c hapter 2

Transcription

c hapter 2

©2003 Dynojet Research, Inc. All Rights Reserved.
Installation Guide For Model 200i and 250i Motorcycle Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual 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 89031, USA.
Printed in USA.
Part Number: 98220104 Version 2 (05/03)
TABLE OF CONTENTS
Warnings
Chapter 1
................................................ v
Specifications and Operating Requirements
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Your Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Dynamometer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Shop Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Power Requirements and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Other Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
12 Volt Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Motorcycle Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Model 200i Motorcycle Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Model 250i Motorcycle Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Model 200i and 250i Motorcycle Dynamometer Installation Guide
i
TABLE OF CONTENTS
Chapter 2
Installation
Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Routing the Computer, Pendant, and Starter Cables . . . . . . . . . . . . . . . . . 2-6
Installing the Theta Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installing the Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Replace the Drum Side and Top Covers . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Ramp Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Ground Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
Chapter 3
Dyno Electronics
Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Atmospheric Sensing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
RPM Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Dynamometer Input/Output Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
CPU Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Accessing the Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Chapter 4
Accessories
Removing and Replacing the Top and Side Drum Covers . . . . . . . . . . . .4-2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Air Pump and Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Installing the Filter and Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Cleaning the Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Pump Head Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Routing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Replacing the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27
Replacing the Theta Controller Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
Removing the Standard Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
Installing the Extended Carriage Support Bracket . . . . . . . . . . . . . . . . . . .4-32
Installing the Extended Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34
ii
TABLE OF CONTENTS
High Pressure Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-38
Installing the Blower Arm Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-39
Installing the High Pressure Blower Assemblies . . . . . . . . . . . . . . . . . . . . .4-40
Power Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-41
Monitor Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-42
Installing the Support Arm and Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43
Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Removing the Hand Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-44
Installing the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-45
Safety Switch Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Chapter 5
Basic Dyno Operation
Loading the Bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Using the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
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—Excluding North America
Power Requirements and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Index
Version 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i
iii
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 Requires Proper Grounding
Various dynamometer components are equipped with a three-pronged plug (grounded) to guard
against shock hazards. The plug should be plugged directly into a properly grounded three-prong
receptacle. In locations where a two-prong wall receptacle is installed, it must be replaced with a
properly grounded three-prong dedicated outlet in accordance with the U.S. National Electric Code,
or equivalent, and local codes and ordinances. The work should be performed by a qualified
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.
v
WARNINGS
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.
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.
vi
WARNINGS
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.
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.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured to the dyno.
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.
Version 2
vii
CHAPTER
1
SPECIFICATIONS AND OPERATING
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 WinPEP 7 software and a Dynojet dynamometer will give you the
professional results you are looking for.
This document provides instructions for installing the Dynojet Motorcycle
Dynamometer (dyno). This document will walk you through operating requirements,
hardware installation, electronics set up, dyno accessories, and basic dyno operation.
To ensure safety and accuracy in the procedures, perform the procedures as they are
described.
Document Part Number: 98220104
Version 2
Last Updated: 05-23-03
This chapter is divided into the following categories:
• Introduction, page 1-2
• Dyno Specifications, page 1-5
• Power Requirements and Installation, page 1-8
• Other Requirements, page 1-10
• Model 200i Dynamometer, page 1-11
• Model 250i Dynamometer, page 1-12
1-1
CHAPTER 1
Introduction
INTRODUCTION
...................................
Thank you for purchasing the Dynojet motorcycle dyno. 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 R EQUIREMENTS
This chapter describes the requirements and specifications for the dyno.
IN STALLATIO N
This chapter describes the procedures for installing the dyno.
ELECTRO NICS
This chapter describes the specifications for the dyno electronics.
A CCESSORIES
This chapter lists each dyno accessory alphabetically and describes the procedures for
installing and using the accessory.
BASIC D YNO O PERATION
This chapter describes basic dyno operating procedures.
R ED H EAD I NSTALLATION
This appendix describes the procedures for installing the Red Head anchors.
P OWER R EQUIREM ENTS —EXCLUDING
N ORTH AMERICA
This appendix describes the power requirements and installation instructions for all
locations excluding North America.
1-2
SPECIFICATIONS AND OPERATING REQUIREMENTS
Introduction
CONVENTIONS USED IN THIS M ANU AL
The conventions used in this manual are designed to protect both the user and the
equipment.
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/or the
dynamometer equipment.
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 89031.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, 3D visualizations, and press releases
about our latest product lines.
YOUR DYNO ROO M
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 controlled environment for testing
• provide a view window (safety glass) for customers
• be designed with safety in mind
Cooling Fan—After building your dyno room, you will need to supply a cooling fan.
The cooling fan supplies air to cool the bike’s engine while supplying fresh oxygen for
you and your bike to breathe. It is a common misconception that you cannot tune a
bike without a large fan simulating exact road conditions; however, a good cooling
fan is the only requirement for consistent diagnostics and tuning.
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.
Version 2
1-3
CHAPTER 1
Introduction
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. For more information on building a dyno room, read the DynoSource
newsletter Volume 1, No. 7 (published by Dynojet) included in your information
pack. 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.
Figure 1-1: Custom Dyno Room
1-4
Dynamometer Specifications
DYNAMOMETER SPECIFICATIONS
...................................
The Model 200i and 250i dynamometers require a dedicated 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.
For more information on power requirements refer to page 1-8.
CHASSIS SPECIFICATIONS
description
Length
with standard carriage
with extended carriage
Height
to top of dyno cover
Width
model 200i
model 250i
Weight
model 200i dyno/crated dyno
model 250i dyno/crated dyno
Drum
diameter
width
Frame
Maximum Horsepower
Maximum Speed
Maximum Motorcycle Length (front of
front wheel to center of rear wheel)
standard carriage
extended carriage
Remote Switches
Version 2
specifications
allow 271.78 cm (107 inches)
allow 322.58 cm (127 inches)
45.97 cm (18.10 inches)
106.68 cm (42.00 inches)
179.60 cm (70.71 inches)
725 kg (1600 pounds)/771 kg (1700 pounds)
1,077.28 kg (2,375 pounds)/1.133.98 kg (2500 pounds)
45.72 cm (18 inches)
50.80 cm (20 inches)
structural steel channel and angle
500 HP (373 KW)
200 MPH (322 KPH)
213 cm (84 inches)
256.54 cm (101 inches)
remote software control
1-5
CHAPTER 1
model 200i
carriage: allow 68.33 cm (26.9 in.)
extended carriage: allow
119.38 cm (47.0 in.)
45.97 cm (18.10 in.)
152.40 cm
(60.00 in.)
202.77 cm
(79.83 in.)
106.68 cm
(42.00 in.)
model 250i
127.74 cm
(50.29 in.)
72.92 cm
(28.71 in.)
179.60 cm
(70.71 in.)
carriage: allow 68.33 cm (26.9 in.)
extended carriage:
allow 119.38 cm
(47.0 in.)
202.77 cm
(79.83 in.)
Figure 1-2: Model 200i and 250i Dimensions
1-6
ELECTRICAL REQU IREMENTS
description
Power Requirements
Frequency
Voltage
normal
min./max
Current
Power Consumption
Power Cord
length
end
wall receptacle (included with dyno)
Full Load Amperage (FLA)
specifications
240v 30 amp single phase circuit
50 or 60 Hz
240 VAC
215 VAC/245 VAC except Japan 195 VAC/245 VAC
30 amps
7200 watts
P/N 76950401
3.048 m (10 ft.)
twist-lock plug or three-pin IEC plug
twist-lock four wire grounded 30A NEMA L14-30 or
three-pin IEC grounded 30A
30A
ENVIRONMENTAL REQU IREMENTS
description
Temperature
operating min./max
storage min./max
Humidity
specifications
10°C/50°C (50°F/122°F)
0°C/60°C (32°F/140°F)
0 to 95% non condensing
SHOP AIR REQU IREM ENTS
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)
Version 2
1-7
CHAPTER 1
Power Requirements and Installation
POWER REQUIREMENTS AND INSTALLATION
...................................
The following power requirements and instructions are for North America, Japan, and
locations using 60 Hz power. All other locations should refer to the instructions
found in Appendix B.
The model 200i and 250i dynamometers require a dedicated wall receptacle which
must be wired for operation and is included with the dyno. The dyno is equipped
with a ten foot power cord with a twist lock plug pre-wired on the end. The power
cord is located at the front of the dyno. Refer to page 1-11 for the location of the
power cord.
The dedicated wall receptacle is a twist lock four wire grounded 30A NEMA L14-30
type and must be wired in accordance with local building codes and requirements.
Installation may require a licensed electrician and must conform to UL and NEC safety
standards.
Local and national electrical codes require a grounded receptacle box.
• This circuit should have a dedicated 30A double pole circuit breaker.
• The dyno should be the only device connected to this circuit.
• It may be necessary to install a delayed trip breaker due to the inrush current
drawn by the high pressure blowers.
INSTALLING
THE
WALL RECEPTACLE
The wall receptacle is included with your dyno and is shipped in a box the center of
your dyno. Refer to page 2-3 for more information on removing the hardware shipped
with the dyno.
The wall receptacle is a single 240 volt 30A dedicated circuit with a neutral connection
and a ground. The neutral connection is required to split the 240 volt into two 120
volt connections internal to the dyno.
The cable carrying the power to this receptacle should be ten gauge or larger. Check
with local building codes for the correct size.
1
2
3
4
Connect one of the 240V legs to the X terminal (gold colored screw).
Connect the other 240V leg to the Y terminal (gold colored screw).
