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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 #
Dynamometer Number:
RECORD #
Eddy Current Brake Number:
TABLE OF CONTENTS
Warnings .......................................................... v
Chapter 3 Accessories
Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Removing the Drum Top and Side Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Removing the Center Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Routing the Air Brake Cable and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Removing the Standard Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Installing the Extended Carriage Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Installing the Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
High Pressure Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Installing the Blower Arm Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Installing the High Pressure Blower Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Connecting Power to the Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Removing the Hand Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
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.
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.
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.
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 persons 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).
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
manufacturers 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.
Grounding Requirements
Always ground the vehicle to the dynamometer. Never operate the dynamometer without properly
grounding the vehicle to the dyno.
The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for
disconnect before service.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Any dyno room design must incorporate sufficient exhaust extraction.
Always wear proper ear and eye protection when operating the dynamometer.
Never operate the dynamometer with the covers removed.
Never stand behind the dynamometer when in operation.
Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems
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.
Introduction
INTRODUCTION
Before installing your dyno, please take a moment to read this guide for installation
instructions, dyno features, and other important information.
This guide is designed to be a reference tool in your everyday work and includes the
following chapters and information:
DYNO INSTALLATION
This chapter describes the procedures for installing the dyno.
A CCESSORIES
This chapter lists each dyno accessory alphabetically and describes the procedures for
installing and using this accessory.
P OWER REQUIREMENTS
This appendix describes power requirements and installation instructions.
EEC K IT
This appendix describes the procedures for installing the EEC finger guards and door
safety switch.
T ORQUE VALUES
This appendix describes standard and metric torque values.
1-2
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S
Introduction
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, and press releases about our latest
product lines.
Introduction
Intake Air FanAfter building your dyno room, you will need to supply an intake air
fan. The intake air fan supplies air to cool the vehicles 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
installed fan should be 5200 CFM.
Equalizer BoxIf 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.
Industrial Noise Control, IncIndustrial Noise Control, Inc. offers a zinc-coated steel
room custom built to your specifications. This room meets all dyno room
requirements. The dyno room must be clean and dry with a comfortable room air
temperature above 32 degrees Fahrenheit (0 degrees Celsius), and have some system
of exhaust extraction. For more information on a dyno room, refer to your
Pre-Installation Guide For Model 200i, 250i, 200ip, and 250ip Motorcycle
Dynamometers (P/N 98129103).
1-4
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S
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
Length
with standard carriage allow 271.78 cm (107.00 inches)
with extended carriage allow 322.58 cm (127.00 inches)
Height
to top of dyno cover 45.97 cm (18.10 inches)
Width
model 200i 106.68 cm (42.00 inches)
model 250i 179.60 cm (70.71 inches)
Weight
model 200i dyno/crated dyno 725 kg (1600 pounds)/771 kg (1700 pounds)
model 250i dyno/crated dyno 1,077.28 kg (2,375 pounds)/1,133.98 kg (2,500 pounds)
Drum
diameter 45.72 cm (18.00 inches)
width 50.80 cm (20.00 inches)
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 cm (84.00 inches)
extended carriage 256.54 cm (101.00 inches)
Remote Switches remote software control
model 200i
202.77 cm
106.68 cm (79.83 in.)
152.40 cm (42.00 in.)
(60.00 in.)
model 250i
127.74 cm
(50.29 in.)
72.92 cm
(28.71 in.)
carriage: allow 68.33 cm (26.9 in.)
extended carriage: allow
119.38 cm (47.0 in.)
179.60 cm 202.77 cm
(70.71 in.) (79.83 in.)
1-6
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S
COMPRESSED AIR
The following requirements are needed when the optional air brake is included.
regulator set to 65 psi max (450 kilopascal)
air dryer
shut off valve
gauge on the regulator
1/4-inch NPT pipe thread connector (to attach air to the dyno)
COMPUTER SPECIFICATIONS
You will need to provide a computer system to run the Power Core software.
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.
description specifications
Power Requirements 240v 30 amp single phase circuit
Frequency 50 or 60 Hz
Voltage
normal 240 VAC
min./max 215 VAC/245 VAC except Japan 195 VAC/245 VAC
Current 30 amps
Power Consumption 7200 watts
Power Cord P/N 76950401
length 3.048 m (10 ft.)
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
ENVIRONMENTAL REQUIREMENTS
description specifications
Temperature
operating min./max 10C/50C (50F/122F)
storage min./max 0C/60C (32F/140F)
Humidity 0 to 95% non condensing
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 1,133.98 kg (2,500 lbs.) to attach to the
dyno. Dynojet recommends using single loop style straps.
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 dynamometer. Refer to Grounding the Vehicle on page 5-9.
1-8
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S
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.
Tire Carriage
Tire Stop
MC144
Breaker
Hand Wheel
Power Cord
Control Panel Interface
DynoWare RT houses the main power breaker,
eddy current brake driver, and
battery disconnect
Air Connector
1-10
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S
Wheel Clamp
Eddy Current
Brake Module
Power
Carriage
MC157
Tire Carriage
Tie-down Loop
used to secure the
motorcycle to dyno
Drum
precision balanced
and knurled Air Brake
Air Pump
Assembly
DynoWare RT Electronics
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.
1-12
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S
DynoWare RT Electronics
1
1 2 C
A B Linx
1 2
Status 1 2
Analog
1 2 3 4
! 2191 Mendenhall Drive
N. Las Vegas, NV 89081
100-240 VAC
50-60 Hz
1.0 A
Communication I/O Connect to auxiliary Dynojet Auxiliary Switch Connect to the brake air
products such as the Power pressure switch on 248 and
A Commander, Wideband 2, older 224 dynos.
Power Vision, etc.
Communication I/O Connect to auxiliary dyno Emergency Stop Connects the dyno electronics
electronics such as the to the emergency stop input on
pendant, atmospheric module, the 200i/250i dynos.
!
B
AFR module, etc.
Communication I/O Connect to internal dyno Network Connects the dyno electronics
electronics and controllers Connection to your computer or computer
C such as the ECB controller. network.
Drum Connect to the drum 1 and Refer to Do not press this button unless
drum 2 speed inputs and Instructions instructed to do so by a Dynojet
digital brake outputs. Technician. This button may
need to be pressed to update
the device.
