2008 Dynojet Research, Inc. All Rights Reserved. Model 200iPX/250iPX Upgrade Installation Guide

Transcription

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2 2008 Dynojet Research, Inc. All Rights Reserved. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, as well as the software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license. This manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Dynojet. Dynojet assumes no responsibility or liability for any error or inaccuracies that may appear in this manual. Except as permitted by such license, no part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Dynojet. The Dynojet logo is a trademark of Dynojet Research, Inc. Any trademarks, trade names, service marks, or service names owned or registered by any other company and used in this guide are the property of their respective companies. Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA. Printed in USA. Part Number: Version 01 (03/2008)

3 TABLE OF CONTENTS Warnings iii Chapter 1 Model 200iPX/250iPX Upgrade Introduction Conventions Used In This Manual Technical Support Confirmation of Compliance Testing and Certification Model 200iPX/250iPX Upgrade Specifications Chassis Specifications Verify the Pit Dimensions Dyno Preparation Disconnecting the Power Removing the Cable Cover, End Cap, and Junction Box Cover Removing the Right Side Drum Cover Removing the Monitor Tray and Arms Disconnecting the Cable Track and Moving the Cables Removing the Monitor Support and Junction Box Installing the Monitor Support and the Junction Box on the Left Side Installing the Junction Box Cover, End Cap, and Cable Cover Installing the Monitor Arms, Monitor Tray, and Left Blower Assembly Drum Installation Removing the Items from Crate Installing the ipx Drum Module Installing the Right Blower Mount and Blower Assembly Pit Cover Installation Ground Hook Installation i

4 TABLE OF CONTENTS Chapter 2 Basic Dyno Operation Loading the Vehicle Connecting the RPM Pickup RPM Pickup Descriptions Connecting the Secondary Inductive Pickup Connecting The Primary Inductive Pickup Pre-Run Inspection Before Starting the Engine Engine Warm Up After Engine Warm Up Making a Test Run Preventative Maintenance Appendix A Red Head Anchor Installation Installation A-2 Index Index-i ii

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

6 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. 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. iv

7 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. 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. Version 1 v

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9 C HAPTER 1 MODEL 200IPX/250IPX UPGRADE Thank you for purchasing the 200iPX/250iPX upgrade for Dynojet s Model 200iP/250iP Motorcycle Dynamometer. This upgrade will allow you to run a kart, ATV, or trike on your 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 200iPX/250iPX upgrade to Dynojet s Model 200iP/250iP Motorcycle Dynamometer (dyno). This document will walk you through the installation and basic dyno operation. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: Version 1 Last Updated: This section is divided into the following categories: Introduction, page 1-2 Model 200iPX/250iPX Upgrade Specifications, page 1-3 Verify the Pit Dimensions, page 1-6 Dyno Preparation, page 1-7 Drum Installation, page 1-17 Pit Cover Installation, page 1-23 Ground Hook Installation, page

10 CHAPTER 1 Introduction INTRODUCTION Before installing your 200iPX/250iPX upgrade, please take a moment to read this guide for installation instructions, dyno features, and other important information. CONVENTIONS USED IN THIS MANUAL 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 , or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV Visit us on the World Wide Web at where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product lines. CONFIRMATION OF COMPLIANCE TESTING AND CERTIFICATION Dynojet Model 200iP, 200iPX, 250iP, and 250iPX dynamometers have been tested to NFPA 79:2002 and UL 508(A) standards and pass the requirements. Certificate Number: US

11 MODEL 200IPX/250IPX UPGRADE Model 200iPX/250iPX Upgrade Specifications MODEL 200IPX/250IPX UPGRADE SPECIFICATIONS The following specifications and requirements will help you set up your dyno area for the 200iPX/250iPX upgrade. Refer to the model 200iP/250iP installation guide for specifications and requirements for the bike dyno. CHASSIS SPECIFICATIONS description Length dyno with standard carriage dyno with extended carriage ipx drum module pit covers Height from bottom of dyno to top of dyno from top of pit to drum guard from top of pit to top of tire carriage Width dyno with upgrade pit covers Weight 200iPX/250iPX drum module/crated Drum diameter, 200iPX/250iPX upgrade width, 200iPX/250iPX upgrade Frame Maximum Speed Maximum Motorcycle Length (front of front wheel to center of rear wheel) standard carriage extended carriage Remote Switches specifications allow cm ( in.) allow cm ( in.) cm (30.00 in.) cm (54.00 in.) cm ( in) 5.40 cm (2.13 in) cm (16.00 in) cm ( in) cm ( in) 136 kg (300 pounds)/363 kg (800 pounds) cm (18.00 inches) cm (22.00 inches) structural steel 322 KPH (200 MPH) 213 cm (84.00 inches) cm ( inches) remote software control Version 1 1-3