Connect the neutral conductor to the W or WH terminal (silver screw).
Connect the ground conductor to the green grounding screw.
1-8
TES TING
FOR
CORRECT V OLTAGES
You must test the receptacle for proper voltages before the dyno is connected to the
outlet.
Using a voltmeter that is capable of measuring AC voltage, measure between the
points listed below and verify that the correct voltages are present.
probe 1
2
1
1
1
3
probe 2
4
4
2
3
box
desired voltage measurement
225V to 250V
108V to 130V
108V to 130V
<5V
<5V
3
2
4
1
Figure 1-3: Dedicated Power Receptacle
CONNECTING
1
2
3
4
5
6
Version 2
THE
DYNO
Turn off the main circuit breaker for the dyno. This is the large breaker in the
center of the power distribution assembly behind the door on the left hand side
of the dyno. Refer to page 1-11 for breaker location. Off is the down position.
Once you verify the voltages on the receptacle, connect the dyno to the
receptacle.
Connect the high pressure blowers to the dyno. For more information on
installing and connecting the blowers, refer to page 4-38.
Turn on the main dyno breaker. Refer to page 1-11 for breaker location.
Test the blowers for operation.
Turn on the dyno electronics and verify operation.
1-9
CHAPTER 1
Other Requirements
OTHER REQUIREMENTS
...................................
12 VO LT BATTERY
A motorcycle starting system is included with your dyno. You will need to purchase an
automotive battery locally to use this feature. The dyno is designed to carry a group
24 deep cycle series battery with a minimum of 600 cold cranking amps.
For more information on installing the battery, refer to page 2-15.
COMPUTER SPECIFICATIONS
You will need to provide a computer system to run the WinPEP software. WinPEP 7
includes complete documentation in online Help. From the WinPEP 7 menu bar,
choose Help ? WinPEP 7 Help or visit www.winpep.com.
minimum system requirements
recommended systems requirements
• Microsoft® Windows 98/ME/NT 4.0 or later/2000/XP
• Microsoft® Windows 2000/XP
• 400 MHz Processor
• 700 MHz Processor or greater
• 32 MB of available RAM for Windows 98/ME
• 128 MB of available RAM for Windows 2000/XP or greater
• 64 MB of available RAM for Windows NT 4.0
• one COM port, two COM ports for Tuning Link, USB port
• 128 MB of available RAM for Windows 2000/XP
• mouse and keyboard
• one COM port
• 1280x1024 SVGA monitor or better
• mouse and keyboard
• 24 bit video color or better
• 800x600 VGA monitor or better
• 100 MB of available hard-disk space
• 16 bit video color or better
• printer, if hard copies are needed
• 30 MB of available hard-disk space
• printer, if hard copies are needed
MOTORCY CLE 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.
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.
1-10
Model 200i Motorcycle Dynamometer
MODEL 200I MOTORCYCLE DYNAMOMETER
...................................
Drum
Tie-down Loop
precision balanced
and knurled
used to secure the
motorcycle to dyno
Tire Carriage
Breaker
Breakout Board
Power Cord
Air Connector
Dyno Electronics Enclosure
Power Distribution Enclosure
houses the dyno electronics and
power supply
houses the Breakout board, main
power breaker, and battery disconnect
Figure 1-4: Model 200i Basic Dyno
Version 2
1-11
CHAPTER 1
Model 250i Motorcycle Dynamometer
MODEL 250I MOTORCYCLE DYNAMOMETER
...................................
Power Carriage
not shown
Monitor Tray
supports the monitor,
keyboard, and mouse
High Pressure Blower
cools the bike’s engine
Eddy Current
Brake Module
Theta Controller
controls the eddy
current brake
Tire Carriage
Tie-down Loop
used to secure the
motorcycle to dyno
Drum
Air Brake
precision balanced
and knurled
Air Pump
Assembly
Figure 1-5: Model 250i With Optional Accessories
1-12
CHAPTER
2
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.
• Unpacking and Inspecting the Dyno, page 2-2
• Route the Computer, Pendant, and Starter Cables, page 2-6
• Install the Theta Controller, page 2-7
• Tire Carriage, page 2-8
• Remove the Dyno from the Crate, page 2-12
• Pickup Card, page 2-14
• Battery, page 2-15
• Drum Side and Top Covers, page 2-16
• Ramp Bracket, page 2-18
• Ground Hooks, page 2-21
2-1
CHAPTER 2
Unpacking and Inspecting the Dyno
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 with unpacking.
Use the following steps to unload your dyno. You will need to provide equipment
capable of lifting a minimum of 1700 lb. (771 kg.) to move the crated dyno into
position in your dyno room. Refer to “Dynamometer Specifications” on page 1-5 for
more information.
1
2
3
4
5
Move the crated dyno to a clear area near your dyno room.
Using a pry bar, or a large flat screwdriver, and a hammer, remove the top and
sides of the crate.
Remove the crate braces and sides.
Note: At this point, you will want to inspect the exterior of the dyno for any
indications of damage. Report any damage immediately.
Remove the tire carriage. The tire carriage is fastened to the bottom of the crate.
Remove the support arm. You will only have the support arm if you ordered a
monitor tray. The support arm is fastened to the bottom of the crate.
For more information on the support arm and monitor tray refer to page 4-42.
support arm
tire carriage
Figure 2-1: Remove the Tire Carriage and Support Arm from the Crate
2-2
INSTALLATION
6
Remove the six 1/4-inch screws securing the top cover on the dyno and remove
the cover.
Note: Dynojet recommends using a hardened 5/32-inch hex driver (such as
Snap-On FA5E) to remove the 1/4-inch screws. A standard allen key may round off
in the shallow screw head.
7
Remove the tire stop, tire lock, and hardware from the middle of the dyno.
top cover
tire stop and tire lock
in middle
Figure 2-2: Remove the Top Cover
Version 2
2-3
CHAPTER 2
8
9
Remove the eight screws securing the top drum cover to the dyno and set aside.
Remove the drum cover and set aside.
Remove the two top screws securing each side drum cover to the dyno and set
aside.
top drum cover
side drum cover
side drum cover
Figure 2-3: Remove the Top Drum Cover
2-4
INSTALLATION
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.
side drum cover
side drum cover
access holes in drum
bulkhead (only two
visible from this view)
Figure 2-4: Remove the Side Drum Covers
Version 2
2-5
CHAPTER 2
ROUTING
THE
1
COM PUTER , PENDANT, AND STARTER CABLES
With the top cover off, route the computer cable through the front access hole on
the dyno.
Note: You will need to remove the access panel in order to route the cables
through it.
1a
1b
2
Remove the two screws securing the access panel to the dyno.
If needed, cut a slit in the grommet in order to fit the grommet around the
cables.
1c Replace the access panel using the screws removed earlier.
Route the pendant and starter button cables through one of the top access panels
on the dyno.
Note: You will need to pull the dyno electronics enclosure out in order to get the
cables through the access panel on the left.
2a
2b
2c
2d
Remove the four screws securing the electronics enclosure.
Slide the enclosure out of the dyno.
Route the pendant and starter button cables through the access panel.
Replace the electronics enclosure.
route pendant cable
through top access
panel
route starter button
cable through top
access panel
route computer cable
through front access
panel
slide electronics
enclosure out
Figure 2-5: Route Computer, Pendant, and Starter Cables
2-6
INSTALLATION
INSTALLING
THE
THETA CONTROLLER
With the top cover off, now is a good time to install the Theta Controller. You will
only have a Theta Controller if you ordered an Eddy Current Brake. The Theta
Controller is shipped in the eddy current brake crate. For more information on
unpacking the eddy current brake, refer to page 4-19.
1
2
3
Secure the Theta Controller to the drum module bulkhead using four
8-32 x 3/8-inch screws.
Attach the input power cable to the Theta Controller (on top).
Route the control cable from the Theta Controller to the Breakout Board through
the hole in the power distribution enclosure shown in Figure 2-6.
The control cable will be connected to the Breakout board on page 4-26.
4
Replace the top cover using the screws you removed earlier. Refer to Figure 2-2.
attach input power
cable on top
route control cable
through opening in
electronics box
theta controller
Figure 2-6: Install the Theta Controller
Version 2
2-7
CHAPTER 2
INSTALLING
THE
T IRE CARRIAGE
You will need to install the tire carriage on the dyno before removing the dyno from
the crate (helps balance the dyno during lifting). 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” on page 1-5 for
more information.
The tire carriage is fastened to the bottom of the crate next to the dyno. Refer to
step 4 on page 2-2 for instructions on removing the tire carriage from the crate.
1
2
Install the three carriage clamps and shims using two 5/16-inch bolts and washers
each.
Install the nut block and shim using two 5/16-inch bolts and washers.
carriage clamp
shim
nut block
shim
Figure 2-7: Install the Carriage Clamps and Nut Block
2-8
INSTALLATION
3
Using a 5/32-inch allen wrench, remove the two 1/4 x 1/2-inch button-head screws
securing the screw support bracket. Remove the bracket and set the screws and
bracket aside.
screw support
bracket
carriage screw
Figure 2-8: Remove the Screw Support Bracket
4
5
6
Slide the carriage under the carriage clamps and the nut block until the carriage
screw is touching the nut block.
Slide the hand crank onto the end of the carriage screw.
Secure the hand crank to the screw shaft by tightening the set screw using a
5/32-inch allen wrench.
carriage
hand crank
Figure 2-9: Install the Tire Carriage and Secure the Hand Crank
Version 2
2-9
CHAPTER 2
7
8
Using the hand crank, screw the carriage through the nut block.
