98200049.06 above ground model 250i motorcycle …

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.
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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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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
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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
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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.
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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
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.
Dynamometer Specifications and Requirements
DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS
The following specifications and requirements will help you set up your dyno area and verify you have the requirements 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
1-6
1-7
Figure 1-2: Model 250i Dimensions
C H A P T E R 1
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
Figure 1-4: Model 250i With Optional Accessories
MC157
Eddy Current Brake Module
Power Carriage
Tire Carriage
motorcycle to dyno
Drum precision balanced
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
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.
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
Humidity 0 to 95% non-condensing
C H A P T E R 1
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
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.
Figure 1-5: DynoWare RT Electronics
air fuel ratio module
eddy current brake driver
DynoWare RT main module
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
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
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
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
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
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
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
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
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
2-9
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
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
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.
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
Starter Installation
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
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
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
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
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
Pickup Card Installation
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
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
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
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
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
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
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
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
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
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
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
Support Arm and Monitor Tray Installation
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.
• 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
2-32
MA021
2-33
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.
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
J. MaxwellJ. Ma xwell
A
C
C
C
C
2-35
Cable Routing
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 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.
Cable Routing
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
Cable Routing
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
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 2-36.
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
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.
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.
• 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
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
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
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
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
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
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
Load Cell Calibration
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.
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
calibration arm assembly P/N 61319001
C H A P T E R 2
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
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

98200049.06 above ground model 250i motorcycle …

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