12 CHAPTER 1 Model 200iPX/250iPX Upgrade Specifications Figure 1-1: Model 250iPX Dyno Dimensions 1-4

13 MODEL 200IPX/250IPX UPGRADE Model 200iPX/250iPX Upgrade Specifications Monitor Support and Tray Control Panel Wheel Clamp Option Control Panel Interface houses all electronics (not shown) Power Carriage Option High Pressure Blower Eddy Current Brake Model 250iP Dyno Module ipx Drum Module Air Brake Option (not shown) Air Pump Option (not shown) Figure 1-2: Model 250iPX Dyno with Accessories Version 1 1-5

14 CHAPTER 1 Verify the Pit Dimensions VERIFY THE PIT DIMENSIONS Before placing the dyno in the pit, take a moment to verify that the dimensions of the pit are correct. Refer to the pit dimensions (P/N ) you received from your salesman for more detailed specifications. pit depth: cm (18.00 in) pit length: cm ( in) pit width: cm (48.00 in) Figure 1-3: Verify the Pit Dimensions 1-6

15 MODEL 200IPX/250IPX UPGRADE Dyno Preparation DYNO PREPARATION Use the following instructions to prepare the dyno for installing the upgrade kit. If your monitor stand is installed on the right side of the dyno, you will need to use the following instructions to move it to the left side of the dyno. DISCONNECTING THE POWER Use the following steps to connect and disconnect power to the dyno. Always turn the power off when connecting and disconnecting cables. 1 Use the main breaker to turn power on and off to the dyno. The main breaker is located inside the CPI door. When the handle is in the down position all power into the dyno is turned off. 2 Disconnect the power plug to ensure all power has been removed from the dyno before performing certain installation procedures. PD025 power plug main breaker Figure 1-4: Main Dyno Power Version 1 1-7

16 CHAPTER 1 Dyno Preparation REMOVING THE CABLE COVER, END CAP, AND JUNCTION BOX COVER If your monitor stand is mounted on the left side of your dyno, skip to Removing the Right Side Drum Cover on page If this is a new dyno installation, skip to Installing the Monitor Support and the Junction Box on the Left Side on page Remove the four 8-32 screws securing the cable cover to the end cap and one 8-32 screw securing the cable cover to the junction box and set aside. 2 Remove the cable cover and set aside. 3 Remove the two 1/4-20 button-head screws securing the end cap to the pit cover and set aside. 4 Remove the end cap and set aside. end cap cable cover PD042 Figure 1-5: Remove the Cable Cover and End Cap 1-8

17 MODEL 200IPX/250IPX UPGRADE Dyno Preparation 5 Remove the two 8-32 screws securing the junction box cover and set aside. 6 Remove the junction box cover and set aside. junction box cover Figure 1-6: Remove the Junction Box Cover Version 1 1-9

18 CHAPTER 1 Dyno Preparation REMOVING THE RIGHT SIDE DRUM COVER 1 Remove the four 3/8-16 x 1/2-inch button-head flange screws securing the right side drum cover to the dyno and set aside. 2 Remove the four 1/4-20 x 1/2-inch button-head flange screws securing the right side drum cover to the drum guard bracket and set aside. 3 Remove the right side drum cover and discard. This cover will be replaced. 4 Remove the four 3/8-16 x 1/2-inch button-head flange screws securing the middle drum cover to the dyno and set aside. Note: You do not need to remove the cover. Removing the screws will allow the cables to be routed under this cover later. right side drum cover middle drum cover Figure 1-7: Remove the Right Side Drum Cover 1-10

19 MODEL 200IPX/250IPX UPGRADE Dyno Preparation REMOVING THE MONITOR TRAY AND ARMS If your monitor stand is mounted on the left side of your dyno, skip to Drum Installation on page Disconnect any cables to the control panel along with any other cables you may have attached to the monitor arms and monitor tray. Refer to the model 200iP/250iP installation guide for more information. 2 Remove the monitor tray and set aside. 3 Remove each arm and the washers and set aside. monitor tray poly washer second arm poly washer first arm poly washer support arm Figure 1-8: Remove the Monitor Tray and Arms Version

20 CHAPTER 1 Dyno Preparation DISCONNECTING THE CABLE TRACK AND MOVING THE CABLES 1 Remove the 1/4-20 screw securing the cable track bracket to the wheel clamp and move the cable track aside. Replace this screw in the wheel clamp. 2 Remove the two 4-40 screws securing the wheel clamp cable track bracket to the cable track. 3 Flip the wheel clamp cable track bracket over and secure to the cable track using the two 4-40 screws removed earlier. 4 Remove the two 8-32 screws securing the cable track bracket to the junction box and set aside. 5 Lift the cable track and the two cables and place on the left side of the tire carriage. 6 Remove the two screws securing each blower connector to the junction box and set aside. 7 Pick up the blower connectors and cables and move to the left side of the carriage. Note: Be sure to make note which is the left blower connector and which is the right blower connector. cable track bracket junction box wheel clamp wheel clamp cable track bracket blower connectors Figure 1-9: Remove the Cable Track and Blower Connectors 1-12