Install the screw support bracket.
8a Place the belleville washers over the end of the carriage screw. It is
important the belleville washers are installed in the configuration shown in
Figure 2-10.
8b Place the screw support bracket in front of the carriage screw. The two
threaded holes in the bracket should face the two matching holes in the
carriage. Loosely install the two 1/4 x 1/2-inch button-head screws.
8c Before tightening the screws, apply some pressure to the bracket to
compress the belleville washers. The handle should still turn freely, but the
turning force should now be around five to six pounds.
To adjust the force needed to turn the crank handle, adjust the compression
of the belleville washers.
8d Using a 5/32-inch allen wrench, tighten the two button-head screws.
Tighten the clamp and nut block bolts with a 1/2-inch wrench.
9
screws
support
bracket
carriage screw
belleville washers
Figure 2-10: Install the Screw Support Bracket
2-10
INSTALLATION
10 Secure the tire stop to the carriage with four 3/8 x 1/2-inch bolts.
11 Secure the tire lock to the tire carriage using four 3/8 x 1/2-inch bolts.
tire lock
tire stop
Figure 2-11: Install the Tire Stop and Tire Lock
Version 2
2-11
CHAPTER 2
REMOVING
THE
DYNO
FRO M THE
CRATE
You will need to provide equipment capable of lifting a minimum of 1600 lb.
(725 kg.) 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 1600 lb. (725 kg.) to attach to the
dyno. Dynojet recommends using single loop style straps.
1
2
3
4
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.
The pickup card may be taped to the lifting eye. Remove the pickup card and set it
aside.
Wrap the single loop straps through the lifting eyes in front of the drum.
Lift the dyno off the crate and move into position in your dyno room.
bolt and washer
bolt and washer
lifting eye
lifting eye
bolt and washer not
visible from this view
bolt and washer
Figure 2-12: Remove the Dyno from the Crate Base
2-12
INSTALLATION
5
Secure the dyno to the floor in your dyno room. Skip this step if you will be
installing the eddy current brake.
Note: Dynojet recommends you secure your dyno to the floor in your dyno room
using concrete anchors. You will want to mark and drill the holes in your
concrete before adding any accessories or replacing the covers on your dyno.
5a
5b
Mark and drill holes.
Refer to Appendix A for Red Head Anchor installation instructions.
mark and drill hole
mark and drill holes
hole not visible from
this view
Figure 2-13: Anchor Hole Placement
Version 2
2-13
CHAPTER 2
Pickup Card
PICKUP CARD
...................................
The pickup card is an electronic circuit board that accurately senses each drum
revolution.
1
2
3
4
Locate the pickup card bracket on the right side of the dyno just ahead of the
drum.
Install the pickup card to the bracket using two No. 8 screws. Do not tighten, the
card must be aligned first.
Note: If your dyno is equipped with an air brake, you will need to attach
compressed air and power to your dyno before you can turn the drum. Refer to
the page 4-4 for more information on attaching compressed air to your dyno.
Align the optical pickup card with the tab on the dyno drum axle. Be sure the tab
passes freely through the optical pickup. You may need to loosen the bracket to
help with alignment.
Once aligned, tighten the screws to secure the pickup card in place.
The optical pickup is very delicate. Be careful not to damage the optical pickup
during alignment.
tab on dyno
optical pickup
pickup card
top view of pickup card, optical
pickup, and tab on dyno
pickup card
bracket
tab on dyno
pickup card
Figure 2-14: Install the Pickup Card
2-14
INSTALLATION
Battery
BATTERY
...................................
A bike starting system is included with your Dynojet dyno. You will need to provide
an automotive battery to use this system. The dyno is designed to carry a group 24
series battery with a minimum of 600 cold cranking amps.
1
2
3
4
5
Locate the red battery cable on the inside of the dyno.
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.
Secure the red battery cable to the positive (+) battery post.
Secure the black battery cable to the negative (-) battery post.
Secure the battery to the tray with the battery hold-down.
battery
Figure 2-15: Install the Battery
Version 2
2-15
CHAPTER 2
Replace the Drum Side and Top Covers
REPLACE THE DRUM SIDE AND TOP COVERS
...................................
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 four for accessory installation instructions.
1
Secure each side drum cover to the dyno using the six screws you removed earler.
side drum cover
side drum cover
Figure 2-16: Replace the Side Drum Covers
2-16
INSTALLATION
Replace the Drum Side and Top Covers
2
3
Secure the top of the side drum covers with the screws you removed earlier.
Secure the top drum cover to the dyno using the eight screws removed earlier.
Note: Drum guards must be adjusted to less than 5 mm from the surface of the
drum.
top drum cover
Figure 2-17: Replace the Top Drum Cover
Version 2
2-17
CHAPTER 2
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
2
With the ramp upside down, center the ramp bracket under the lip at the top of
the ramp.
Using the larger holes on the bracket, mark and drill two 3/8-inch holes in the
ramp.
ramp lip
ramp bracket
24 inches
Figure 2-18: Ramp Assembly
2-18
INSTALLATION
Ramp Bracket
3
Insert the 3/8-inch bolts from the top of the ramp and secure using 3/8-inch
washers and nuts.
Figure 2-19: Secure Bolts to Ramp
4
5
Remove the four 1/4-inch bolts from the rear of the drum cover.
Secure the ramp bracket to the rear drum cover using the bolts you just removed.
Figure 2-20: Secure Bracket to Drum Cover
Version 2
2-19
CHAPTER 2
Ramp Bracket
6
Place the ramp on the ramp bracket slipping the bolts on the ramp through the
large holes on the ramp bracket.
Figure 2-21: Place Ramp on Dyno
2-20
INSTALLATION
Ground Hooks
GROUND HOOKS
...................................
You may wish to install additional ground hooks (included with your dyno) for
securing the motorcycle. Use the following instructions as a guide in placing your
ground hooks.
1
2
Locate each ground hook approximately 96.5 cm (38 inches) from the front of the
dyno and approximately 20 cm (8 inches) from the side of the dyno
(approximately 147 cm, 58 inches, apart).
Using the ground hooks as a pattern, install the Red Head Anchors using the
hardware included with the ground hook kit. Refer to Appendix A for Red Head
Anchor installation instructions.
approx. 147 cm (58 in.)
approx.
20 cm
(8 in.)
app rox. 96.5 cm (38 in .)
Figure 2-22: Ground Hooks
Version 2
2-21
CHAPTER
3
DYNO ELECTRONICS
This chapter provides instructions for installing the dyno electronics. To ensure safety
and accuracy in the procedures, perform the procedures as they are described.
• Dyno Electronics, page 3-2
• Atmospheric Sensing Module, page 3-2
• RPM Module, page 3-3
• Dynamometer Input/Output Module, page 3-4
• CPU Module, page 3-5
• Accessing the Dyno Electronics, page 3-6
3-1
CHAPTER 3
Dyno Electronics
DYNO ELECTRONICS
...................................
The standard DynoWare EX+ dynamometer electronics package is comprised of four
interconnected modules: Atmospheric Sensing Module, RPM Module, Dynamometer
Input/Output Module, and the CPU Module.
system expansion
connector
atmospheric
sensing module
RPM module
inductive pickup socket
dynamometer
input/output module
25-pin socket
9-pin, hand held
pendant
9-pin, RS-232 socket
CPU module
3-pin power plug
Figure 3-1: Dyno Electronics
ATM OSPHERIC S ENS ING MODULE
The atmospheric sensing module measures absolute pressure, air temperature, and
relative humidity. These measurements are used by WinPEP to correct power and
torque measurements to standard atmospheric conditions according to a DIN, SAE, or
other formula.
LED indicator
description
The green LED glows when the atmospheric sensing
module is receiving power.
The flashing amber LED indicates the module processor
is operating properly.
3-2
DYNO ELECTRONICS
Dyno Electronics
RPM MODULE
The RPM module receives and processes signals from up to two inductive pickups for
measurement of engine RPM. Each input has an automatic gain circuit to compensate
for a wide variance of ignition systems.
Figure 3-2: RPM Module
LED indicator
description
The green LED glows when the RPM module is receiving
power.
The amber LED flashes when an RPM signal is detected.
A steady flash rate, proportional to engine RPM, indicates
a good RPM signal.
These connectors are the inputs for both primary and
secondary inductive pickup clips. Either input may be
used with a primary inductive pickup or a secondary
inductive pickup on a single ended coil. Both inputs can
be used for a wasted spark ignition.
Version 2
3-3
CHAPTER 3
Dyno Electronics
DYNAMOMETER INPUT/OU TPUT MODU LE
The dynamometer input/output module sends and receives data from the
dynamometer and the hand-held pendant. The module also contains a buzzer and
light which are activated when either the vehicle or the dynamometer speed limit is
approached.
Figure 3-3: Dynamometer Input/Output Module
LED indicator
description
The green LED glows when the dynamometer
input/output module is receiving power.
The amber LED flashes proportionally to dynamometer
drum RPM.
This 25-pin connector attaches to the shielded cable from
the dynamometer.
This 9-pin connector attaches to the hand held pendant
which houses the button used to start/stop acquiring
data. The pendant may also contain a brake switch.
3-4
DYNO ELECTRONICS
Dyno Electronics
CPU M ODU LE
The CPU module contains a 32-bit processor which acquires data from the expansion
modules and communicates to the main computer running the WinPEP software. The
processor queries the expansion modules to determine their identity and capabilities.
