dyno electronics connects to your computer
directly or over a Local Area Network. If you have an existing
network, connect the DynoWare RT main module to a router or a
network switch on your network. If you do not have an existing
network, you can create a network for the DynoWare RT by connecting
the main module to a router.
There are some advantages to connecting the DynoWare RT to a
network, particularly 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 allows you to control the dyno from
inside the vehicle without a cable running to the DynoWare RT main
module.
Note: The DynoWare RT allows only one computer at a time to
connect.
When the DynoWare RT main module is on a network connected to the
internet, automatic updates for both the DynoWare RT and software
are possible.
Figure 1-6: DynoWare RT Network Connections
connection method auto updates multi-computer connection wireless
connection
Wireless Network Internet
Yes Yes Yes
Wireless Network Router
2-1
CHAPTER 2
DYNO 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:
• Unpacking and Inspecting the Dyno, page 2-2
• Dyno Installation, page 2-10
• Starter Installation, page 2-13
• Battery Installation, page 2-18
• Eddy Current Brake Installation, page 2-20
• Secure the Dyno and Brake Module to the Floor, page 2-30
• Support Arm and Monitor Tray Installation, page 2-31
• Cable Routing, page 2-33
• Side and Top Cover Installation, page 2-48
• Load Cell Calibration, page 2-51
• Ramp Bracket, page 2-56
• Zip Tube, page 2-60
Unpacking and Inspecting the Dyno
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
2-2
UNPACKING AND INSPECTING 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.
Use the following steps to unload your dyno. You will need to
provide equipment capable of lifting a minimum of 1,133.98 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
crate. 2 Inspect the exterior of the dyno for any indications of
damage. Report any damage
immediately. 3 Remove the tire carriage. The tire carriage is
fastened to the bottom of the crate. 4 Remove the support arm. The
support arm is fastened to the bottom of the crate.
Refer to“Support Arm and Monitor Tray Installation” on page 2-31
for more information.
Figure 2-1: Remove the Tire Carriage and Support Arm from the
Crate
D 036C
tire carriage
support arm
2-3
D Y N O I N S T A L L A T I O N
Unpacking and Inspecting the Dyno
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
5 Remove the six 1/4-inch screws securing the center panel on the
dyno and remove the center panel. Note: Dynojet recommends using a
T30 Torx driver (Snap-On PFTx30E) to remove the 1/4-inch
screws.
6 Remove the tire stop, tire lock, and hardware from the middle of
the dyno.
Figure 2-2: Remove the Center Panel
D 037C
center panel
C H A P T E R 2
Unpacking and Inspecting the Dyno
Above Ground Model 250i Motorcycle Dynamometer Installation
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 and set aside.
Figure 2-3: Remove the Top Drum Cover
D 038C
2-5
D Y N O I N S T A L L A T I O N
Unpacking and Inspecting the Dyno
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
9 Remove the remaining six side screws securing each side drum
cover to the dyno and set aside. Remove the side drum covers and
set aside. Note: For future reference, note the three access holes
in the drum bulkhead. These access holes will be used to route
cables when installing accessories once the top cover is back
on.
#RECORD Be sure you record the dynamometer number on the inside
cover of this manual.
Figure 2-4: Remove the Side Drum Covers
D 039C
visible from this view)
C H A P T E R 2
Unpacking and Inspecting the Dyno
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
2-6
10 Remove the boxes and loose parts from the crate, verify their
condition and contents, and set them aside.
part description part description
grounding kit P/N 76100015
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 Head anchor P/N 37518200
blower assembly P/N 76722003
network cable P/N 42900000
cable clamp (7) P/N 43428232
cable, wheel clamp P/N 76950307
optional accessory
cable, power carriage P/N 76950308
optional accessory
2-7
D Y N O I N S T A L L A T I O N
Unpacking and Inspecting the Dyno
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
battery hold down kit P/N 49418001
cable, pickup/brake P/N 76950548
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
optional accessory
refer to page 2-20
tire stop P/N 63310902
cable, CAN control, 15' P/N 76950791
on dyno air fuel ratio assembly P/N 64100008
optional accessory
DynoWare RT main module P/N 66100016
cable, CAN control adapter P/N 76950807
part description part description
Unpacking and Inspecting the Dyno
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
2-8
starter assembly P/N 66900000
see list of parts below
speed pick up P/N 68300002
power carriage P/N 82943001
ramp bracket assembly P/N 69100001
banner, Dynojet (2) P/N D706
carriage assembly P/N 71323002
hand wheel P/N DM150-016-006
wheel clamp P/N 71329000
bolt, 3/8-16 x 3/4" hex (4) P/N DM150-019-008
pendant assembly P/N 76100007
part description part description
2-9
D Y N O I N S T A L L A T I O N
Unpacking and Inspecting the Dyno
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
The following parts are included in the Grounding Kit P/N
76100015:
grounding bracket P/N 21600084
screw, 1/4-20 x 1/2" P/N 36560834
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 36932100
bolt, 3/8-16 x 1", hex (2) P/N DM150-019-012
anchor, Red Head, 3/8" (2) P/N 37513200
The following parts are included in the Nut Block Assembly P/N
79100001:
carriage clamp (3) P/N 21224104
nut block assembly P/N 61324102
carriage clamp spacer (3) P/N 21224105
bolt, 5/16-18 x 1.5", hex (8) P/N DM150-002-003
nut block spacer P/N 21224106
washer, lock, 5/16" (8) P/N DM150-02-004
part description part description
Dyno Installation
2-10
DYNO INSTALLATION
This section will walk you through removing the dyno from the crate
and installing the dyno in your dyno room.