DynoWare RT Electronics
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 don't 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, you don't have to have one
dedicated computer for the dyno. 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: Only one computer at a time can connect.
When the DynoWare RT main module is on a network connected to the internet,
automatic updates for both the box and software are possible.
multi-computer
connection method auto updates connection wireless connection
Wireless Network Yes Yes Yes
Internet
Wireless Network Yes Yes
Router
Direct Connection
Point to Point
1-14
C HAPTER 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.
DC036
support arm
tire carriage
Figure 2-1: Remove the Tire Carriage and Support Arm from the Crate
2-2
D Y N O I N S T A L L AT I O N
6 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.
7 Remove the tire stop, tire lock, and hardware from the middle of the dyno.
center panel
DC037
8 Remove the eight screws securing the top drum cover to the dyno and set aside.
Remove the drum cover and set aside.
9 Remove the two top screws securing each side drum cover to the dyno and set
aside.
DC038
2-4
D Y N O I N S T A L L AT I O N
10 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.
DC039
11 Remove the boxes and loose parts from the crate, verify their condition and
contents and set them aside.
2-6
D Y N O I N S T A L L AT I O N
grounding kit
P/N 76100015
see list of parts below
The following parts are included in the Grounding Kit P/N 76100015:
grounding bracket cable, vehicle ground
P/N 21600084 P/N 76950788
2-8
D Y N O I N S T A L L AT I O N
The following parts are included in the Nut Block Assembly P/N 79100001:
carriage clamp (3) nut block assembly
P/N 21224104 P/N 61324102
Dyno Installation
DYNO INSTALLATION
This section will walk you through removing the dyno from the crate and installing the
dyno in your dyno room.
2-10
D Y N O I N S T A L L AT I O N
Dyno Installation
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.
lifting eye
lifting eye
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.
Dyno Installation
MC076A
opening in
dyno frame
2-12
D Y N O I N S T A L L AT I O N
Battery Installation
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.
battery
MC147
The optical pickup is very delicate. Be careful not to damage the optical
pickup during alignment.
wheel on dyno
optical pickup
pickup card
pickup card
bracket
wheel on dyno
pickup card
2-14
D Y N O I N S T A L L AT I O N
remove boxes
2 Remove any hardware and parts boxes from the crate and verify the box contents.
driveline assembly
P/N 62240130
2-16
D Y N O I N S T A L L AT I O N
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.
top cover
front of dyno
retarder
connector plates
temperature
sensor
coupler
retarder
connector plates
eddy current brake set up for left side installation eddy current brake set up for right side installation
2-18
D Y N O I N S T A L L AT I O N
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.
line up panels
EB238
lifting eye
key
EB239
2-20
D Y N O I N S T A L L AT I O N
3 Keeping the panels parallel, slide the eddy current brake towards the dyno. Slide
the coupler over the key on the dyno shaft. You will need to support the coupler as
you slide it onto the dyno shaft.
4 Continue sliding the eddy current brake towards the dyno until the covers on the
brake and dyno are flush.
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: 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.
EB240
Figure 2-17: Secure the Retarder Connector Plate and Starter Brace
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.
EB241
9 Replace the existing set screws on the coupler with the thread-lock set screws
provided.
10 Tighten the coupler set screws.
set screw
2-22
D Y N O I N S T A L L AT I O N
2-24
D Y N O I N S T A L L AT I O N
poly washer
second arm
monitor tray
poly washer
first arm
poly washer
support arm
MA021
Cable Routing
CABLE ROUTING
Use the following instructions to identify and route the cables. You will need to route
the cables before installing the covers.
F - 76950548 speed pick up/brake cable connects the brake solenoid and speed pick up to the
DynoWare RT
G - 76950549 e-stop to CPI cable connects the DynoWare RT to P7 on the front of the
CPI panel
a
J.M lxw
e lJ.M
e
xw
a
!
H - 76950569 IR temp sensor cable connects to the temp sensor cable to the eddy current
brake driver
I - 76950573 load cell cable, optional accessory connects the load cell to the eddy current brake
driver
2-26
D Y N O I N S T A L L AT I O N
Cable Routing
K - 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
C
L - 76950798 CAN dyno user cable, 15' connects the POD intercept to the DynoWare RT
using the CAN adapter cable
C
M - 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
C
N - 76950807 CAN control cable, adapter, 2' connects the DynoWare RT to the CAN control and
CAN dyno user cables
C
O - 76951501 control panel cable connects the CPI to the control panel
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 Routing
MC154
2-28
D Y N O I N S T A L L AT I O N
Cable Routing
11 Attach the CAN adapter cable (N) to the back of the DynoWare RT main module.
12 Attach the CAN dyno user cable (L) to the CAN adapter cable (N) and route to the
POD intercept board. Attach the CAN dyno user cable (L) to the POD intercept
board.
13 Attach the CAN control cable (K) to the T on the CAN dyno user cable (L) and
route to the eddy current brake driver. Attach the CAN control cable (K) to the
eddy current brake driver.
14 Attach the CAN dyno user cable (M) to the T on the CAN control cable (K) and
route to the AFR assembly. Attach the CAN dyno user cable (M) 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 (M).
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.
16 Route the e-stop cable (G) 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 (P) to your network. Refer to Network Connections on
page 1-14.
20 Route the power cable (Q) from the DIN rail to the back of the DynoWare RT
module.
21 Attach remote atmos cable (A) 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 (J).
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.
Cable Routing
2-30
D Y N O I N S T A L L AT I O N
Cable Routing
top screw
CP025
rear screws
top nuts
Figure 2-25: Locate the Control Panel and Remove the Back Cover
Cable Routing
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.
access hole button board
cable tie
Figure 2-26: Attach the Control Panel Cable to the Button Board
2-32
D Y N O I N S T A L L AT I O N
Cable Routing
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 2-28.
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 2-47
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.
control panel
CP023
Cable Routing
2-34
D Y N O I N S T A L L AT I O N
Cable Routing
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.