Figure 3-4: CPU Module
LED indicator
description
The green LED glows when the CPU module is receiving
power.
The blue LED is lighted when data from the modules is
being acquired and saved.
One of these connectors is used to communicate to the
main computer. The 9-pin connector (left) attaches to
the PC’s RS-232 serial communications port.
This connector provides a synchronization signal to a
third party data acquisition system.
This connector provides 12 volt DC power to a third
party data acquisition system.
This connector accepts 12 volt DC power from a power
supply or battery. The adjacent LED glows bright green
when power is properly connected.
When this switch is on, power is supplied to all
connected modules.
Version 2
3-5
CHAPTER 3
Accessing the Dyno Electronics
ACCESSING THE DYNO ELECTRONICS
...................................
You may need to access your dyno electronics in order to add modules or perform
any troubleshooting. Use the following steps to access the dyno electronics.
To prevent possible injury, place the breaker inside the power distribution
enclosure to the off position and unplug the dyno. Refer to Figure 1-4 for
breaker location.
1
2
Remove the four screws securing the dyno electronics enclosure and set aside.
Slide the enclosure toward you and out of the dyno. Be sure not to pinch or pull
any cables.
Figure 3-5: Remove the Dyno Electronics Enclosure
3-6
DYNO ELECTRONICS
Accessing the Dyno Electronics
3
Remove the 12 screws securing the cover and lift the cover off.
Figure 3-6: Remove Electronics Enclosure Cover
dyno electronics
power switch
power supply
RPM connectors
Figure 3-7: Inside the Electronics Enclosure
Version 2
3-7
CHAPTER
4
A CCESSORIES
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 Dynojet’s Product Specialist’s at 1-800-992-3525 for
pricing and availability.
Installation instructions for some of these options can be found in this chapter.
Complete installation instruction manuals may also be found by browsing the
Manuals folder on your WinPEP installation CD
• Removing and Replacing Drum Covers, page 4-2
• Air Brake, page 4-4
• Air Pump and Filter Assembly, page 4-11
• Eddy Current Brake, page 4-18
• Extended Carriage, page 4-30
• High Pressure Blower, page 4-38
• Monitor Tray, page 4-42
• Power Carriage, page 4-44
• Safety Switch, page 4-48
4-1
CHAPTER 4
Removing and Replacing the Top and Side Drum Covers
REMOVING AND REPLACING THE TOP AND SIDE DRUM COVERS
...................................
You will need to remove and replace the drum top and side covers to access many of
the accessory areas. Refer to the following instructions.
1
2
Remove the eight screws securing the top drum cover to the dyno and set aside.
Remove the drum cover.
Remove the two screws securing the top of each side drum cover to the dyno and
set aside.
top drum cover
side drum cover
Figure 4-1: Remove the Top Drum Cover
4-2
side drum cover
ACCESSORIES
Removing and Replacing the Top and Side Drum Covers
3
Remove the remaining six screws securing each side drum cover to the dyno and
set aside. Remove the side drum covers.
side drum cover
side drum cover
Figure 4-2: Remove the Side Drum Covers
Version 2
4-3
CHAPTER 4
Air Brake
AIR BRAKE
...................................
The air brake 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, the air brake is ready to use.
connect shop air supply
Figure 4-3: Connect Your Shop Air Supply
PARTS LIST
The following table lists all of the parts included in the Air Brake (P/N 63920005)
Installation kit. Check your kit against the parts listed to make sure you have received
all of the parts. If any part is missing, contact Dynojet Technical Support.
part number
21222201
21222601
21622201
32904080
32920128
36488100
36581270
36585670
36820840
36952100
37620844
63920004
63990002
BR102-055
DM150-002-007
description
Brake Caliper Stop
Brake Adjusting Shim
Brake Bracket
Hairpin Cotter, 7/16-3/4” shaft size
Clevis Pin, 5/8 x 4”
Nut, 3/8-16, Nylock
Bolt, 3/8-16 x 3/4”, with Taper lock
Bolt, 3/8-16 x 3-1/2”, Hex
Bolt, 5/8-11 x 1, Hex
Washer, 5/8”, splitlock, stl
Woodruff Key, 1/2 x 2-3/4”, #1622-1
Air Brake Assembly
Rotor/Taper Lock Assembly with Hub and Key
Purple Brake Spring
Washer, 5/16”, Flat
4-4
quantity
1
1
1
3
2
1
2
1
2
2
1
1
1
1
3
ACCESSORIES
Air Brake
FINAL ADJUSTMENTS
1
AND
TESTS
Verify the dyno is set up properly, the dyno electronics is powered up and
operational, and the air supply is connected properly.
Use the red brake button on the pendant to activate and deactivate the brake.
Listen for air leaks and double check all connections.
Verify the brake pads release far enough so they do not touch the rotor. There
should be equal pad clearance on both sides of the rotor. If the pads touch the
rotor during a run, the information provided by the dyno will be inaccurate.
2
3
Refer to page 4-10 for instructions on adjusting the brake pad clearance.
CHANGING
THE
BRAKE P ADS
breaker location.
1
2
3
Remove the top and right side covers from the dyno. Refer to page 4-2.
For safety, apply the brake and disconnect the air supply at the front of the dyno.
Refer to Figure 4-3 on page 4-4.
Remove the hairpin cotter and loosen the castle nut until the pads clear the rotor.
outboard brake pad
adjust castle nut
remove hairpin cotter
Figure 4-4: Loosen the Castle Nut
Version 2
4-5
CHAPTER 4
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
nut, washer,
and spring
bolt
Figure 4-5: Remove the Purple Spring
4-6
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.
brake bracket
brake caliper stop
Figure 4-6: Remove the Brake Caliper Stop
6
Remove the hairpin cotter from the bottom clevis pin located on the front of the
air brake assembly.
hairpin cotter
bottom clevis pin
Figure 4-7: Remove Bottom Hairpin Cotter
Version 2
4-7
CHAPTER 4
Air Brake
7
8
Push the bottom clevis pin towards the back of the assembly (drum side). You do
not need to remove the pin completely.
Remove the hairpin cotter from the top clevis pin located on the drum side of the
air brake assembly.
top hairpin cotter
top clevis pin
bottom clevis pin
Figure 4-8: Remove Bottom Pin and Top Hairpin Cotter
9
Remove the top clevis pin.
top clevis pin
Figure 4-9: Remove the Top Clevis Pin
4-8
ACCESSORIES
Air Brake
10 Lift the air brake assembly up and away from the dyno.
Figure 4-10: Remove the Brake Assembly
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 4-10.
14 Replace the top and bottom clevis pins and secure with the hairpin cotters
removed earlier. Refer to Figure 4-7, Figure 4-8, and Figure 4-9.
15 Using two bolts and two washers, secure the brake caliper stop to the brake
bracket. Refer to Figure 4-6.
16 Secure the spring using the bolt, washer, and nut you removed earlier. Refer to
Figure 4-5.
17 Tighten the castle nut and replace the hair pin cotter. Refer to Figure 4-4.
18 Adjust the brake pad clearance. Refer to page 4-10 for complete instructions.
19 Replace the top and right side covers. Refer to page 4-2.
20 Connect your shop air.
Version 2
4-9
CHAPTER 4
Air Brake
ADJUS TING
THE
BRAK E PAD CLEARANCE
There should be equal pad clearance on both sides of the rotor. If the pads touch the
rotor during a run, the information provided by the dyno will be inaccurate. Use the
following steps to adjust the clearance.
1
2
3
4
5
6
Loosen the brake caliper stop bolts.
Insert the brake adjusting shim between the inboard brake pad and the brake
rotor. Refer to Figure 4-11.
Remove the hairpin cotter and hand tighten the castle nut on the caliper assembly
to clamp the brake pads against the rotor and shim. Refer to Figure 4-4 for hairpin
and castle nut location.
Tighten the brake caliper stop bolts.
Loosen the castle nut and remove the shim.
Adjust the clearance between the outboard brake pad and rotor. Loosen the castle
nut to increase the clearance.
There should be equal space on both sides of the rotor.
7
Replace the hair pin cotter in the castle nut.
Note: Cycle the brake to verify the brake pads release far enough so they do not
touch the rotor. If the pads touch the rotor during a run, the information
provided by the dyno will be inaccurate.
brake adjusting shim
rotor
inboard brake pad
brake caliper stop bolts
Figure 4-11: Adjust Brake Pad Clearance
4-10
ACCESSORIES
Air Pump and Filter Assembly
AIR PUMP AND FILTER ASSEMBLY
...................................
This section describes how to install the on dyno air pump and filter assembly.
• Dynojet recommends running the pump between dyno runs to help reduce the
chance of moisture contamination on the sensor.
• Remember to empty the exhaust collection bottles regularly.
• Leaks in the system will result in erroneous readings. Verify there are no cracks or
holes in the hoses and filter bowl. Verify the sensor is seated properly in the sensor
block.
• Do not allow the filter bowl to fill with water during operation. Refer to the Air Fuel
Ratio Module User Guide for filter bowl information.
• Before turning the pump on, verify there is no water in the filter bowl. Always
empty the bowl before turning the pump on.
• Always allow the air pump to run after the dyno runs are complete to clear all water
from the filter bowl and allow the air pump to cool.
Refer to the Air Fuel Ratio Module Installation and User Guide for proper operating
and maintenance procedures. Failure to follow proper procedures may result in
inaccurate data or damage to the equipment. This manual can be found on your
WinPEP CD or at www.dynojet.com/manuals.shtml.