REMOVING THE DYNO FROM THE CRATE
You will need to 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 same weight. Dynojet recommends using a
single loop style strap.
1 Remove the four lag bolts and washers securing the dyno to the
crate base using a 9/16-inch socket, open or box end wrench.
2 The pickup card may be taped to the lifting eye. Remove the
pickup card and set it aside.
Figure 2-5: Remove the Dyno from the Crate Base
bolt and washer not visible from this view
lifting eye
2-11
D Y N O I N S T A L L A T I O N
Dyno Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
3 Route the single loop strap through the lifting eyes in front of
the drum as shown in Figure 2-6. Note: The dyno should only be
lifted using the lifting eyes. Verify no other part of the dyno is
interfering with the strap. Do not place the strap around the cable
routing bracket or any other part of the dyno.
Figure 2-6: Loop Strap Placement
4 Carefully lift the dyno off the crate and move into position in
your dyno room. Note: While the dyno is supported by the forklift
and before it is placed in your dyno room, the power cable must be
routed through the front of the dyno.
Figure 2-7: Lift the Dyno off the Crate
lifting eye
lifting eye
Dyno Installation
2-12
ROUTING THE POWER CABLE
1 Locate the power cable inside the dyno. 2 Slide the strain relief
on the power cable through the opening in the dyno frame. 3 Tighten
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 the carriage. Refer to “Dynamometer Specifications and
Requirements” on page 1-5 for more information.
Figure 2-8: Route the Power Cable
MC076A
jam nut inside dyno
opening in dyno frame
knurled nut outside dyno
2-13
D Y N O I N S T A L L A T I O N
Starter Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
STARTER INSTALLATION
The starter allows you to use the momentum of the drum to start
motorcycles that are not equipped with an on-board starting system.
The starter is optional; if you do not wish to install the starter,
verify the red positive cable terminal from the battery cable is
not touching metal and is secured and protected.
The starter requires a battery to operate. Refer to “Battery
Installation” on page 2-18.
Gear clearances must be checked before using the starter. Damage to
the starter gear or the drum ring gear is possible without proper
alignment.
INSTALLING AND ALIGNING THE STARTER
The rear drum cover is not shown for clarity.
1 Locate the starter in a box secured to the battery tray inside
the dyno. 2 Using the two included bolts, attach the ground wire
from the battery cable as
shown in Figure 2-9 and loosely secure the starter to the frame
rail on the dyno. Leave these bolts finger tight.
3 Verify the gap between the starter gear and the drum ring gear is
approximately 1/8-inch when the starter gear is in its relaxed
position.
Figure 2-9: Install the Starter and Verify Clearance
starter
C H A P T E R 2
Starter Installation
2-14
4 Using a large flathead screwdriver or pry bar, carefully pry the
starter gear away from the starter to engage the ring gear on the
drum and hold it in place. You may need to rotate the drum slightly
to engage the gear. Note: If the drum cannot be engaged even when
wiggling the starter around or rotating the drum, you will need to
move the starter using the included shims. Refer to “Moving the
Starter Using Shims” on page 2-16. In very rare occasions, you may
need to move the drum; refer to “Moving the Drum” on page
2-17.
5 Verify the starter gear engages the drum ring gear and that the
starter gear and drum ring gear are parallel with each other.
6 Verify the clearance is .040-inch ± .015-inch (1 mm). The average
standard size paper clip is .030-inch and may be used as a gauge
stick to verify clearance.
Insert the paper clip between the starter gear and the drum ring
gear. If there is only room for one paper clip, the clearance is
adequate.