WC016
2-36
D Y N O I N S T A L L AT I O N
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.
carriage clamp
spacer
nut block
spacer
TC069
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.
carriage screw
screw
bearing
bracket
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 3-33 for installation instructions.
carriage
nut block
carriage screw
hand wheel
TC070
bearing bracket
Figure 2-33: Install the Tire Carriage and Secure the Hand Wheel
2-38
D Y N O I N S T A L L AT I O N
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 3-37 for installation instructions.
13 Secure the tire lock to the carriage using four 3/8-16 x 1/2-inch button-head
flange bolts.
tire lock
tire stop
TC071
MC149
2-40
D Y N O I N S T A L L AT I O N
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 top drum cover to the dyno using the eight screws removed earlier.
MC150
6 Secure the eddy current brake top cover with the screws you removed earlier.
eddy current
brake cover
EB242
2-42
D Y N O I N S T A L L AT I O N
Ramp Bracket
RAMP BRACKET
The ramp bracket allows you to attach your own ramp to the dyno. You will need to
modify your ramp to secure it to the ramp bracket.
1 With the ramp upside down, center the ramp bracket under the lip at the top of
the ramp.
2 Using the larger holes on the bracket, mark and drill two 3/8-inch holes in the
ramp.
ramp lip
ramp bracket
24 inches
Ramp Bracket
3 Insert the 3/8-inch bolts from the top of the ramp and secure using 3/8-inch
washers and nuts.
4 Remove the four 1/4-inch bolts from the rear of the drum cover.
5 Secure the ramp bracket to the rear drum cover using the bolts you just removed.
MC151
2-44
D Y N O I N S T A L L AT I O N
Ramp Bracket
6 Place the ramp on the ramp bracket slipping the bolts on the ramp through the
large holes on the ramp bracket.
MC152
approx. 20.00 cm
(8.00 in.)
approx. 96.50 cm
(38.00 in.)
GH009
2-46
D Y N O I N S T A L L AT I O N
Zip Tube
ZIP TUBE
The zip tube encases the multiple cables running to the control panel. You will need to
use the cable wrap tool (P/N 16510001) to insert the cables into the zip tube.
1 Rotate the cable holder to the open position.
2 Insert the cable(s) into the cable holder.
Pendant Cable
Control Panel Cable
RPM cable(s)
Additional cables, if desired
cable(s)
cable holder
guide body
end of cables
guide body
zip tube
This chapter discusses the various optional accessories that are available for the
Dynojet Motorcycle Dynamometer (dyno) to meet your individual needs. All of these
options can be added at the factory at the time of original dyno purchase, or purchased
separately and added at any time thereafter. For more information about these
accessories, please contact Dynojets Product Specialists at 1-800-992-3525 for
pricing and availability or visit www.dynojet.com.
Installation instructions for some of these options can be found in this chapter.
Complete installation instruction manuals may also be found at
http://www.dynojet.com/Downloads.
main breaker
3-2
ACCESSORIES
Air Brake
AIR BRAKE
The air brake (P/N 63920008) comes installed and ready to use. You will need to
provide an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply
(60 psi, 415 kilopascal, max constant line pressure) to the dynamometer. Once air
pressure is connected and the air brake cable is routed, the air brake is ready to use.
AB127
Air Brake
MC150
3-4
ACCESSORIES
Air Brake
4 Remove the remaining six screws securing the side drum cover to the dyno and set
aside. Remove the side drum cover and set aside.
MC156
side drum cover
Air Brake
tire carriage
carriage clamp
carriage screw
screws
TC072
hand wheel
bearing
bracket
3-6
ACCESSORIES
Air Brake
4 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps
and shims and set aside.
5 Remove the three carriage clamps and shims and set aside.
6 Remove the two 5/16-inch bolts and washers securing the nut block and shim and
set aside.
7 Remove the nut block and shim and set aside.
8 Remove the six 1/4-20 x 5/8-inch pan head screws securing the center panel to
the dyno carriage and set aside.
9 Remove the center panel and set aside.
carriage clamp
shim screw
bolt
washer
nut block
shim
TC073
center panel
Air Brake
P7 on the
CPI board
3-8
ACCESSORIES
Air Brake
7 Route the air hose from the air brake through 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 connect your clean,
dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the
dynamometer.
bulkhead fitting
air hose
access hole
air brake
Air Brake
top screw
top nuts
side screw
rear screws
3-10
ACCESSORIES
Air Brake
button board
screw
3 Unscrew the black switch body nut and remove the switch body. Set the nut and
switch body aside.
switch body
Air Brake
4 Place the emergency stop sticker over the dyno shutdown sticker.
DYNO
N
U TDOW
97415160
CP015
3-12
ACCESSORIES
Air Brake
5 Secure the switch body to the control panel using the switch body nut removed
earlier.
switch body
control panel
6 Secure the Button board to the control panel using the four screws removed
earlier.
button board
screw
Air Brake
top nuts
rear screws
side screw
3-14
ACCESSORIES
Air Brake
To prevent possible injury, 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 Remove the top and right side covers from the dyno. Refer toRemoving the Drum
Top and Side Covers on page 3-4.
2 For safety, apply the brake and disconnect the air supply at the front of the dyno.
Refer to Figure 3-2 on page 3-3.
3 Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor.
Air Brake
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 drum is not shown.
nut, washer,
and spring
bolt
3-16
ACCESSORIES
Air Brake
5 Remove the two bolts and two washers securing the brake caliper stop to the brake
bracket and remove the brake caliper stop.
Note: For clarity, the drum and parts of the dyno frame are not shown.
6 Remove the hairpin cotter from the bottom clevis pin located on the front of the
air brake assembly.
Air Brake
7 Push the bottom clevis pin towards the back of the assembly (drum side). You do
not need to remove the pin completely.
8 Remove the hairpin cotter from the top clevis pin located on the drum side of the
air brake assembly.
Figure 3-20: Remove the Bottom Pin and the Top Hairpin Cotter
3-18
ACCESSORIES
Air Brake
10 Lift the air brake assembly up and away from the dyno.
11 Remove the brake pad retaining springs and slide the pads out.
Note: You will need to use pliers to remove the spring securing the outside pad
(closest to the castle nut).
12 Install the new brake pads and secure the pads with new springs.
13 Place the air brake assembly back on the brake bracket. Refer to Figure 3-22.
14 Replace the top and bottom clevis pins and secure with the hairpin cotters
removed earlier. Refer to Figure 3-19, Figure 3-20, and Figure 3-21.