Note: The Air Pump Assembly has a twelve month warranty.
Leaded racing fuels and two-stroke applications will contaminate the sensor
and dramatically shorten its service life.
The sensor is not covered by a warranty. Be sure to read and understand the Air
Fuel Ratio Module manuals.
Running the pump with the filter clogged, hose kinked, or filter removed will
damage the pump and void the warranty.
Version 2
4-11
CHAPTER 4
PARTS LIST
The following table lists all of the parts included in the Air Pump and Filter Assembly
(P/N 64193009 Domestic or P/N 64193010 European) Installation kit. Check your kit
against the parts listed to make sure you have received all of the parts. If any part is
missing, contact Dynojet Technical Support.
part number
21125500
21626204
21696204
31991331
34420001
34491000
39460210
43310600
46115050
or
46115051
description
Filter and Sensor Housing
Pump Bracket
Pump Bottle Bracket
1/2” Diameter Rubber Hose
Filter Assembly
Filter Kit Replacement
Drip Bottle, Clear, Plastic
Grommet, 7/16” ID x 3/4” OD
Pump, Thomas 2107, 120V
or
Pump, Thomas 2107, 240V
INSTALLING
1
2
3
THE
quantity
1
1
1
2
1
5
2
2
1
FILTER AND P UM P ASSEMBLIES
Remove the side drum cover from the right side of the dyno. Refer to “Removing
and Replacing the Top and Side Drum Covers” on page 4-2.
Remove the four 1/4-inch screws securing the AFR blanking plate to the dyno and
remove the plate. Set the screws aside, they will be used later.
Remove the lower two 3/8-inch bolts, washers, and nuts from the lower right
corner of the rear of the dyno and set aside to be used later.
blanking plate
lower bolts,
washers, and nuts
Figure 4-12: Remove the Blanking Plate
4-12
ACCESSORIES
4
Install the filter assembly with the four 1/4-inch screws removed in step two.
filter assembly
Figure 4-13: Install the Filter Assembly
5
Install the pump assembly and exhaust bottle bracket using the two 3/8-inch bolts
removed in step 3.
exhaust bottle bracket
pump assembly
Figure 4-14: Install the Pump Assembly
Version 2
4-13
CHAPTER 4
6
Connect the 1/4-inch inlet hose and the 1/8 inlet hose.
1/8-inch inlet hose
1/4-inch inlet hose
Figure 4-15: Connect the Inlet Hoses
7
8
Install two grommets and the outlet hoses as shown in Figure 4-16.
Install the exhaust bottles and insert the outlet hoses into the bottles.
outlet hoses
exhaust bottles
grommets
Figure 4-16: Install the Exhaust Bottles, Hoses, and Grommets
4-14
ACCESSORIES
9 Attach the sensor to the sensor block.
10 Attach the sensor cable to the corresponding cable from the inside back panel of
the dyno.
sensor cable
sensor
back view of filter assembly
Figure 4-17: Install the Sensor
11 Locate the wiring harness coming from the switch at the bottom of the filter
assembly. This wiring harness has two connectors. One connector attaches to the
pump while the other attaches to the dyno.
11a Attach the female three-pin connector to the pump cable.
11b Attach the male three-prong connector to the black power cord from the
dyno. This power cord is located on the inside back panel of the dyno.
12 Replace the right side drum cover. Refer to “Removing and Replacing the Top and
Side Drum Covers” on page 4-2.
CLEANING
THE
F ILTER ASSEMBLY
Refer to the Air Fuel Ratio Module Installation and User Guide for detailed filter
assembly cleaning procedures. Failure to follow proper procedures may result in
If cleaning the filter does not result in free air flow, replace the filter. Be sure to check
for other restrictions in the system.
Note: A clogged filter may cause erroneous readings or slow response. Clean the
filter daily or more often depending on usage.
Version 2
4-15
CHAPTER 4
PU MP HEAD M AINTENANCE
Depending on usage, the pump will need periodic maintenance. Use the following
instructions to remove the pump from the dyno. Once removed, refer to the Air Fuel
Ratio Module Installation and User Guide for detailed pump head maintenance
procedures.
breaker location.
1
2
Remove the exhaust collection bottles from the bracket.
Disconnect the outlet hoses from the pump.
outlet hoses
exhaust
collection bottles
Figure 4-18: Remove the Exhaust Bottles, Hoses, and Grommets
3
Disconnect the 1/4-inch inlet hose and the 1/8 inlet hose.
1/8-inch inlet hose
1/4-inch inlet hose
Figure 4-19: Disconnect the Inlet Hoses
4-16
ACCESSORIES
4
5
Remove the two 3/8-inch bolts securing the bracket to the pump assembly and set
the bolts and bracket aside.
Remove the pump assesmbly.
bottle bracket
pump assembly
Figure 4-20: Remove the Pump Assembly
6
7
Remove the four screws securing the pump to the bracket and set aside.
Remove the pump from the bracket.
bracket
pump
Figure 4-21: Remove the Pump from Bracket
8
Version 2
Refer to the Air Fuel Ratio Module Installation and User Guide for detailed pump
head maintenance procedures. Failure to follow proper procedures may result in
4-17
CHAPTER 4
Eddy Current Brake
EDDY CURRENT BRAKE
...................................
This section will walk you through removing the eddy current brake from the crate,
attaching the brake to your dyno, routing and wiring the temperature sensor cable to
the Breakout board, and wiring the Theta Controller to the Breakout Board.
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.
breaker location.
PARTS LIST
The following table lists all of the parts included in the Eddy Current Brake (P/N
63223700) Installation kit. Check your kit against the parts listed to make sure you
have received all of the parts. If any part is missing, contact Dynojet Technical
Support.
part number
21227107
21629403
36582034
37620622
49950030
61228400
63223700
66411003
description
Retarder Connector Plate (already installed)
Bar, Load Cell
Screw, 3/8”-16 x 1 1/4”, BH-FLNG
Woodruff Key, 3/8” x 1 3/8”
Temperature Sensor
Hood, Top, Retarder Module
Retarder Module
Theta-2 Controller 240V
4-18
quantity
2
1
8
1
1
1
1
1
ACCESSORIES
Eddy Current Brake
UNPACK ING
1
2
3
THE
EDDY CURRENT BRAKE
Remove the top and sides of the crate.
Remove the four screws securing the top cover and set aside. Remove the cover
and set aside.
Remove the hardware box and Theta Controller from the crate and verify the
hardware box contents using the parts list.
For more information on installing the Theta Controller refer to page 2-7.
top cover
Figure 4-22: Remove the Covers
Version 2
4-19
CHAPTER 4
Eddy Current Brake
4
5
Remove the four bolts securing the brake to the crate.
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
5b
5c
Move the coupler 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 4-24.
Move the retarder connector plates to the other side of the brake.
Move the temperature sensor to the other side of the brake.
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
Figure 4-23: Identifying Left or Right Side Brake Set Up
shaft
apply force using
hammer and punch
key
Figure 4-24: Removing the Key
4-20
apply force using
hammer and punch
ACCESSORIES
Eddy Current Brake
6
7
8
9
Remove the side drum cover, if not already removed, from the dyno.
Refer to page 4-2.
Place the nylon loop strap through the lifting eyes on either side of the brake.
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.
Remove the eight bolts, washers, and nuts from the dyno frame where the
connector plates will attach.
lifting eye
line up panels
remove bolts, washers, and
nuts from dyno frame
lifting eye
Figure 4-25: Move the Brake Next to the Dyno
Version 2
4-21
CHAPTER 4
Eddy Current Brake
INSTALLING
THE
EDDY CURRENT B RAKE
The eddy current brake comes with the coupler already installed on the brake shaft.
The eddy current brake can be installed on either side of your dyno. It is not
necessary to remove the air brake if you are installing the eddy current brake on the
right side.
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
2
Insert the key into the keyway.
Use a c-clamp to press the key in.
key
key way on dyno shaft
retarder connector plate
Figure 4-26: Install the Key
4-22
ACCESSORIES
Eddy Current Brake
3
4
5
6
7
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.
Continue sliding the eddy current brake towards the dyno until the covers on the
brake and dyno are flush.
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 4-26.
Note: Do not tighten the bolts.
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.
Once aligned, tighten all retarder connector plate bolts and nuts.
retarder connector plate
three bolts not visible
from this view
Figure 4-27: Secure the Retarder Connector Plate
Version 2
4-23
CHAPTER 4
Eddy Current Brake
8
Secure the side panels on the eddy current brake to the panels on the dyno using
a 1/4-20 bolt, washer, and nut. Do this on each side.
not visible from
this view
Figure 4-28: Secure the Side Panels to the Dyno
9
Replace the existing set screws on the coupler with the thread-lock set screws
provided.
10 Tighten the coupler set screws.
dyno shaft
brake shaft
set screw
Figure 4-29: Tighten the Set Screws
4-24
ACCESSORIES
Eddy Current Brake
ROUTING CABLES
1
Route the temperature sensor cable from the eddy current brake through the air
hole in the drum bulkhead, through the opening on the side of the power
distribution enclosure, and over to the Breakout board.
For more information on wiring the Breakout board refer to page 4-26.
2
Attach the brake power cable from the eddy current brake through the air hole in
the drum bulkhead to the Theta Controller (underneath).