Note: If the gap exceeds .055-inch (the width of two paper clips),
you will need to move the starter using shims or the drum will need
to be moved for tighter engagement and to prevent damage to the
starter or drum ring gear. Refer to“Moving the Starter Using Shims”
on page 2-16 or “Moving the Drum” on page 2-17.
Gear clearances must be checked before using the starter. Damage to
the starter gear or the drum ring gear is possible without proper
alignment.
7 Torque the starter bolts 38 ft.-lb. 8 If the drum was moved,
torque the bearing bolts to 112 ft.-lb.
Figure 2-10: Align the Starter Gear and Drum Ring Gear
drum ring gear
use a screwdriver to hold the starter gear into the
drum ring gear
2-15
D Y N O I N S T A L L A T I O N
Starter Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
WIRING AND TESTING THE STARTER
The battery will need to be connected before you can test the
starter. Refer to “Battery Installation” on page 2-18.
1 Connect the red battery cable to the B terminal. 2 Connect the
blue wire with the spade terminal to the S spade terminal. 3 Verify
the ground wire is connected to the starter mounting bolt. 4 Verify
the battery is connected. Refer to “Battery Installation” on page
2-18. 5 Press and release the starter button quickly. Do not hold
the button. Refer to
“Using the Starter” on page 4-6. 6 As long as the drum rotates and
there is no grinding, the starter is installed
correctly.
Do not continue to push the starter button if you hear any grinding
or if the drum does not turn. Damage to the starter gear or the
drum ring gear is possible without proper alignment. Recheck
alignment.
Figure 2-11: Wiring the Starter
S spade terminal blue wire
B terminal
Starter Installation
2-16
MOVING THE STARTER USING SHIMS
Before moving the drum, try moving the starter by adding or
removing the shims included with the starter.
1 Use the triangle shim to move the starter away from the drum ring
gear. 2 Use the rectangle shim between the starter and the frame
rail to move the starter
away from the drum ring gear. 3 You can also remove existing shims
from the starter to move the starter into
position.
rectangle shim
triangle shim
2-17
D Y N O I N S T A L L A T I O N
Starter Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
MOVING THE DRUM
Note: Before moving the drum, try using shims to move the starter.
Refer to “Moving the Starter Using Shims” on page 2-16.
If the drum cannot be engaged even when wiggling the starter around
or rotating the drum, you will need to loosen the bolts securing
the bearings to the frame rail.
Note: If you have to move to the drum, you will need to check the
alignment of the pickup card and the alignment of the top drum
cover window with the drum.
1 Loosen the drum bearing bolts. 2 Move the drum in very small
increments.
2a Place a pry bar between the collar and the bearing to move the
drum slightly to the left or right.
2b Place a pry bar between the bolt and bearing to move the drum
slightly forward or back.
3 Verify the starter gear engages the drum ring gear and that the
starter gear and drum ring gear are parallel with each other.
4 Once the gears are engaged, verify the pickup card alignment. Be
sure the wheel passes freely through the optical pickup. Refer to
“Pickup Card Installation” on page 2-19.
5 Verify the drum top cover and finger guards fit properly. Refer
to Figure 2-43 on page 2-48.
6 Torque the drum bearing bolts to 112 ft.-lb.
Figure 2-13: Moving the Drum
insert pry bar between the bolt and bearing to move the drum to
the
forward or back
insert pry bar between collar and bearing to move
the drum left or right
C H A P T E R 2
Battery Installation
2-18
BATTERY INSTALLATION
The model 200i/250i dyno is designed to carry a group 24 deep-cycle
discharge series battery for operating the starter, optional power
carriage, and optional wheel clamp. The typical dimensions for this
series of batteries are 27 cm long by 17 cm wide by 23 cm tall
(10.625-inches by 6.75-inches by 9.125-inches). The mounting is
flexible so a battery that has dimensions close to this will work
satisfactorily. The built-in battery cables are configured for
top-post batteries. This battery is not included with your dyno.
You will need to provide this battery.
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 danger of explosion if the battery is incorrectly
connected or replaced. Wear protective clothing, eye, and face
protection when charging or handling batteries. Refer to Warnings
for more information.
1 Locate the red battery cable on the inside of the dyno. 2 Place
the battery in the battery carrier on the inside of the dyno so the
red cable
can reach the positive (+) post on the battery and the black
battery cable can reach the negative (-) post.
3 Secure the red battery cable to the positive (+) battery post. 4
Secure the black battery cable to the negative (-) battery post. 5
Secure the battery to the tray with the battery hold-down.