15 Using two bolts and two washers, secure the brake caliper stop to the brake
bracket. Refer to Figure 3-18.
16 Secure the spring using the bolt, washer, and nut you removed earlier. Refer to
Figure 3-17.
17 Tighten the castle nut and replace the hair pin cotter. Refer to Figure 3-16.
18 Adjust the brake pad clearance. Refer toAdjusting the Brake Pad Clearance on
page 3-20 for complete instructions.
19 Replace the top and right side covers. Refer to page 3-4.
20 Connect your shop air.
Air Brake
3-20
ACCESSORIES
Extended Carriage
EXTENDED CARRIAGE
The extended carriage (P/N 71323003) option increases the maximum wheel base
(measured from the front of the front wheel to the center of the rear wheel) from 84
inches to 101 inches for testing raked cruisers and drag bikes.
To prevent possible injury, 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.
Extended Carriage
tire carriage
carriage clamp
carriage screw
bearing
bracket
3-22
ACCESSORIES
Extended Carriage
4 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps
and shims and set aside.
5 Remove the three carriage clamps and shims and set aside.
6 Remove the two 5/16-inch bolts and washers securing the nut block and shim and
set aside.
7 Remove the nut block and shim and set aside.
carriage clamp
and shim
bolt
washer
nut block
and shim
TC074
Figure 3-25: Remove the Tire Carriage, Nut Block, and Clamps
Extended Carriage
extended carriage
support bracket
TC075
3-24
ACCESSORIES
Extended Carriage
4 Secure the extended carriage strap to the dyno using two 5/16 x 1-inch bolts and
two 5/16-inch lock washers.
Note: If your support bracket does not have holes, use the strap as a template to
drill them.
bolt
lock washer
strap
5 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 nuts.
bolt
lock washer
strap
support
bracket
flat washer
nut
Extended Carriage
6 Using the original shim and the large shim included with the kit, attach the nut
block to the front of the extended carriage support bracket using two
5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock
washers, and two 5/16-inch nuts.
7 Using the original shim and the small shim included with the kit, attach the
carriage clamp to the front of the extended carriage support bracket using two
5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock
washers, and two 5/16-inch nuts.
bolt
carriage
lock washer clamp
nut block
extended carriage
support bracket
TC076
flat washer
nut
carriage screw
screw
bearing bracket
3-26
ACCESSORIES
Extended Carriage
3 Starting from the back of the dyno, slide the carriage under the front carriage
clamp and the nut block.
4 Slide the hand wheel onto the end of the carriage screw.
5 Secure the hand wheel to the screw shaft by tightening the set screw using a
5/32-inch allen wrench.
6 Screw the carriage screw into the nut block until 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 the carriage using four 1/4-20 x 1/2-inch
button-head flange bolts.
8 Using the hand wheel, screw the carriage screw completely through the nut block
and into the screw support bracket
Note: If you ordered the power carriage accessory, refer to Power Carriage on
page 3-33 for installation instruction.
extended carriage
nut block
carriage screw
TC077
hand wheel
carriage clamp
bearing bracket
Extended Carriage
9 Using the hand wheel, move the carriage forward until the holes for the rear
carriage clamps are accessible.
10 Attach the two rear carriage clamps to the dyno using the shims, washers, and
bolts removed earlier.
bolt
washer
carriage clamp
shim
TC078
3-28
ACCESSORIES
Extended Carriage
11 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 3-37 for installation instructions.
12 Secure the tire lock to the carriage using four 3/8-16 x 1/2-inch button-head
flange bolts.
tire lock
tire stop
TC079
To prevent possible injury, 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.
1/4-inch thick
poly washer
clamp lever
blower arm
assembly
clamp lever
3-30
ACCESSORIES
intake facing in
blower assembly
1/8-inch thick
poly washer
blower arm
power cord
from blower
power cord
from blower
plug into
dyno chassis
3-32
ACCESSORIES
Power Carriage
POWER CARRIAGE
The power carriage (P/N 82943001) replaces the standard hand wheel with an
electrically powered tire carriage allowing you to easily adjust for various wheel base
distances with the press of a button. This option is ideal for dynos that 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 carriage, refer to Using the Power
Carriage on page 4-6.
To prevent possible injury, 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.
Power Carriage
flange bearing
bolt
hand wheel
3-34
ACCESSORIES
Power Carriage
motor mount
flange bearing
coupler jaw
PC023B
Power Carriage
4 Bring the power carriage cable (two-pin connector) from the front of the dyno
over to the motor mount. Refer to Cable Routing on page 2-26 for more
information.
5 Secure the power carriage cable strain relief to the side of the motor assembly
cover.
6 Insert the plastic coupler spider on the carriage screw half of the coupler.
power carriage
cable
strain relief
coupler spider
PC024B
motor assembly
cover
Figure 3-39: Secure the Strain Relief
7 Place the power carriage motor assembly near the motor mount and plug the
motor connector into the power carriage cable.
8 Turn the carriage screw to align the coupler jaws with each other and slide the
coupler jaws together until the motor assembly cover is flush with the motor
mount.
9 Secure the motor assembly cover to the motor mount with four 1/4-20 x 1/2-inch
button-head screws.
motor assembly
PC024C
motor assembly
cover
Figure 3-40: Assemble the Power Carriage
3-36
ACCESSORIES
Wheel Clamp
WHEEL CLAMP
The wheel clamp (P/N 71329000) replaces the standard tire stop with an electrically
powered wheel clamp allowing you to easily secure the front tire with the push of a
button. For more information 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.
cover
2 Place the wheel clamp on the carriage. Align the four holes on the wheel clamp
with the holes on the carriage.
3 Secure the wheel clamp to the carriage using four 3/8-16 x 1/2-inch bolts, lock
washers and flat washers.
wheel clamp
WC004B
Wheel Clamp
4 Bring the wheel clamp cable (three-pin connector) from the front of the dyno over
to the wheel clamp. Refer to Cable Routing on page 2-26 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 wheel clamp motor.
strain relief
WC005A
cover
WC006A
3-38
ACCESSORIES
This chapter will walk you through the basic operating procedures and how to
maintain and troubleshoot the components associated with the control panel interface
(CPI). To ensure safety and accuracy in the procedures, perform the procedures as
they are described.