Note: The control cable was routed from the Theta Controller on page 2-7.
theta controller
air hole in drum
bulkhead
temperature
sensor cable
control cable
breakout board
brake power cable
Figure 4-30: Route Cables
Version 2
4-25
CHAPTER 4
Eddy Current Brake
WIRING
1
THE
B REAKOUT BOARD
Attach the temperature sensor cable to the Breakout board. The temperature
sensor cable has five wires which connect to the wiring block labeled TEMP. This
cable was routed to the Breakout board on page 4-25.
• Green wire connects to G1
• White wire connects to W1
• Black wire connects to B1
• Red wire connects to R1
• Ground (shield) wire connects to S1
2
Attach the control cable to the Breakout board. The control cable has five wires
which connect to the wiring block labeled LOAD CONTROL. This cable was
routed to the Breakout board on page 2-7.
• Black wire connects to V-
• Red wire connects to V+
• White wire connects to O+
• Green wire connects to O-
• Ground (shield) wire connects to SH
3
Verify jumpers J1 and J2 are set either for the eddy current brake and air brake or
for the air brake only as shown in Figure 4-31.
If you have an eddy current brake and air brake, the air brake will only be
activated when the dyno electronics power is turned off or the optional door
interlock is installed and activated.
4
Close the power distribution enclosure door.
temp
jumpers
J1 and J2
eddy current brake and air
brake jumper settings
air brake only jumper settings
load control
Figure 4-31: Wire the Breakout Board
4-26
ACCESSORIES
Eddy Current Brake
REPLACING
THE
COVERS
Note: Dynojet recommends you anchor the eddy current brake, along with the
dyno, to the floor in your dyno room.
1
Before you replace the covers, secure the eddy current brake and the dyno to the
ground using Red Head Anchors. Refer to Appendix A for Red Head Anchor
installation instructions.
Secure the eddy current brake to the ground using the same holes used to secure
the brake to the crate.
2
Using the six of the eight screws removed earlier, secure the side cover to the
brake.
side cover
Figure 4-32: Install the Side Cover
Version 2
4-27
CHAPTER 4
Eddy Current Brake
3
4
Using two of the eight screws removed earlier, secure the top part of the side
cover to the brake.
Using the four screws removed earlier and two 1/4 x 1/2-inch screws, secure the
top cover to the brake and dyno.
Note: If you are unable to secure the covers, then the brake may not be properly
aligned with the dyno. You should not need to force the covers on.
top cover
side cover screws
top of side cover
Figure 4-33: Install the Top Cover
4-28
ACCESSORIES
Eddy Current Brake
REPLACING
THE
THETA CONTROLLER F USES
The Theta controller has two fuses. For more information on installing the Theta
Controller refer to page 2-7.
Hazardous voltage. To avoid risk of electrical shock, place the breaker inside
the power distribution enclosure to the off position and unplug the dyno. Refer
to Figure 1-4 for breaker location.
1 Open the power distribution enclosure cover.
2 Remove the four screws securing the blanking plate and remove the plate.
3 Reach through this opening to access the fuses on the Theta Controller.
4 Gently push the fuse holder slightly inward and rotate counterclockwise. Remove
the fuse holder.
5 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.
• Buss P/N BAF-15, 15A Fuse
• Little Fuse, KLK 15
• Fast Blow, Dynojet P/N 54211201
remove blanking
plate
reach through opening to
theta controller fuses
Figure 4-34: Replace Theta Controller Fuses
Version 2
4-29
CHAPTER 4
Extended Carriage
EXTENDED CARRIAGE
...................................
The extended carriage 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 102 inches
for testing raked cruisers and drag bikes.
breaker location.
PARTS LIST
The following table lists all of the parts included in the Extended Carriage Installation
kit. Check your kit against the parts listed to make sure you have received all of the
parts. If any part is missing, contact Dynojet Technical Support.
part number
36488100
36560834
DM150-002-008
DM150-011-002
DM150-015-001
DM150-016-007
DM150-019-012
EXT100-206
EXT100-206
DM150-019
DM150-014-002
DM150-015-002
DM150-002-003
DM150-002-004
description
Nut, 3/8"-16, Nylock
Screw, 1/4-20 x 1/2", Button-head
Nut, 5/16"
Washer, 3/8", Flat
Nut Block
Carriage Screw Support Bracket
Bolt, 3/8 x 1", Hex
Extended Carriage Support Bracket
Carriage and Tire Stop
quantity
6
2
4
12
1
1
6
1
1
Small Leveling Shim
Large Leveling Shim
Bolt, 5/16 x 1 1/2"
Washer, 5/16", Lock
1
1
4
4
4-30
ACCESSORIES
Extended Carriage
REMOVING
1
2
3
bolt
THE
STANDARD T IRE CARRIAGE
Using a 5/32-inch allen wrench, remove the two button-head screws securing the
carriage screw support bracket and remove the bracket. Refer to Figure 2-10 on
page 2-10 for information on the carriage screw support bracket.
Using the hand crank, unscrew the carriage screw until it is free from the nut
block. Slide the carriage off the dyno.
Using a 1/2-inch wrench, remove the bolts (discard bolts) and washers securing
the nut block and front clamp to the dyno cover and set aside.
Note: Leave the two rear carriage clamps in place.
carriage clamp
and shim
washer
nut block
and shim
Figure 4-35: Remove the Tire Carriage, Nut Block, and Clamps
Version 2
4-31
CHAPTER 4
Extended Carriage
INSTALLING
1
2
3
THE
EXTENDED CARRIAGE S UPPORT BRACKET
Loosely attach the extended carriage support bracket to the front of the dyno
using six 3/8-inch bolts.
Using a straight edge, line the top of the support bracket with the top of the dyno
chassis.
Tighten all six screws.
extended carriage
support bracket
Figure 4-36: Install the Extended Carriage Support Bracket
4-32
ACCESSORIES
Extended Carriage
4
5
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.
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.
carriage clamp
nut block
extended carriage
support bracket
Figure 4-37: Install the Nut Block and Front Clamp
Version 2
4-33
CHAPTER 4
Extended Carriage
INSTALLING
1
2
3
THE
EXTENDED CARRIAGE
Slide the extended carriage through the nut block and clamps until the carriage
screw contacts the nut block. Be sure the slide plate is under the rear carriage
clamps.
Install the hand wheel.
Using the hand wheel, screw the carriage screw through the nut block.
extended carriage
hand wheel
Figure 4-38: Install the Extended Carriage
4-34
ACCESSORIES
Extended Carriage
4
Install the screw support bracket.
4a Place the belleville washers over the end of the carriage screw. It is
important the belleville washers are installed in the configuration shown in
Figure 4-39.
4b
Place the screw support bracket in front of the carriage screw. The two
threaded holes in the bracket should face the two matching holes in the
carriage. Loosely install the two 1/4 x 1/2-inch button-head screws.
4c
Before tightening the screws, apply some pressure to the bracket to
compress the belleville washers. The handle should still turn freely, but the
turning force should now be around five to six pounds.
4d
To adjust the force needed to turn the crank handle, adjust the compression
of the belleville washers.
Using a 5/32-inch allen wrench, tighten the two button-head screws.
screws
support
bracket
carriage screw
belleville washers
Figure 4-39: Install the Screw Support Bracket
Version 2
4-35
CHAPTER 4
Extended Carriage
5
Secure the tire stop to the carriage with four 5/16 x 1-1/2-inch bolts,
four 5/16-inch lock washers, and four 5/16-inch flat washers.
nut
lock washer
flat washer
tire stop
carriage
bolt
Figure 4-40: Install the Tire Stop
4-36
ACCESSORIES
Extended Carriage
6
Secure the tire lock to the tire carriage using four 5/16 x 1-1/2-inch bolts, four
5/16-inch lock washers, and four 5/16-inch flat washers.
Note: The washer and nut are up under the extended carriage lip. Only two are
visible from this view.
bolt
lock washer
tire lock
the washer and nut are
up under the carriage
(only two are visible
from this view)
Figure 4-41: Install the Tire Lock
Version 2
4-37
CHAPTER 4
HIGH PRESSURE BLOWER
...................................
The high pressure blower supplies air to cool the bike’s engine. This section will walk
you through the blower installation procedures.
breaker location.
PARTS LIST
The following table lists all of the parts included in the High Pressure Blower
Installation kit. Check your kit against the parts listed to make sure you have received
all of the parts. If any part is missing, contact Dynojet Technical Support.
part number
75722003
63413004
63413001
26215521
35712992
description
Lower Blower Arm Assembly
Upper Blower Arm Assembly
Washer, 1.87 x 1.25 ID x .25 THK (Poly Washer)
Clamp Lever
4-38
quantity
1
2
2
2
2
ACCESSORIES
INSTALLING
THE
BLOWER ARM ASSEM BLIES
If you have a monitor tray, the support arm must be installed before the blower arm
assemblies. Refer to “Monitor Tray” on page 4-42 for more information.
Repeat the following steps for each blower arm assembly.
1
2
3
Place a poly washer around the stud on the blower arm assembly.
Insert the stud on the lower blower arm into the dyno.
Secure the clamp lever to the dyno.
blower arm
assembly
poly washer
clamp lever
blower arm
assembly
clamp lever
Figure 4-42: Secure the Blower Arm Assemblies to the Dyno
Version 2
4-39
CHAPTER 4
INSTALLING
THE
HIGH PRESSU RE BLOWER AS SEMBLIES
Repeat the following steps for each blower assembly.
1
2
Place a poly washer around the stud on the blower assembly.
Insert the stud on the blower assembly into the blower arm.
blower assembly
poly washer
blower arm
Figure 4-43: Install the Blower Assembly
4-40
ACCESSORIES
PO WER HO OKUP
Each blower has it’s own power cord and will plug directly into the dyno chassis.