Figure 2-14: Install the Battery
MC147
battery
2-19
D Y N O I N S T A L L A T I O N
Pickup Card Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
PICKUP CARD INSTALLATION
The pickup card is an electronic circuit board that accurately
senses each drum revolution.
1 Locate the pickup card bracket on the right side of the dyno just
ahead of the drum.
2 Install the pickup card to the bracket using two No. 8 screws. 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 aligned, tighten the screws to secure the pickup card
bracket in place.
The optical pickup is very delicate. Be careful not to damage the
optical pickup during alignment.
Figure 2-15: Install the Pickup Card
pickup card bracket
wheel on dyno
top view of pickup card, optical pickup, and tab on dyno
wheel on dyno
Eddy Current Brake Installation
2-20
EDDY CURRENT BRAKE INSTALLATION
The eddy current brake is an optional accessory. This section will
walk you through removing the eddy current brake from the crate,
and attaching the brake to your dyno. If you did not purchase the
eddy current brake, skip this section and continue with “Secure the
Dyno and Brake Module to the Floor” on page 2-30.
You will need to provide equipment capable of lifting the eddy
current brake off the crate and into position in your dyno room.
You will also need a pair of straps. Dynojet recommends using
continuous nylon loop style straps.
Refer to Appendix B for information on the power requirements for
the eddy current brake.
To prevent possible injury, verify all power cords are
unplugged.
UNPACKING THE EDDY CURRENT BRAKE
1 Remove the top and sides of the crate. 2 Remove any hardware and
parts boxes from the crate and verify the box contents.
Figure 2-16: Remove the Crate Top
remove boxes
2-21
D Y N O I N S T A L L A T I O N
Eddy Current Brake Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
part description part description
top cover P/N 63200000
eddy current brake driver P/N 66400019
washer, 3/8", flat (2) P/N 36923100
cable, controller P/N 66952003
cable, IR temp sensor P/N 76950569
installation tool, Red Head anchor P/N 37518200
bolt, 3/8-16 x 1", hex (2) P/N DM150-019-012
driveline assembly P/N 62240070
Eddy Current Brake Installation
2-22
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 cover of this manual.
Figure 2-17: Remove the Covers
top cover
2-23
D Y N O I N S T A L L A T I O N
Eddy Current Brake Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
4 Remove the four bolts securing the brake to the crate. 5
Determine if the brake is to be mounted on the left or right side
of your dyno.
Make the following adjustments to the eddy current brake only if
you want to mount the brake on the opposite side of the dyno that
it is currently set up for.
5a Move the driveline and key to the other side of the brake.
To remove the key, use a punch and a hammer to apply pressure in
the direction of the arrows shown in Figure 2-19.
5b Move the retarder connector plates to the other side of the
brake. 5c Move the temperature sensor to the other side of the
brake.
Figure 2-18: Identifying Left or Right Side Brake Set Up
Figure 2-19: Remove the Key
retarder connector plates
eddy current brake set up for left side installation eddy current
brake set up for right side installation
driveline
shaft
key
Eddy Current Brake Installation
2-24
6 Remove the side drum cover, if not already removed, from the
dyno. Refer to Figure 2-4 on page 2-5.
7 Place the nylon loop 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 dyno are parallel.
9 Remove the eight bolts, washers, and nuts from the dyno frame
where the
connector plates will attach.
EB238
2-25
D Y N O I N S T A L L A T I O N
Eddy Current Brake Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
INSTALLING THE EDDY CURRENT BRAKE
The eddy current brake comes with the driveline already installed
on the brake shaft.
The eddy current brake can be installed on either side of your
dyno. The air 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 requirements of your local country may require that
both brakes are installed. Be sure to follow the safety
requirements specific to your country.
1 Insert the key into the keyway. 2 Use a c-clamp to press the key
in, if necessary.
Figure 2-21: Install the Key
EB239
key
Eddy Current Brake Installation
2-26
3 Keeping the panels parallel, slide the eddy current brake 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.
4 Continue sliding the eddy current brake towards the dyno until
the covers on the brake and dyno are flush. Make sure the brake
driveline is aligned and straight.
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 2-22.
Note: Do not tighten the bolts.
6 Verify the covers on the brake and the dyno line up. These covers
must be flush and parallel. If these covers are not flush, place
shims between the floor and the eddy current brake or the dyno
until they are flush.
7 Once aligned, tighten all retarder connector plate bolts and
nuts.
Figure 2-22: Secure the Retarder Connector Plate and Starter
Brace
three bolts not visible from this view
retarder connector plate
2-27
D Y N O I N S T A L L A T I O N
Eddy Current Brake Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
8 Secure the side panels on the eddy current brake to the panels on
the dyno using a 1/4-20 bolt. Do this on each side.