21 MODEL 200IPX/250IPX UPGRADE Dyno Preparation REMOVING THE MONITOR SUPPORT AND JUNCTION BOX 1 Remove the left blower assembly if installed. 2 Remove the four 3/8 x 1-inch bolts and four washers securing the left blower mount and set aside. Do not remove the blower mount. 3 Remove the right blower assembly. 4 Remove the four 3/8 x 1-inch bolts and four washers securing the support arm and junction box to the pit floor and set aside. 5 Remove the junction box and set aside. 6 Remove the support arm and move to the left blower mount. 7 Set the right blower mount aside. This will be installed in a new location. blower mount PD039 support arm junction box right blower mount (under support arm) Figure 1-10: Remove the Monitor Stand and Junction Box Version

22 CHAPTER 1 Dyno Preparation INSTALLING THE MONITOR SUPPORT AND THE JUNCTION BOX ON THE LEFT SIDE 1 Secure the support arm and junction box to the pit floor using the four 3/8 x 1-inch blots and four washers removed earlier. Note: The left blower mount is secured under the support arm. 2 Remove the blank plate on the junction box and secure it in the location shown in Figure Route the blower cables through the junction box and secure the blower connectors to the junction box using the screws removed earlier. 4 Secure the cable track bracket to the junction box using the two 8-32 screws removed earlier. 5 Remove the bottom left screw from the wheel clamp and secure the wheel clamp cable track bracket to the wheel clamp. blank plate fan connectors support arm junction box blower mount (under support arm) Figure 1-11: Install the Junction Box and Monitor Support 1-14

23 MODEL 200IPX/250IPX UPGRADE Dyno Preparation INSTALLING THE JUNCTION BOX COVER, END CAP, AND CABLE COVER 1 Remove the four screws securing the cable routing cover to the middle drum cover. Set the screws and the cover aside. 2 Route all the cables under the middle drum cover and through the cable routing opening as shown in Figure Replace the four 3/8-16 x 1/2 button-head flange screws removed earlier from the middle drum cover. 4 Route the cables through the junction box. 5 Secure the junction box cover to the junction box using the two 8-32 screws removed earlier. 6 Secure the end cap to the pit cover using the two 1/4-20 button-head screws removed earlier. 7 Secure the cable cover to the end cap using the four 8-32 screws removed earlier. 8 Secure the cable cover to the junction box cover using one 8-32 screw removed earlier. Note: Verify the cables are placed inside the cable cover. cable cover junction box cover end cap cable routing opening middle drum cover Figure 1-12: Install the Junction Box Cover, End Cap, and Cable Cover Version

24 CHAPTER 1 Dyno Preparation INSTALLING THE MONITOR ARMS, MONITOR TRAY, AND LEFT BLOWER ASSEMBLY 1 Replace the monitor arms, washers, and tray. 2 Connect the cables removed earlier to the control pod and monitor arms. Refer to the model 200iP/250iP installation guide for more information. 3 Replace the left blower assembly. Note: The right blower assembly will be installed later. 4 Remove the two 1/4-20 screws securing the upright bar and set aside. 5 Remove the upright and set aside. Note: The upright bar will be installed on the ipx drum module later. tray arms washers washer monitor support left blower assembly upright bar Figure 1-13: Installing the Monitor Arms, Monitor Tray, and Left Blower Assembly 1-16

25 MODEL 200IPX/250IPX UPGRADE Drum Installation DRUM INSTALLATION When you receive your ipx upgrade kit, 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 drum and items. You will need to provide equipment capable of lifting a minimum of 363 kg (800 lb.) to move the crated drum into position in your dyno room. REMOVING THE ITEMS FROM CRATE 1 Move the crate to a clear area near your dyno room. 2 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the top and sides of the crate. 3 Remove the following parts from the crate and set aside. part description part description drum guard mounting bracket P/N pit cover, middle P/N drum safety cover P/N pit cover, right P/N drum guard (2) P/N retarder driveline assembly P/N screw, 1/4-20 x 5/8", panhead, torx (12) P/N drum module, pit P/N bolt, 3/8-16 x 1/2", buttonhead, flange, allen (6) P/N ground hook kit (4) P/N see list of parts below Version

