Dynajet 200iP User manual

©2004-2011 Dynojet Research, Inc. All Rights Reserved.
Installation Guide For In Ground Model 200iP and 250iP 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 89081, USA.
Printed in USA.
Part Number: 98229103 Version 4 (03/2011)
#
RECORD
Dynamometer Number: ____________________________________________________
Eddy Current Brake
(Retarder) Number:_________________________________________________________

In Ground Model 200iP/250iP Motorcycle Dynamometer Installation Guide i
T ABLE OF C ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Chapter 1 Specifications and Operating Requirements
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Confirmation of Compliance Testing and Certification . . . . . . . . . . . . . . . . 1-3
Your Dyno Room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . .1-5
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Verify the Pit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Chapter 2 Installation
Dyno Drum Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Unpacking the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Placing the Dyno in the Pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

In Ground Model 200iP/250iP Motorcycle Dynamometer Installation Guide
TABLE OF CONTENTS
ii
Secure the Drum and Brake Module to the Pit Floor . . . . . . . . . . . . . . . .2-16
Pickup Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Carriage Plate and Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Installing the Carriage Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Installing the Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
Blower and Monitor Support Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Mark and Drill Blower Mounts and Support Arm Mounting Holes . . . . . . 2-22
Installing the Monitor Support and Junction Box . . . . . . . . . . . . . . . . . . . 2-23
Installing the Blower Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Installing the Monitor Arms and Monitor Tray . . . . . . . . . . . . . . . . . . . . . 2-25
Cable Track Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Routing Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
Battery Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-30
Accessing the CPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Routing the Control Panel and Pendant Cables . . . . . . . . . . . . . . . . . . . .2-32
Routing the High Pressure Blower Cables . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Routing the Power Carriage and Wheel Clamp Cables . . . . . . . . . . . . . . .2-37
Routing the Eddy Current Brake, Battery, and Dyno Power Cables . . . . . . 2-38
Routing the Pickup Card and Dyno Electronics Cables . . . . . . . . . . . . . . .2-40
Routing the Air Pump Power, Air Fuel Sensor, and Dyno Electronics
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
Wiring the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
Power Carriage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
Tire Stop Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Turning On the Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
High Pressure Blower Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47
Power Carriage Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . .2-47
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-48
Changing the Eddy Current Brake Cover for Right Side Installations . . . . .2-48
Installing the Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-50
Junction Box Cover, Cable Cover, and End Cap . . . . . . . . . . . . . . . . . . .2-55
Zip Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-56
Chapter 3 Accessories
Main Dyno Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Routing the Air Brake Cable and Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Installing the Emergency Stop Sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Air Brake Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Changing the Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Compressed Air Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Installing the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Wheel Clamp Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . 3-20

TABLE OF CONTENTS
Version 4 In Ground Model 200iP/250iP Motorcycle Dynamometer Installation Guide
iii
Chapter 4 Control Panel Interface Operation
Basic CPI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Using the Air Fuel Ratio Air Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Using the Emergency Stop/Dyno Shutdown . . . . . . . . . . . . . . . . . . . . . . . 4-4
Using the High Pressure Blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Understanding Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Using the Power Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Using the Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Using the Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Using the Wheel Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Power Distribution Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Main Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
High Pressure Blower Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Maintenance and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Maintaining and Troubleshooting the Wheel Clamp . . . . . . . . . . . . . . . . .4-9
Replacing the Theta Controller Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Troubleshooting CPI Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Chapter 5 Basic Dyno Operation
Loading the Motorcycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Connecting the Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . 5-8
Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13
Appendix A Red Head Anchor Installation
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . .A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Appendix B Power Requirements and Installation
Locations Using 60 Hz Power (North America and Japan) . . . . . . . . . . . .B-2
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

In Ground Model 200iP/250iP Motorcycle Dynamometer Installation Guide
TABLE OF CONTENTS
iv
Locations Using 50 Hz Power
(Locations other than North America and Japan) . . . . . . . . . . . . . . . . . . . .B-7
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
Replacing the Power Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Connecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
Appendix C EEC Finger Guard and Door Safety
Switch Installation
EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
Adjusting the EEC Finger Guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3
Door Safety Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Installing the Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-4
Appendix D Theta Controller
Power Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Accessing the Dip Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i