Figure 2-23: Secure the Side Panels to the Dyno
9 Replace the existing set screws on the driveline with the
thread-lock set screws provided.
10 Tighten the driveline set screws.
Figure 2-24: Tighten the Set Screws
EB241
brake shaft dyno shaft
Eddy Current Brake Installation
2-28
INSTALLING THE LOAD CELL
The load cell is an optional accessory. This section describes how
to remove the existing bar on the eddy current brake and install
the load 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 2-30.
You will need the following part:
1 Verify the main dyno power is disconnected. Refer to“Main Dyno
Power” on page 3-2 for more information.
2 Remove the two bolts and nuts securing the existing bar on the
eddy current brake and remove the bar. Set the bolts and nuts
aside.
Figure 2-25: Remove the Existing Bar
part description
bar
2-29
D Y N O I N S T A L L A T I O N
Eddy Current Brake Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
3 Verify the eyelets on the load cell are spaced the same as the
bar removed earlier.
Adjust the load cell spacing by loosening the lock nut and turning
the eyelet.
Figure 2-26: 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 2-33 for more information on
routing the load cell cable.
Refer to “Load Cell Calibration” on page 2-51 for more information
on calibrating the load cell.
Figure 2-27: Install the Load Cell
distance must be the same
eyeletbar
C H A P T E R 2
Secure the Dyno and Brake Module to the Floor
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
2-30
SECURE THE DYNO AND BRAKE MODULE TO THE FLOOR
Dynojet recommends you anchor the eddy current brake, along with
the dyno, to the floor in your dyno room using concrete anchors.
You will want to drill the holes and secure the dyno before adding
any accessories or replacing the covers on your dyno.
You will need the following parts:
• 36923100Washer, 3/8", Hardened, Flat, Steel (6) • 37513200Anchor,
Red Head, 3/8" (6) • 37518200Red Head Anchor Installation Tool •
DM150-019-012Bolt, 3/8-16 x 1", Hex (6)
1 Using the dyno and brake module as a template, mark and drill
each hole needed to secure the dyno to the floor.
2 Install the Red Head anchors. Refer to Appendix A for
installation instructions. 3 Secure the dyno and brake module to
the floor using six 3/8-16 x 1-inch hex bolts
and six 3/8-inch flat washers.
Figure 2-28: Secure the Dyno and Brake Module to Floor
MC122
mark and drill holes for red head
anchors
2-31
D Y N O I N S T A L L A T I O N
Support Arm and Monitor Tray Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
SUPPORT ARM AND MONITOR TRAY INSTALLATION
This articulated arm and platform supports the monitor, keyboard,
and mouse in a convenient position for operation while seated on
the motorcycle. The support arm can be mounted on either side of
the dynamometer.
You will need the following parts:
• 61329101PMonitor Tray
• 61329500Support Arm Upright • 61329100Monitor Arm (2) •
26215520Washer, 1.87 x 1.25 x 12 (3) • 35521420Cap Plug (4)
INSTALLING THE SUPPORT ARM AND TRAY
The support arm and monitor 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, secure the support arm to the dyno frame
with four 3/8-16 x 1/2-inch button-head flange screws you removed
earlier.
3 Place a poly washer around the pin of the first arm and insert
the arm into the support arm.
4 Place a poly washer around the pin of the second arm and insert
the arm into the first arm.
5 Place a poly washer around the pin of the tray and insert the
tray into the second arm.
6 Insert a plastic cap in both ends of each arm. 7 Check for
clearance between the monitor arm and motorcycle, walls, ceiling,
etc.
Note: Dynojet does not recommend placing the computer CPU on the
monitor/keyboard tray since vibration can cause damage to the
computer.
C H A P T E R 2
Support Arm and Monitor Tray Installation
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
2-32
MA021
2-33
D Y N O I N S T A L L A T I O N
Cable Routing
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
CABLE ROUTING
Use the following instructions to identify and route the cables.
You will need to route the cables before installing the
covers.