Introduction
INTRODUCTION
The control panel interface (CPI) consists of a main control board which is mounted
internal to the 200i/250i motorcycle dyno or in an external box for a pit dyno or
retrofit. This board provides switching and control of many functions within the dyno.
The front panel of this board is accessible through the side door on the dyno or door
on the external box. The user interface is through the control panel which is normally
mounted on the side of the monitor tray. The control panel allows the user to control
the following items:
Optional AFR Air Pump
Optional High Pressure Blowers
Optional Power Carriage
Starter
Optional Wheel Clamp
The CPI main control board has an on-board microprocessor which reads the user
input from the control panel, monitors interlock and E-Stop inputs, and controls the
various dyno outputs. The CPI is powered internally from the main power that is
provided to the dyno. The power supplied is 240VAC 50 or 60 Hz.
4-2
C O N T R O L PA N E L I N T E R F A C E O P E R AT I O N
status indicator
light
4-4
C O N T R O L PA N E L I N T E R F A C E O P E R AT I O N
The blower outlets on the front of the dyno are designed to only work with
Dynojet provided blowers. Connecting other electrical loads or other
blowers to the outlets on the dyno may damage the dyno and void the
warranty.
If the blower indicator light on the control panel is on but the blower is not running,
perform the following steps.
1 Verify the switch on the blower is on.
2 Verify the blower power plug is firmly plugged into the dyno.
3 Verify the blower circuit breakers in the CPI.
If the button on the breaker is extended, an overload has occurred and the breaker
has tripped. Press in the breaker button to reset the breaker. If the breaker
continues to trip, contact Dynojet.
UNDERSTANDING INTERLOCKS
The interlock circuit provides inputs for normally closed switches which open when it
is not safe to run the dyno. Typically these switch inputs will be tied to safety gates and
safety switches that are required in Europe. If the Interlock circuit is open the Status
Indicator light will blink on and off with the on time equal to the off time. This will
continue until this circuit is closed or an overriding E-Stop condition is sensed. In a
dyno configured to comply with CE requirements the interlock signal will activate the
drum air brake.
Never perform a dyno run if the tie-down straps are not in place or they
are damaged.
If the carriage movement is slow during parts of its travel, investigate and correct the
source of the problems. If you reach the end of travel of the carriage or the carriage
binds and you continue to hold down the carriage movement button, the motor will
draw too much current and blow the carriage fuse F2. There is a short time delay built
into the button operation to allow the carriage motor to coast to a stop before it moves
in the opposite direction. This delay is needed to prevent the motor from drawing too
much current by rapidly reversing the motor.
4-6
C O N T R O L PA N E L I N T E R F A C E O P E R AT I O N
Pinch hazard. Keep hands, body parts, and other loose items clear.
Failure to follow these instructions can result in serious injury or
equipment damage.
Risk of injury. Be sure the wheel clamp is free and clear of any
obstruction. Do not operate the dyno if the wheel clamp indicator light is
not on steady.
Do not run into the edges of the wheel clamp pads with the bike tire. Make
sure the wheel clamp is sufficiently open before loading the motorcycle.
1 Once the bike's front tire is fully seated in the clamp, press and hold the close
button (left hand yellow square button).
As you hold the button, the wheel clamp mechanism will close on the bikes wheel
and tire. The wheel clamp status light will blink as the clamp is closing.
For proper and safe operation, the wheel clamp must grip the wheel as
well as the tire. If the front tire is too wide to allow the clamp pads to grip
the wheel, you must use the wheel strap.
2 Continue to hold the button down as the clamp applies pressure to the wheel and
tire. During this process, the CPI is monitoring the current that is going to the
wheel clamp.
When the wheel clamp has reached sufficient clamping force to secure the bike,
the current drive to the wheel clamp is cut and the wheel clamp indicator light will
turn on steady indicating that the wheel is secured.
Do not operate the dyno if the wheel clamp indicator light is not on steady.
Never perform a dyno run if the tie-down straps are not in place or they
are damaged.
4-8
C O N T R O L PA N E L I N T E R F A C E O P E R AT I O N
Even if this breaker is turned off there is still the potential for lethal
voltages to be present in the CPI. Always disconnect the main power plug
before removing the covers.
CP036
WHEEL CLAMP
Make sure the bike tire and wheel are clean to reduce the possibility of scratching
the rim.
Keep the wheel clamp pads clean using Isopropyl Alcohol. Do not allow any
products to be applied or transferred to the wheel clamp that could interfere with
the gripping action.
If you run the clamp all the way open against the hard stops, the CPI will turn off
the motor before any damage can occur.
Follow the prescribed service for the wheel clamp lubrication for frequency and
type of lube. Grease or lube the screw and slides monthly or every 500 bikes.
Do not run into the edges of the wheel clamp pads with the bike tire.
If the wheel clamp movement is binding for any reason, stop using the wheel clamp
and correct the problem. It is possible for the wheel clamp to bind and give a false
indication that the wheel is clamped.
If the wheel has been clamped and the wheel clamp indicator light is on steady then
the dyno power is turned off or the E-Stop activated, the wheel clamp indicator
light will go back to the blinking state as the clamp status is unknown. Pressing the
clamp button again will secure the clamp.
If the E-Stop circuit is open or the Emergency Stop button is pressed, the wheel
clamp will not operate.
4-10
C O N T R O L PA N E L I N T E R F A C E O P E R AT I O N
Hazardous voltage. To prevent possible injury, 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 Open the Control Panel Interface (CPI) cover and set aside.
2 Gently push the fuse holder slightly inward and rotate counterclockwise. Remove
the fuse holder.
3 Replace the fuse with a fuse type listed below.
For continued protection against risk of fire, replace only with a fuse of
the same type and having the same electrical rating.
20A, Bussman BAF-20
Fast Blow, Dynojet P/N 54200014
MC153
fuses
CP036
4-12
C HAPTER 5
BASIC DYNO OPERATION
The Dynojet Dynamometer gives you the state of the art technology, durability, and
accuracy that you need. Dynojets advanced engineering delivers the precise
horsepower measurements a technician needs to make quick and accurate evaluations
of engine performance and drive train problems.