In Ground Model 200iP/250iP Motorcycle Dynamometer Installation Guide v
W ARNINGS
Disclaimers
Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the contents
hereof and specifically disclaims any implied warranties of merchantability for any particular purpose.
Dynojet reserves the right to revise this publication and to make changes from time to time in the
content hereof without obligation of Dynojet to notify any person of such revision or changes.
Dynojet is not responsible for false operation due to unexpected dynamometer operation such as may
be caused by static, software bugs, hardware failure, etc.
Dynojet is not responsible for damage resulting from improper installation of the dynamometer or
from improper service rendered to the dynamometer. Dynojet is not responsible for damage incurred
due to alteration of the dynamometer or components, use of unapproved parts, or abuse to the
dynamometer.
Do not connect or disconnect cables or components on the dynamometer with the power on.
Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when
using and servicing the dynamometer.
Equipment Power Requirements
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.
Potentially Lethal Voltages
Components attached to and within the dynamometer operate with potentially lethal voltages. To
provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power
source before servicing electrical components or wiring. Disconnect all power cords before servicing
electrical components for the greatest assurance of safety.

In Ground Model 200iP/250iP Motorcycle Dynamometer Installation Guide
WARNINGS
vi
Electrostatic Discharge Precautions
Electrostatic Discharge
Electrostatic Discharge (ESD), or static shock, can damage electronic components within the
dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade
the component, resulting in a premature component failure later. To avoid ESD damage, always
practice good ESD control precautions when servicing the dynamometer. Dynojet designs its
dynamometers to be very tolerant of static shocks by the users, but the electronics are vulnerable when
the electronics are exposed. ESD occurs as a result of a difference of potential between two objects
when the two objects touch. Damage occurs as a result of the energy released when the discharge
(touch) occurs. The difference of potential can accumulate by as simple an action as a user moving
across carpet or a seat. If that person’s energy is discharged directly to the electronics, the electronics
can be damaged.
Precautions
To protect against ESD damage, you must eliminate the difference of potential before the electronics
are handled. Touch the chassis of the dynamometer before touching any of the electronics. By touching
the chassis, you discharge any static shocks to the chassis instead of to the electronics.
If you are holding a circuit board or dynamometer component in your hand when you approach the
machine, touch the chassis of the dynamometer with your hand before installing the circuit board or
component.
When handing a circuit board or component to someone, touch that person with your hand first, then
hand them the component.
Always carry circuit boards in anti-static bags when the boards are exposed (removed from the
dynamometer).
Battery Fire and Explosion Hazards
There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Discard used batteries according to the
manufacturer’s instructions.
Automotive Batteries
In operation, batteries generate and release flammable hydrogen gas. They must always be assumed
to contain this gas which, if ignited by burning cigarette, naked flame or spark, may cause battery
explosion with dispersion of casing fragments and corrosive liquid electrolyte. Carefully follow
manufacturer's instructions for installation and service. Keep away all sources of gas ignition and do
not allow metallic articles to simultaneously contact the negative and positive terminals of a battery.
Do not allow the positive and negative terminals to short-circuit. The dynamometer chassis is tied to
the negative side of the battery. Do not short between the positive battery terminal or the starter
connections to the chassis. In addition, make sure metal tools such as screw drivers, wrenches, and
torque wrenches do not come in contact with the negative and positive terminals of the battery. Short
circuiting the terminals of the battery can cause burn injuries, damage to the dynamometer, or trigger
explosions.
Charging
Batteries being charged will generate and release flammable hydrogen gas. Charging space should be
ventilated. Keep battery vent caps in position. Prohibit smoking and avoid creation of flames and sparks
nearby.
Wear protective clothing, eye and face protection, when charging or handling batteries.

WARNINGS
Version 4 In Ground Model 200iP/250iP Motorcycle Dynamometer Installation Guide
vii
Other Potential Hazards
The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for
disconnect before service.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Any dyno room design must incorporate sufficient exhaust extraction.
Always wear proper ear and eye protection when operating the dynamometer.
Never operate the dynamometer with the covers removed.
Never stand behind the dynamometer when in operation.
Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems
before proceeding.
Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured to the dynamometer.
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.