IDENTIFYING THE CABLES
cable brief routing description
A - 42900000 network cable connects the DynoWare RT to your local
network
B - 66400011 remote atmos cable assembly connects to the DynoWare
RT
C - 76100007 CAN pendant cable assembly connects to the DynoWare
RT
D - 76950201 primary RPM pick up cable - 76950203 secondary pick up
cable
connects to the DynoWare RT
E - 76950307 wheel clamp cable assembly connects P5 on the front of
the CPI panel to the wheel clamp
F - 76950308 power carriage cable assembly connects P8 on the front
of the CPI panel to the power carriage
G - 76950310 power in cable connects the CPI power to the back of
the DynoWare RT
H - 76950548 speed pick up/brake cable connects the brake solenoid
and speed pick up to the DynoWare RT
B
B
Cable Routing
2-34
I - 76950549 e-stop to CPI cable connects the DynoWare RT to P7 on
the front of the CPI panel
J - 76950569 IR temp sensor cable connects to the temp sensor cable
to the eddy current brake driver
K - 76950573 load cell cable connects the load cell to the eddy
current brake driver
*optional accessory
L - 76950680 CAN powersports cable connects Dynojet Powersports
products to the DynoWare RT (PCV, OBD2)
M - 76950791 CAN control cable, 15' connects the eddy current brake
driver to the DynoWare RT using the CAN adapter cable or CAN
network cable chain
N - 76950798 CAN dyno user cable, 15' connects the POD intercept to
the DynoWare RT using the CAN adapter cable
O - 76950798 CAN dyno user cable, 15' connects the air fuel module
to the DynoWare RT using the CAN adapter cable or CAN network cable
chain
*optional accessory
P - 76950807 CAN control cable, adapter, 2' connects the DynoWare
RT to the CAN control and CAN dyno user cables
cable brief routing description
J. MaxwellJ. Ma xwell
A
C
C
C
C
2-35
D Y N O I N S T A L L A T I O N
Cable Routing
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
INSTALLING THE DYNOWARE RT MAIN MODULE
Slide the DynoWare RT main module into the bracket assembly in the
dyno.
Figure 2-30: Install the DynoWare RT Main Module
Q - 76951501 control panel cable connects the CPI to the control
panel (POD)
R - 76423025 PCV CAN termination plug connects to the PCV module
when connected to the DynoWare RT using the CAN Powersports
cable
S - 76423045 CAN termination plug connects to the last CAN cable in
the CAN network cable chain
cable brief routing description
Cable Routing
2-36
ROUTING THE CABLES
Use the following instructions along with Figure 2-32 on page 2-38
for routing and connecting the cables.
Refer to the i-Dyno Wiring Schematic P/N 98200082 for additional
wiring information and schematics.
1 Remove the two screws securing the cable pass through cover
closest to the monitor support and set it aside.
2 Route the CAN pendant cable (C) through the cable pass through
closest to the monitor support and attach to the front of the
DynoWare RT module.
3 Route the network cable (A) to the back of the DynoWare RT
module. 4 Route the 15-pin control panel (Q) 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 2-39.
5 Place a split snap bushing around the pendant cable and secure
the cable through one hole in the cable pass through cover.
6 Place a split snap bushing around the control panel cable and
secure it in the other hole on the cable pass through cover. The
bushing should be around the cable protective wrap.
7 Secure the cable pass through cover to the dyno using the two
screws removed earlier.
8 Attach the speed pickup/brake cable (H) to the back of the
DynoWare RT module. Note: The white two-pin connector on the speed
pickup/brake cable is only used if an air brake is installed.
9 Attach the temp sensor cable (J) to the eddy current brake
driver. 10 Attach the load cell cable (K), if present, to the eddy
current brake driver.
D Y N O I N S T A L L A T I O N
Cable Routing
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
11 Attach the CAN adapter cable (P) to the back of the DynoWare RT
main module. 12 Attach the CAN dyno user cable (N) to the CAN
adapter cable (P) and route to the
POD intercept board. Attach the CAN dyno user cable (N) to the POD
intercept board.
13 Attach the CAN control cable (M) to the “T” on the CAN dyno user
cable (N) and route to the eddy current brake driver. Attach the
CAN control cable (M) to the eddy current brake driver.
14 Attach the CAN dyno user cable (O) to the “T” on the CAN control
cable (M) and route to the AFR assembly. Attach the CAN dyno user
cable (O) to the AFR assembly. Note: The AFR assembly is an
optional accessory.
15 Insert the CAN termination plug (S) in the CAN dyno user cable
(O). Note: If you do not have an eddy current brake and/or AFR
assembly, insert the CAN termination plug (S) at the end of your
CAN network cable chain.
Figure 2-31: CAN Network Cable Configuration
16 Route the e-stop cable (I) from P7 on the front panel of the CPI
to the back of the DynoWare RT main module.