This chapter includes instructions for basic dyno operation. For more detailed
instructions, refer to the Power Core Help.
Keep the motorcycle balanced while driving on and off the dyno.
Risk of injury. Always wear proper eye and ear protection when operating
the dyno.
Never perform a dyno run if the tire strap is not in place or is damaged.
4 Turn the carriage screw handle until the rear axle is aligned with the center of the
drum.
5 With the motorcycle in neutral, align the wheel in the center of the knurl by
pressing the dyno starter switch.
tire stop
tire strap
5-2
B A S I C D Y N O O P E R AT I O N
6 Attach the tie-down straps from a solid place on the bike to the tie-downs on the
dyno or the ground hook locations (refer to page 2-23). Position the straps to
allow proper clearance for the brake pedal, the shift lever and the exhaust pipes.
For best results, hook the straps at the rear of the bike so they pull down and
forward.
7 Sit on the bike with your feet on the pegs. Remove the slack from the straps.
Gently shift your weight from side to side while tightening the straps, being
careful to not overtighten the straps. The straps are used to stabilize the bike. They
should not add any additional weight to the bike.
Never perform a dyno run if the tie-down straps are not in place or they
are damaged.
Inductive pickups are very fragile. The ferrite core can easily be damaged
and is not covered under warranty. Dropping, snapping, vibration, and
heat can all damage the ferrite core.
The DynoWare RT contains the electronics that sense the RPM pulses. An auto-gain
circuit looks at only the peak voltage of the vehicles spark, ignoring the lower voltages
to help reduce electronic noise problems. Wasted spark ignition systems will produce
a lower voltage level on the exhaust stroke than the compression stroke. By definition
of the auto-gain circuit, lower voltage spark levels will be ignored, missing every other
spark the vehicle would produce.
5-4
B A S I C D Y N O O P E R AT I O N
1 Clip the primary inductive pickup to the primary wire of the coil opposite the
battery source.
2 Route the primary wire cable clear of devices that produce electronic noise.
Note: You must ground the vehicle to the dyno for the electronics to function
properly. Refer to Grounding the Vehicle on page 5-9.
connect the primary
pickup opposite the
battery source
Depending on accessibility, the user can make a primary wire hookup from the coil or
the ignition module. Ignition modules can be found usually under the seats or side
covers. Refer to the following table to determine the wire color when hooking up the
inductive tack lead to the primary side of the ignition.
5-6
B A S I C D Y N O O P E R AT I O N
1 Clip the secondary inductive pickup around one spark plug wire.
2 Route the inductive pickup cable clear of devices that produce electronic noise
(spark plug wires, coil wire, coil etc.).
Note: Inductive pickup placement is important. Position the inductive pickup so
that it is not making contact with any other spark plug wires. Separate the spark
plug wire from the spark plug wire bundle for proper operation.
Note: You must ground the vehicle to the dyno for the electronics to function
properly. Refer to Grounding the Vehicle on page 5-9.
Note: When using one secondary pickup, disconnect the other pickup from the
dyno electronics.
connect a secondary
pickup to an available
spark plug wire
5-8
B A S I C D Y N O O P E R AT I O N
Pre-Run Inspection
PRE-RUN INSPECTION
Perform a vehicle inspection before making a run.
Check the radiator coolant and oil levels.
Check the fuel source.
Rotate the drum(s) and check for rocks caught in the tire tread that could fly out.
For motorcycles, check the chain and the chain master link. Make sure it is
lubricated and adjusted to the proper tension.
Check the tire pressure and tire speed rating. Improperly inflated tires or exceeding
the maximum speed rating can result in premature wear or severe tire damage.
Make sure the tire has no major deficiencies (cracks in sidewalls,
tread life, etc.).
Visually inspect the vehicle. Make sure it is in safe running order.
Make sure ear protection and safety glasses are used when the dyno is being
operated.
Check the tie-down straps to make sure that they are tight and secured.
Check the drive tires to be sure that they are aligned correctly on the
dynamometers drums.
Keep all rotating components clear at all times.
Only the operator should be near the dyno or the vehicle during the test.
Never allow any person(s) to stand behind the dyno or vehicle when it is being
operated.
Perform any other safety inspections appropriate to running your vehicle on the
dyno.
Never allow any person(s) to stand behind the dyno or vehicle when it is
being operated. Only the operator should be near the dyno or the vehicle
during the test.
5-10
B A S I C D Y N O O P E R AT I O N
Pre-Run Inspection
ENGINE WARM UP
Warm the vehicles engine and drivetrain before beginning testing. Consistent engine
temperatures will assure your runs are repeatable.
5-12
B A S I C D Y N O O P E R AT I O N
Never perform a dyno run if the vehicle is not grounded to the dyno.
3 Double-click the Power Core program icon to start the software.
4 Click Dyno Control from the Application Launcher.
5 Test the tachometer operation.
5a Rev the engine. The gauges on the computer screen should be moving. If the
tachometer is moving but not registering the correct RPM values, the
number of degrees of revolution of the crank shaft (the plug fires number) is
incorrect.
5b Select Run File Information to enter vehicle information.
6 Place the vehicle in a low gear and release the dyno brake using the hand held
pendant.
7 Slowly accelerate the vehicle to 20 m.p.h.
8 Press the red brake button to apply 100% braking and slow down the vehicle.
Using the vehicles own brakes to slow or stop the drum at speeds over 30
m.p.h. can severely over heat the brake parts. Dynojet dynamometers
with the air brake or eddy current brake accessory can be used to slow the
vehicle and drum to a full stop at any speed. The vehicles brakes should
be used in an emergency stop situation only.
9 Shut the engine off and put the vehicle in gear (manual transmission) or park
(automatic transmission).
10 Set the vehicles parking brake and leave the dyno brake on.
11 Select MakeRun Configuration Run Information, and enter the correct value for
the plug firing order.
12 Perform a final inspection.
Verify the drive tires alignment on the dyno drums.
Make any adjustments to the tie-down straps as needed.
Perform any other safety checks that you deem appropriate to your particular
situation.
You are now ready to make a high speed run on the dyno. Refer to your Power Core
Help for more detailed instructions.