1
2
Plug the power cord from the blower into the power source located on the dyno
chassis.
Activate the blowers using the switches on the on the blower motor. The blowers
are independent of one another; each blower can be turned on and off
individually.
Risk of injury. Eye protection required. Be aware of debris from blowers. Be
sure the blowers are free and clear of any obstruction. The blowers can run at
any time once the cord is plugged into a power source.
power cord
from blower
power cord
from blower
plug into
dyno chassis
Figure 4-44: Power Hookup
Version 2
4-41
CHAPTER 4
Monitor Tray
MONITOR TRAY
...................................
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.
PARTS LIST
The following table lists all of the parts included in the Monitor Stand Installation kit.
Check your kit against the parts listed to make sure you have received all of the parts.
If any part is missing, contact Dynojet Technical Support.
part number
21229300
32391064
35521420
36701100
36801253
36932100
36942100
36943100
61329100
description
Monitor Arm Tray
Bushing, 1" x 2", 10 Gauge, Stl
Plastic Cap, 1-3/4" x 1/2", Black
Nut, 1/2-13, Hex
Screw, 1/2-13 x 1-1/2", Sh-Cap
Washer, 3/8", Splitlock, Stl
Washer, 1/2", Splitlock, Stl
Washer, 1/2", Flat, Stl
Monitor Arm
4-42
quantity
1
3
4
2
2
1
2
4
2
ACCESSORIES
Monitor Tray
INSTALLING
THE
SUPPORT ARM
AND
TRAY
The support arm and monitor tray may be installed on either side of your dyno.
1
2
3
4
5
6
7
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.
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.
Place a poly washer around the pin of the first arm and insert the arm into the
support arm.
Place a poly washer around the pin of the second arm and insert the arm into the
first arm.
Place a poly washer around the pin of the tray and insert the tray into the second
arm.
Insert a plastic cap in both ends of each arm.
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.
poly washer
second arm
poly washer
monitor tray
first arm
poly washer
support arm
Figure 4-45: Install the Support Arm and Monitor Tray
Version 2
4-43
CHAPTER 4
Power Carriage
POWER CARRIAGE
...................................
The power carriage replaces the standard hand crank 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 crank is
difficult to access. The power carriage will also reduce the time spent making
adjustments for various length motorcycles.
The power carriage motor is preset to be installed with the carriage screwed in
all the way. Do not run the motor prior to installing it on your dyno.
breaker location.
PARTS LIST
The following table lists all of the parts included in the Power Carriage Installation kit.
Check your kit against the parts listed to make sure you have received all of the parts.
If any part is missing, contact Dynojet Technical Support.
part number
36561284
36561670
36912100
REMOVING
1
description
Screw, 1/4-20 x 3/4” Button-Head
Bolt, 1/4-20 x 1”, Hex
Washer, 1/4”, Splitlock, STL
THE
quantity
2
2
2
HAND CRANK
Remove the hand crank from the tire carriage.
1a Screw the carriage all the way in.
1b
Loosen the set screw on the hand crank and remove the hand crank.
set screw
hand crank
Figure 4-46: Remove the Hand Crank
4-44
ACCESSORIES
Power Carriage
2
3
4
Using a 5/32-inch allen wrench, loosen the two set screws in the lock collar and
remove it from the screw shaft.
Using a 7/16-inch wrench, remove the two bolts securing the flange bearing.
Pry the flange bearing from the carriage screw shaft with a flat screwdriver and set
aside.
Note: Clean the shaft with a fine grit emery cloth to remove any remaining thread
lock residue. This will make it easier to slide the motor assembly and flange
bearing on the shaft.
set screw on lock collar
(only one visible)
shaft
flange bearing
bolts
Figure 4-47: Remove the Flange Bearing
INSTALLING
1
THE
POWER CARRIAGE
Remove the two button-head screws securing the aluminum cover to the motor
mount assembly and set aside.
button-head screws
aluminum cover
motor mount assembly
Figure 4-48: Remove the Aluminum Cover
Version 2
4-45
CHAPTER 4
Power Carriage
2
Slide the motor mount assembly and flange bearing, removed earlier, over the
screw shaft. Make sure the flex coupling is on the shaft.
Note: The flange bearing must be facing as shown in Figure 4-49 so the grease
zerk is accessible.
3
Secure the motor mount assembly and flange bearing to the carriage using two
1/4 x 1-inch bolts and lock washers.
Note: Dynojet recommends using a 1/4-inch ratchet drive with universal joint and
a 7/16-inch shallow socket to secure the flange bearing bolts.
4
Using a 1/8-inch allen wrench, tighten the flex coupling set screw.
grease zerk
flex coupling set screw
flex coupling
screw shaft
flange bearing
flange bearing bolts
motor mount
assembly
Figure 4-49: Install the Motor Mount Assembly
4-46
ACCESSORIES
Power Carriage
5
6
Secure the aluminum cover with the two screws you removed earlier.
Plug the power cord into a 120 volt power source.
Note: For European and 240 volt applications, a step down transformer must be
used to provide 120 volts.
7
Using the pendant, move the power carriage through the entire range of motion
making sure there is no binding or jamming.
Note: When operating the power carriage with a bike on the dyno, make sure the
bike is in neutral.
aluminum cover
pendant
Figure 4-50: Power Carriage Secured to Dyno
Version 2
4-47
CHAPTER 4
Safety Switch Installation
SAFETY SWITCH INSTALLATION
...................................
The safety switch requires the air brake to work. This switch is located on the dyno
room door; when the door is open, the air brake is locked. This prevents the dyno
from being used when the door is open.
1
2
3
4
5
6
Remove the cover on the wire junction box.
Loosen the set screws that hold the jumper wire, and then remove the jumper
wire.
Route the yellow and black wires from the safety switch through the dyno to the
wire junction box.
3a Route the wires through one of the three access panels (one at the front of
the dyno and two on the top cover, refer to Figure 2-5 for panel locations).
3b Continue routing the wires through the dyno and through any of the three
access holes in the drum bulkhead (refer to Figure 2-4 for access hole
locations).
Feed the yellow and black wires through the side of the wire junction box.
The wires from the switch are to be installed across where the jumper lead was
removed. Wire so the yellow lead from the switch lines up with the yellow lead on
the bottom of the terminal strip. Wire the black lead from the switch so that it
lines up the black wire on the bottom of the terminal strip.
The safety switch needs to be mounted at the entry of the dyno cell. The switch is
“open” when the plunger is out, and “closed” when the plunger is depressed.
Mount the switch on the dyno cell door / access gate so that the switch is closed
when the door is closed. When the door is opened, the switch will “open” and the
the dynamometer will stop running.
yellow lead
remove
jumper
Figure 4-51: Wiring the Safety Switch
4-48
black lead
CHAPTER
5
BASIC DYNO OPERATION
This chapter includes instructions for basic dyno operation. For more detailed
instructions, refer to the WinPEP 7 User Guide. This manual can be found on your
• Loading the Bike, page 5-2
• Using the Starter, page 5-4
• Using the Dyno, page 5-4
• Preventative Maintenance, page 5-4
5-1
CHAPTER 5
Loading the Bike
LOADING THE BIKE
...................................
Use the following steps to load a motorcycle on the dyno.
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.
1
2
3
Load the bike on the dyno.
Place the bike on the dyno so the front tire is in the tire stop.
Strap the front wheel to the tire stop and tighten.
Never perform a dyno run if the tire strap is not in place or is damaged.
4
5
Turn the carriage screw handle until the rear axle is aligned with the center of the
drum.
With the motorcycle in neutral, align the wheel in the center of the knurl by
pressing the dyno starter switch.
tire stop
tire strap
center drive axle on
dyno drum
adjust carriage to align
rear axle with drum
Figure 5-1: Align the Wheel and Axle
5-2
BASIC DYNO OPERATION
Loading the Bike
6
7
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 2-21). 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.
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.
tie-down strap
tie-down
Figure 5-2: Attach the Tie-down Straps
Version 2
5-3
CHAPTER 5
Using the Starter
USING THE STARTER
...................................
The starter allows you to use the momentum of the drum to start motorcycles that are
not equipped with an on-board starting system.
1
2
3
Make sure the motorcycle is in neutral or the clutch is in.
Press and hold the starter button to spin the drum. Hold the starter button until
the drum reaches maximum speed then release the starter button.
Use the momentum of the drum to start the bike.
USING THE DYNO
...................................
With the bike properly loaded and secured, you are now ready to begin making runs
and using your dyno. From here you will need to refer to your WinPEP 7 User Guide
for detailed instructions on making and graphing runs.
The WinPEP 7 User Guide can be found on your WinPEP CD or at
www.dynojet.com/manuals.shtml.
PREVENTATIVE MAINTENANCE
...................................
To maintain proper dynamometer operation, Dynojet recommends you make routine
checks of the dyno.
• Drum—keep the drum clean and keep all objects clear of the drum.
• Brake Pads—check the brake pad clearance regularly. Change the brake pads when
they are worn to less than 0.060 inch thick.
• Air Pump Filter—clean the filter daily or more often depending on usage. Change
the filter when necessary.
• Carriage Slide—keep the carriage slide and screw clean and lightly lubricated.
5-4
APPENDIX
A
RED HEAD ANCHOR INSTALLATION
This appendix contains instructions for installing the Red Head Multi-Set™II 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
Always wear safety glasses and other necessary protective devices or apparel
when installing or working with anchors.