17 Route the AFR power cable to the AFR assembly. 18 Insert the O2
sensor(s) into the sensor block on the AFR assembly, plug
sensor
connectors into AFR, and tie the sensor cables. 19 Attach the
network cable (A) to your network. Refer to “Network Connections”
on
page 1-15. 20 Route the power cable (G) from the DIN rail to the
back of the DynoWare RT
module. 21 Attach remote atmos cable (B) to the DynoWare RT module
and stick the atmos
module to the side of the dyno. 22 Remove the PCV CAN termination
plug (R) from the front of the DynoWare RT
module and save for use with the PCV module. 22a Attach the PCV or
OBD2 module using the CAN powersports cable (L). 22b Insert the PCV
CAN termination plug (R) in the PCV module. Note: If you are not
using a PCV, be sure to save the PCV CAN termination plug (R) for
future use.
C H A P T E R 2
Cable Routing
2-38
2-39
D Y N O I N S T A L L A T I O N
Cable Routing
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
CONNECTING THE CONTROL PANEL CABLE
1 Locate the control panel and ready it to connect the control
panel cable. The control panel ships in a separate 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 and set aside. 1d
Remove the four screws on the back of the cover and set aside. 1e
Remove the control panel rear cover and set aside.
Figure 2-33: Locate the Control Panel and Remove the Back
Cover
CP025
Cable Routing
2-40
2 Route the control panel cable through the access hole on the side
of the control panel box and through the cable tie.
3 Attach the control panel cable to the Button board.
Figure 2-34: 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 of the cover removed earlier. 4c Replace the screw
on the side of the cover removed earlier. 4d Replace the two nuts
on the top of the cover removed earlier.
Figure 2-35: Replace the Control Panel Rear Cover
control panel cable with cable harness wrap
access hole
cable tie
button board
2-41
D Y N O I N S T A L L A T I O N
Cable Routing
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
5 Secure the control panel to the monitor tray using two 8-32-inch
screws. Note: If you did not order a monitor tray, install the
control panel spindle to the back of your control panel using four
8-32 screws. Once installed, place the spindle on the control panel
into the support arm where the monitor tray is shown in Figure
2-36.
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 your cables through a zip tube refer to “Zip
Tube” on page 2- 60 and skip the following steps.
8 Attach the cable bundle with the cable clamps that are provided
using 8-32-inch screws. Adjust the service loops to allow for easy
movement of the monitor arms without pulling on the cables.
Figure 2-36: Install the Control Panel
CP035
CP023 control panel
install control panel spindle if you did not purchase the
monitor
tray
Cable Routing
2-42
ROUTING THE POWER CARRIAGE AND WHEEL CLAMP CABLES
The power carriage and wheel clamp are optional accessories. These
cables will only be used if you ordered the accessories.
For installation instructions refer to “Power Carriage” on page
3-36 and “Wheel Clamp” on page 3-40 for more information.
1 Remove the two screws securing the cable pass through cover on
the front of the dyno and set aside.
2 Locate the cables bundled inside the dyno. 3 Route the power
carriage and wheel clamp cables through the opening in the
front
of the dyno.
route cables through
2-43
D Y N O I N S T A L L A T I O N
Cable Routing
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
4 Place a split snap bushing around the wheel clamp cable and
secure 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 cable pass through cover to the dyno with the two
screws removed earlier.
Figure 2-38: Routing Wheel Clamp and Power Carriage Cables
W 016C
Tire Carriage Installation
2-44
TIRE CARRIAGE INSTALLATION
Be sure the location you have chosen for your dyno has enough room
in front of the dyno for the maximum extension of the carriage.
Refer to “Dynamometer Specifications and Requirements” on page 1-5
for more information. If you ordered the extended wheel carriage
accessory, refer to “Extended Carriage” on page 3-17 and install it
at this time.
The tire carriage is fastened to the bottom of the crate next to
the dyno. Refer to page 2-2 for instructions on removing the tire
carriage from the crate.
Note: Before replacing the center panel and installing the tire
carriage install the air hose, the EEC Kit, the door safety switch,
and any additional accessories you may have ordered. Refer to the
appropriate sections of this manual for installation
instructions.
You will need the following parts:
• 21224104Carriage Clamp (3) • 21224105Carriage Clamp Spacer (3) •
21224106Nut Block Spacer • 36580434Bolt, 3/8-16 x 1/2", Bh-Flange
(8) • 61324102Nut Block • 63310902Tire Stop • 71323002Standard
Carriage • DM150-002-003Lock Washer, 5/16" (8) • DM150-002-004Bolt,
5/16-18 x 1.5", Hex (8) • DM150-016-006Hand Wheel
2-45
D Y N O I N S T A L L A T I O N
Tire Carriage Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
1 Replace the center panel using the six 1/4-inch screws you
removed. See Figure 2-2 on page 2-3.