Preventative Maintenance
PREVENTATIVE MAINTENANCE
To maintain proper dynamometer operation, Dynojet recommends you make routine
checks of the dyno.
Drumkeep the drum clean and keep all objects clear of the drum.
Brake Padscheck the brake pad clearance regularly. Change the brake pads when
they are worn to less than 0.060 inch thick.
Carriage Slidekeep the carriage slide and screw clean and lightly lubricated.
Check all air fittings for leaks monthly. Correct any leaks found.
Once per month verify that the drum brake pressure gauge reads 55 to 65psi
(380 to 450kPa). Adjust regulator if pressure is out of specification.
5-14
A PPENDIX A
RED HEAD ANCHOR INSTALLATION
This appendix contains instructions for installing the Red Head Multi-SetII
Anchors. The anchors will be used to secure the dyno to concrete. To ensure safety and
accuracy in the procedures, perform the procedures as they are described. Be sure to
read and understand the warnings included in this appendix.
WARNINGS
Installation
INSTALLATION
Use the table below to determine the catalog number, drill bit size, minimum hole
depth, and setting tool catalog number.
anchor
A-2
R E D H E A D A N C H O R I N S T A L L AT I O N
Installation
3 Using a hammer, drive the anchor flush with the surface of the concrete, or below
the surface if the hole depth exceeds minimum embedment.
4 Using a hammer, expand the anchor with the setting tool. The anchor is properly
expanded when the shoulder of the setting tool is flush with the top of the anchor.
Note: Use only Ramset/Red Head setting tools to insure proper installation.
setting tool
This appendix contains power requirements and installation instructions for the dyno.
To ensure safety and accuracy in the procedures, perform the procedures as they are
described. Be sure to read and understand the warnings included in this appendix.
This Appendix is divided into the following categories:
North America, Japan, and Locations Using 60 Hz Power, on page B-2
Excluding North America and Japan, on page B-5
Power Requirements and InstallationNorth America, Japan, and Locations Using 60 Hz Power
B-2
P O W E R R E Q U I R E M E N T S A N D I N S T A L L AT I O N
Power Requirements and InstallationNorth America, Japan, and Locations Using 60 Hz Power
If the voltage readings do not match the following table, DO NOT connect
the dyno. You must have a licensed electrician correct the power
connection. Connecting the dyno to the incorrect voltage can result in
damage to the dyno and will void the dyno warranty. Contact Dynojet with
any questions.
Using a voltmeter that is capable of measuring AC voltage, measure between the
points listed below and verify that the correct voltages are present.
desired voltage
probe 1 probe 2 measurement
2 4 216V to 260V*
1 4 108V to 130V
1 2 108V to 130V
3 box <5V
*If using two of the three-phase lines of a 120/208 V 3 phase Y system,
then expect to see 187V to 225V.
3 (G)
4 (X)
2 (Y)
1 (W)
Power Requirements and InstallationNorth America, Japan, and Locations Using 60 Hz Power
B-4
P O W E R R E Q U I R E M E N T S A N D I N S T A L L AT I O N
If you are installing your dyno in a location other than North America or
Japan and the dyno is not equipped with a three pin IEC grounded plug,
contact Dynojet before attempting to connect the dyno.
Local and national electrical codes will require that the box containing the receptacle
is grounded.
This circuit should have a dedicated 30A double-pole circuit breaker.
The dyno should be the only device connected to this circuit.
L terminal
B-6
P O W E R R E Q U I R E M E N T S A N D I N S T A L L AT I O N
desired voltage
probe 1 probe 2 measurement
1 3 220V to 250V
2 box <5V
3 (L)
1
2
(ground)
Never operate the dynamometer with the drum module hood removed.
screw
C-2
EEC KIT
screw
finger guard
Figure C-2: Secure 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 screws removed earlier.
Note: For clarity, the eddy current brake and dyno carriage are not shown.
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less
than 0.64 centimeters. Refer to page C-5 for instructions on adjusting the
gap.
screw
C-4
EEC KIT
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less
than 0.64 centimeters.
adjust screw
adjust clearance
CPI cover
C-6
EEC KIT
6 Loosen the screws that hold the jumper wires in place and remove the wire.
7 Route the black and yellow wire from the safety switch through the dyno.
Make sure the switch will not get caught in any moving components or chafed on
any edges.
8 Attach the yellow wire to the 1A position on the J2 connector.
9 Attach the black wire to the 6B position on the J4 connector.
remove
jumper
wire
This appendix contains tables for standard and metric torque values. Use these values
when specified values are not given in other sections of this manual.