ITW Ramset/Red Head Multi-Set II Anchors are designed to operate properly
only when installed with ITW Ramset/Red Head brand Setting Tools.
The use of a 24 to 40 ounce hammer is recommended for expanding Multi-Set II
anchors.
The use of carbide drill bits manufactured with ANSI B94. 12-77 drill bit diameter
requirements is recommended for installation of this anchor.
Not recommended for use in lightweight masonry material such as block or brick.
Use of core drills is not recommended to drill holes for use with this anchor.
Not recommended for use in new concrete which has not had sufficient time to cure.
Anchor spacing and edge distance requirements (anchor installation locations) are
the responsibility of the engineer of record.
CONTACT INFORMATION FOR ITW RAMSET/RED HEAD
Contact ITW Ramset/Red Head at 1-630-350-0370, or 1300 North Michael Drive,
Wood Dale, IL 60191.
A-1
APPENDIXA
Installation
INSTALLATION
...................................
Use the table below to determine the catalog number, drill bit size, minimum hole
depth, and setting tool catalog number.
catalog number
Carbon Steel
RM-38/RL-38 (9.5 mm)
drill bit size
1/2-inch
minimum hole depth
1 5/8-inch (41.2 mm)
setting tool
catalog number
RT-138
Use the following instructions to install the Red Head anchors.
1
Drill the hole in the concrete the same outside diameter as the anchor being used
to any depth exceeding minimum embedment.
Figure A-1: Red Head Anchor—Drill the Hole
2
Insert the anchor.
anchor
Figure A-2: Red Head Anchor—Insert the Anchor
A-2
RED HEAD ANCHOR INSTALLATION
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.
Figure A-3: Red Head Anchor—Drive the Anchor Flush
4
Using a hammer, expand the anchor with the setting tool. The anchor is properly
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 installtion.
setting tool
Figure A-4: Red Head Anchor—Expand the Anchor
Version 2
A-3
APPENDIX
B
POWER REQUIREMENTS—EXCLUDING
NORTH AMERICA
This appendix contains the power requirements and instructions for all locations
excluding North America dyno installations. Refer to page 1-8 for power
requirements and instructions for North America and Japan. To ensure safety and
accuracy in the procedures, perform the procedures as they are described.
B-1
APPENDIXB
POWER REQUIREMENTS AND INSTALLATION
...................................
The model 200i and 250i dynamometers (excluding North America and Japan)
require a dedicated wall receptacle which must be wired for operation and is included
with the dyno. The dyno is equipped with a ten foot power cord with a three-pin IEC
plug pre-wired on the end. The power cord is located at the front of the dyno. Refer
to Figure 1-4 for the location of the power cord.
The dedicated wall receptacle is a three-pin IEC grounded 30A type and must be
wired in accordance with local building codes and requirements. Installation may
require a licensed electrician to conform to applicable safety standards.
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.
• It may be necessary to install a delayed trip breaker due to the inrush current
drawn by the high pressure blowers.
INSTALLING
THE
WALL RECEPTACLE
The wall receptacle is a single 240 volt 30A dedicated circuit with a ground.
The cable carrying the power to this receptacle should be 4.0 mm2 (ten gauge) or
larger. Check with local building codes for the correct size.
1
2
3
Connect one of the 240V legs to the N terminal (white).
Connect the other 240V leg to the L terminal (no color).
Connect the ground conductor to the green terminal.
L terminal
N terminal
(white)
Figure B-1: Wiring the Wall Receptacle
B-2
ground terminal
(green)
POWER REQUIREMENTS—EXCLUDING NORTH AMERICA
TES TING
FOR
CORRECT V OLTAGES
You must test the receptacle for proper voltages before the dyno is connected to the
outlet.
Using a voltmeter that is capable of measuring AC voltage, measure between the
points listed below and verify that the correct voltages are present.
probe 1
1
2
probe 2
3
box
desired voltage measurement
220V to 250V
<5V
3
1
2
Figure B-2: Testing the Wall Receptacle
CONNECTING
1
2
3
4
5
6
Version 2
THE
DYNO
Turn off the main circuit breaker for the dyno. This is the large breaker in the
center of the power distribution assembly behind the door on the left hand side
of the dyno. Refer to Figure 1-4 for breaker location. Off is the down position.
Once you verify the voltages on the receptacle, connect the dyno to the
receptacle.
Connect the high pressure blowers to the dyno. For more information on
installing and connecting the blowers, refer to page 4-38.
Turn on the main dyno breaker. Refer to Figure 1-4 for breaker location.
Test the blowers for operation.
Turn on the dyno electronics and verify operation.
B-3
INDEX
A
accessing dyno electronics 3-6
accessories
air brake 4-4–4-9
air pump and filter assembly 4-11 –4-17
eddy current brake 4-18–4-29
extended carriage 4-30–4-37
high pressure blower 4-38–4-41
monitor tray 4-42–4-43
power carriage 4-44–4-47
safety switch 4-48
air brake 4-4–4-9
adjustments and tests 4-5
brake pads 4-5–4-9
parts list 4-4
air pump and filter assembly 4-11 –4-17
cleaning the filter 4-15
installation 4-12–4-15
parts list 4-12
pump head maintenance 4-16
sensor 4-15
anchor placement
dyno 2-13
eddy current brake 4-27
atmospheric sensing module 3-2
B
battery 1-10, 2-15
battery hazards vi
belleville washers 2-10, 4-35
brake pads 4-5–4-9
breakout board, wiring 4-26
control cable 4-26
jumpers 4-26
temperature sensor 4-26
C
computer cable, routing 2-6
computer specifications 1-10
control cable
routing 2-7
wiring 4-26
conventions 1-3
coupler 4-23
CPU module 3-5
crate
remove dyno 2-12
unpacking dyno 2-2–2-13
unpacking eddy current brake 4-19
D
dimensions 1-6
disclaimers v
document part number 1-1
drum covers
removing 4-2
replacing 2-16, 4-2
dynamometer input/output module 3-4
dyno electronics
accessing 3-6
atmospheric sensing module 3-2
CPU module 3-5
dynamometer input/output module 3-4
RPM module 3-3
E
eddy current brake 4-18–4-29
coupler 4-23
parts list 4-18
right side installation 4-20
routing cables 4-25
theta controller fuses 4-29
unpacking 4-19
wiring breakout board 4-26
electrostatic discharge vi
Index-i
INDEX
ESD precautions vi
exhaust extraction bottles 4-14
extended carriage 4-30–4-37
belleville washers 4-35
installation 4-34
nut block 4-31, 4-33
parts list 4-30
remove tire carriage 4-31
screw support bracket 4-35
shims 4-33
support bracket 4-32
tire lock 4-37
tire stop 4-36
F
filter assembly 4-13
cleaning 4-15
G
grease zerk 4-46
ground hooks 2-21
grounding, equipment v
H
hand crank 2-9
hazards vii
height 1-5
high pressure blower 4-38–4-41
installing arms 4-39
installing blowers 4-40
parts list 4-38
power hookup 4-41
I
Industrial Noise Control, Inc. 1-4
installation requirements
power 1-8, B-2
K
knurl 5-2
L
length 1-5
lifting eyes
dyno 2-12
eddy current brake 4-21
load bike 5-2–5-3
M
manuals, finding on WinPEP cd 4-1
model 200i 1-11
model 250i 1-12
monitor tray 4-42–4-43
parts list 4-42
support arm 2-2, 4-43
motor mount assembly 4-46
Index-ii
N
nut block 2-8, 4-31, 4-33
P
pendant cable, routing 2-6
pickup card 2-14
power 1-8, B-2
connecting the dyno 1-9, B-3
installation 1-8, B-2
requirements 1-8, B-2
testing voltages 1-9, B-3
power carriage 4-44–4-47
flange bearing 4-45
grease zerk 4-46
hand crank 4-44
motor mount assembly 4-46
parts list 4-44
power requirements 4-47
power requirements 1-8, B-2
power carriage 4-47
preventative maintenance 5-4
pump assembly 4-13
pump head maintenance 4-16
R
ramp bracket 2-18–2-20
red head anchor
contact information A-1
installation A-2
setting tool A-3
warnings A-1
requirements 1-8–1-10, B-2–B-3
battery 1-10
computer specifications 1-10
phone and internet access 1-10
tie down straps 1-10
routing cables
brake power 4-25
computer 2-6
control 2-7, 4-25
pendant 2-6
starter 2-6
temperature sensor 4-25
RPM module 3-3
S
safety switch 4-48
extended carriage 4-35
sensor, air pump 4-15
setting tool A-3
specifications 1-5
starter 5-4
starter cable, routing 2-6
support arm 4-43
remove from crate 2-2
T
technical support 1-3
testing voltages 1-9, B-3
theta controller
installation 2-7
replace fuses 4-29
route control cable 2-7
tire carriage 5-2
belleville washers 2-10
hand crank 2-9
nut block 2-8
remove from crate 2-2
tire lock 2-11
tire stop 2-11
tire lock 2-11, 4-37
tire stop 2-11, 4-36
W
warnings v
weight 1-5
width 1-5
WinPEP
finding manuals on 4-1
using the dyno 5-4
wiring breakout board
control cable 4-26
jumpers 4-26
temperature sensor cable 4-26
Y
your dyno room 1-3
cooling fan 1-3
equalizer box 1-3
exhaust extraction 1-4
noise control 1-4
Version 2
Index- iii

c hapter 2

Transcription

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