2 Install the three carriage clamps 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 2-39: Install the Carriage Clamps and Nut Block
4 Remove the four 1/4 x 20-inch button-head screws securing the
bearing bracket. 5 Remove the bearing bracket and the carriage
screw.
Figure 2-40: Remove the Bearing Bracket and Carriage Screw
TC069
Tire Carriage Installation
2-46
6 Starting from the back of the dyno, slide the carriage under the
carriage clamps. 7 Slide the hand wheel onto the end of the
carriage screw. 8 Secure the hand wheel to the screw shaft by
tightening the set screw using a
5/32-inch allen wrench. 9 Slide the carriage screw and the bearing
bracket toward the nut block until the
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 will not have the hand wheel. Carefully turn the carriage screw
using pliers.
11 Secure the bearing bracket to the carriage using four 1/4-20 x
1/2-inch button-head flange bolts removed earlier. Note: If you
ordered the power carriage accessory, refer to “Power Carriage” on
page 3-36 for installation instructions.
Figure 2-41: Install the Tire Carriage and Secure the Hand
Wheel
TC070
2-47
D Y N O I N S T A L L A T I O N
Tire Carriage Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
12 Secure the tire stop 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 3-40 for
installation instructions.
13 Secure the tire lock to the carriage using four 3/8-16 x
1/2-inch button-head flange bolts.
Figure 2-42: Install the Tire Stop and Tire Lock
TC071
Side and Top Cover Installation
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
2-48
SIDE AND TOP COVER INSTALLATION
Before replacing the covers, be sure to install the battery, pickup
card, eddy current brake, and any accessories you may have
purchased with your dyno. Refer to Chapter "Accessories" for
accessory installation instructions.
1 Secure the drum side cover to the dyno using six of the screws
you removed earlier.
2 Secure the eddy current brake side cover to the dyno using six of
the screws you removed earlier.
Figure 2-43: Replace the Side Covers
MC149
2-49
D Y N O I N S T A L L A T I O N
Side and Top Cover Installation
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
3 Secure the top of the side covers with the screws you removed
earlier. 4 If this is a European dyno, you will need to install the
EEC finger guards. Refer to
Appendix C for EEC finger guard installation and adjustment
instructions. 5 Secure the top drum cover to the dyno using the
eight screws removed earlier.
Figure 2-44: Replace the Top Drum Cover
MC150
Side and Top Cover Installation
Above Ground Model 250i Motorcycle Dynamometer Installation
Guide
2-50
6 Secure the eddy current brake top cover with the screws you
removed earlier.
Figure 2-45: Replace the Eddy Current Brake Top Cover
EB242
2-51
D Y N O I N S T A L L A T I O N
Load Cell Calibration
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
LOAD CELL CALIBRATION
The load cell is an optional accessory. Before proceeding, make
sure all cables have been routed and the covers have been
installed. This section provides instructions for calibrating the
load cell. Follow the directions on the screen exactly. Failure to
perform the directions accurately will result in improper torque
values.
You will need the following parts:
1 Verify the dyno is connected to power. Refer to “Main Dyno Power”
on 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 connecting to the DynoWare RT, refer
to the Power Core Quick Start Guide or the Power Core Online
Help.
5 From the Configuration ribbon, click Load Cell Calibration . 6
Remove the calibration arm and mass if it is installed. 7 Release
the dyno brake. Make sure the drums are free to rotate.
Note: There should not be anything resting on the eddy current
brake or the dyno drum during this procedure.
8 Click Next to zero the connected torque cell.
Figure 2-46: Zero Calibration Window
part description part description
calibration arm assembly P/N 61319001
C H A P T E R 2
Load Cell Calibration
2-52
9 Using the drop-down arrow, set the index to zero. Note:
Powersports Dynos have one load cell, leave the index set to
zero.
10 Enter the calibration weight. This value is stamped into the
calibration arm.
Figure 2-47: Calibration Mass Window
Enter the calibration 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 stamped near the bolt pattern in
the center of the arm.
Note: Dynojet recommends you secure the calibration arm using the
bolt pattern closest to the end of the arm unless space constraints
in your dyno room do not allow you to.
Figure 2-48: Calibration Arm Number
bolt pattern closest to the end of the
calibration arm
calibration arm
2-53
D Y N O I N S T A L L A T I O N
Load Cell Calibration
Version 6 Above Ground Model 250i Motorcycle Dynamometer
Installation Guide
11 Install the calibration arm and weights using the bolts at the
end of the calibration arm. Note: If you do not 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. Refer to Figure
2-50.
11a Secure the calibrat