GRADE 5
size torque, plain torque, plated
in-
threads/in inlb ftlb Nm inlb ftlb Nm
1/4-20 101 8 11 76 6 9
1/4-28 116 10 13 87 7 10
5/16-18 209 17 24 157 13 18
5/16-24 231 19 26 173 14 20
3/8-16 371 31 42 278 23 31
3/8-24 420 35 47 315 26 36
7/16-14 593 49 67 445 37 50
7/16-20 662 55 75 497 41 56
1/2-13 905 75 102 678 57 77
1/2-20 1019 85 115 765 64 86
9/16-12 1305 109 147 979 82 111
9/16-18 1456 121 164 1092 91 123
5/8-11 1801 150 203 1351 113 153
5/8-18 2040 170 230 1530 128 173
3/4-10 3194 266 361 2395 200 271
3/4-16 3567 297 403 2675 223 302
7/8-9 5154 430 582 3866 322 437
7/8-14 5679 473 642 4259 355 481
1-8 7727 644 873 5795 483 655
1-12 8453 704 955 6340 528 716
D-2
TO R Q U E VA L U E S
GRADE 8
size torque, plain torque, plated
in-
threads/in inlb ftlb Nm inlb ftlb Nm
1/4-20 143 12 16 107 9 12
1/4-28 164 14 19 123 10 14
5/16-18 295 25 33 221 18 25
5/16-24 326 27 37 245 20 28
3/8-16 523 44 59 392 33 44
3/8-24 593 49 67 444 37 50
7/16-14 837 70 95 628 52 71
7/16-20 935 78 106 701 58 79
1/2-13 1277 106 144 958 80 108
1/2-20 1439 120 163 1079 90 122
9/16-12 1843 154 208 1382 115 156
9/16-18 2055 171 232 1542 128 174
5/8-11 2543 212 287 1907 159 215
5/8-18 2880 240 325 2160 180 244
3/4-10 4509 376 509 3382 282 382
3/4-16 5036 420 569 3777 315 427
7/8-9 7277 606 822 5457 455 617
7/8-14 8017 668 906 6013 501 679
1-8 10908 909 1232 8181 682 924
1-12 11934 995 1348 8951 746 1011
GRADE 8.8
size torque, plain torque, plated
mm x pitch inlb ftlb Nm inlb ftlb Nm
M6 X 1 96 8 11 72 6 8
M8 X 1.25 233 19 26 175 15 20
M10 X 1.5 462 38 52 346 29 39
M12 X 1.75 805 67 91 604 50 68
M14 X 2 1287 107 145 966 80 109
M16 X 2 1997 166 226 1498 125 169
M20 X 2.5 3900 325 441 2925 244 330
M24 X 3 6739 562 761 5054 421 571
GRADE 10.9
size torque, plain torque, plated
mm x pitch inlb ftlb Nm inlb ftlb Nm
M6 X 1 133 11 15 100 8 11
M8 X 1.25 323 27 36 242 20 27
M10 X 1.5 639 53 72 479 40 54
M12 X 1.75 1114 93 126 836 70 94
M14 X 2 1781 148 201 1336 111 151
M16 X 2 2762 230 312 2072 173 234
M20 X 2.5 5395 450 610 4046 337 457
M24 X 3 9322 777 1053 6992 583 790
D-4
INDEX
E K
eddy current brake knurl 5-2
coupler 2-21
installation 2-20 L
replacing fuses 4-11 length 1-5
right side installation 2-18 lifting eyes
secure to floor 2-23 dyno 2-11
unpacking 2-15 eddy current brake 2-19
electrostatic discharge vi load cell cable 2-26
emergency stop 4-4 loading the vehicle 5-2
emergency stop sticker 3-10
equalizer box 1-4
ESD precautions vi M
e-stop cable 2-26 main power 3-2
exhaust extraction 1-4 making a test run 5-13
extended carriage 3-21 metric torque values
installation 3-26 grade 10.9 D-4
nut block 3-26 grade 8.8 D-4
remove tire carriage 3-22 model 200i 1-10
shims 3-26 model 250i 1-11
strap 3-25 monitor tray 2-24
support bracket 3-24 support arm 2-2
tire lock 3-29
tire stop 3-29 N
network cable 2-27
F network connections 1-14
final adjustments and tests 3-39 nut block 2-37, 3-26
fire suppression 1-4
forklift 1-8 P
PDA
G see also power distribution assembly
grade 10.9 torque values D-4 pendant 2-26
grade 5 torque values D-2 pickup card 2-14
grade 8 torque values D-3 power B-2, B-5
grade 8.8 torque values D-4 hard wiring B-4, B-7
ground hook 1-9, 2-46 installation B-2, B-5
grounding bracket 5-9 installing receptacle B-2, B-6
grounding requirements 1-8, 5-9 main dyno 3-2
requirements B-2, B-5
routing cable 2-12
H testing voltages B-3, B-7
hand wheel 2-38 power cable, routing 2-12
hazards vii power carriage 3-33
height 1-5 flange bearing 3-34
high pressure blower 3-30 hand wheel 3-34
circuit breakers 4-9 installing 3-35
installing arms 3-30 routing cable 2-26
installing blowers 3-31 routing cables 2-35
power 3-32 testing 3-39
using 4-5 using 4-6
power distribution assembly 4-9
I high pressure blower circuit breakers 4-9
Industrial Noise Control, Inc. 1-4 main dyno circuit breaker 4-9
intake air fan 1-4 pre-run inspection 5-105-11
interlocks 4-5 preventative maintenance 5-14
IR temp sensor cable 2-26 primary inductive pickup 5-5
R T
ramp bracket 2-43 technical support 1-3
red head anchor termination plug
contact information A-1 CAN 2-27
installation A-2 PCV 2-27
setting tool A-3 testing voltages B-3, B-7
warnings A-1 tie down straps 1-9
remote atmos cable 2-26 tire carriage
requirements carriage clamp 2-37
battery 1-5 hand wheel 2-38
chassis 1-5 installing 2-36
compressed air 1-7 loading the vehicle 5-2
computer specifications 1-7 nut block 2-37
electrical 1-8 remove from crate 2-2
environmental 1-8 removing 3-6
forklift 1-8 tire lock 2-39
ground hook 1-9 tire stop 2-39
grounding 1-8 tire lock 2-39, 3-29
phone, internet access 1-9 tire stop 2-39, 3-29, 5-2
tie down straps 1-9 torque values
routing cables metric D-4
air brake 3-8 standard D-2
air hose 2-26, 3-8
CAN control 2-27 V
CAN dyno user 2-27 vehicle ground cable 5-9
CAN powersports 2-27
CAN termination plug 2-27
control panel 2-27 W
DynoWare RT 2-27 warnings v
e-stop 2-26 weight 1-5
identifying cables 2-26 wheel clamp 3-37
IR temp sensor 2-26 closing 4-8
load cell 2-26 maintenance 4-10
network 2-27 opening 4-8
PCV CAN termination plug 2-27 routing cable 2-26, 2-35
pendant 2-26 testing 3-39
power 2-12 troubleshooting 4-10
power carriage 2-26, 2-35 using 4-7
remote atmos 2-26 width 1-5
RPM pickup 2-26
speed pick up/brake 2-26 Y
wheel clamp 2-26, 2-35 your dyno room 1-4
RPM pickup 5-45-8 equalizer box 1-4
connecting 5-45-8 exhaust extraction 1-4
primary inductive pickup 5-5 fire suppression 1-4
secondary inductive pickup 5-7 intake air fan 1-4
RPM pickup cable 2-26 noise control 1-4
S Z
safety switch C-6 zip tube 2-47
secondary inductive pickup 5-7
setting tool A-3
speed pick up cable 2-26
standard torque values
grade 5 D-2
grade 8 D-3
starter 4-6, 5-12
status indicator 4-4, 4-7
support arm 2-24
remove from crate 2-2