26 CHAPTER 1 Drum Installation part description part description woodruff key, 3/8 x 1-3/8" P/N nut, crush, 1/4-20 (4) P/N DM The following parts are included in the Ground Hook Kit P/N : ground hook/d-ring (4) P/N anchor, redhead, 3/8" (8) P/N D-ring bracket, surface mount (4) P/N washer, 5/16", flat (8) P/N DM washer, 3/8", splitlock, steel (8) P/N bolt, 3/8-16 x 1", hex (8) P/N DM Remove the crate braces that support the top portion of the crate. 5 Remove the four lag bolts and washers securing the drum to the crate base using a 9/16-inch socket, open or box end wrench. 1-18

27 MODEL 200IPX/250IPX UPGRADE Drum Installation INSTALLING THE IPX DRUM MODULE You will need the following parts: Woodruff Key (2) Driveline Assembly ipx Drum Module 1 Place the nylon loop strap around the shaft on either side of the drum module. 2 Using a forklift, lift the drum module from the crate and place the drum module in the pit with the stepped end of the shaft towards the dyno. Make sure the panels on the drum module and the dyno are parallel. 3 Remove the two existing screws from each side of the dyno frame where the connector plates will attach. 4 Insert the woodruff key into the keyway on the drum module shaft. 5 Insert the woodruff key into the keyway on the dyno shaft. 6 Slide the driveline over the key on the drum module shaft. 7 Keeping the panels parallel, slide the drum module towards the dyno. Slide the driveline over the key on the dyno shaft. You will need to support the driveline as you slide it onto the dyno shaft. 8 Continue sliding the drum module towards the dyno until the side panels on the drum module and the dyno are flush. woodruff key existing screws woodruff key ipx drum module existing screws driveline Figure 1-14: Install the Driveline and the Drum Module Version

28 CHAPTER 1 Drum Installation 9 Secure the connector plate on either side of the ipx drum module to the dyno drum module using the bolts removed earlier. 10 Loosen the four bolts on either side of the ipx drum module as shown in Figure Align the ipx drum module panels until they are flush with the top of the pit floor and the dyno drum module panels. 12 Once you have verified the panels are flush and parallel, tighten all the screws. 13 Tighten the driveline set screws. Note: Dynojet recommends using red loctite on the set screws. 14 Install upright bar removed earlier to the side of the ipx drum module using the two 1/4-20 screws removed earlier. dyno drum module panel ipx drum module panel upright bar secure connector plate loosen these bolts on both sides of ipx drum module Figure 1-15: Install the Drum Module to the Dyno 1-20

29 MODEL 200IPX/250IPX UPGRADE Drum Installation INSTALLING THE RIGHT BLOWER MOUNT AND BLOWER ASSEMBLY You will need the following parts: Anchor, Redhead, 3/8" (4) Blower Extension Cord DM Washer, 5/16", Flat (4) DM Bolt, 3/8-16 x 1", Hex (4) 1 Mark the right blower mount placement as shown in Figure Using the blower mount as a template, mark and drill the four holes needed to secure the blower mount to the floor. 3 Install the Red Head anchors. Refer to Appendix A for installation instructions. 4 Secure the blower mount to the floor using four 3/8-16 x 1-inch hex bolts and four 5/16-inch flat washers. right blower mount Figure 1-16: Install the Right Blower Mount Version

30 CHAPTER 1 Drum Installation 5 Place two 1/4-inch thick poly washers around the pin on the tie-down without the monitor arm. 6 Place the lower blower arm over the pin. 7 Place an aluminum washer between the clamp lever and the lower blower arm. 8 Secure the lower blower arm to the tie-down pin using the clamp lever. 9 Place a 1/8-inch thick poly washer around the pin on the upper blower arm. 10 Insert the pin on the upper blower arm into the lower blower arm. 11 Place a 1/8-inch thick poly washer around the pin on the blower. 12 Insert the pin on the blower into the upper blower arm. 13 Plug the power cord from the blower into the supplied blower extension cord (P/N ) and into the power source located on the junction box. Note: This extension cord is only used with the blower mounted on the right side of the dyno. The blowers can run at any time once the cord is plugged into a power source. plug power cord from blower into junction box right blower assembly upper blower arm clamp lever aluminum washer lower blower arm 1/4-inch thick poly washer Figure 1-17: Install the Right Blower Assembly 1-22

31 MODEL 200IPX/250IPX UPGRADE Pit Cover Installation PIT COVER INSTALLATION Use the following instructions to install the pit covers. You will need the following parts: Drum Guard Mounting Bracket Drum Safety Cover Drum Guard (2) Screw, 1/4-20 x 5/8", Pan-Head, Torx (12) Bolt, 3/8-16 x 1/2", Button-Head, Flange, Allen (6) Middle Pit Cover Right Pit Cover DM Nut, crush, 1/4-20 (4) 1 Loosely install the drum guard mounting bracket to the underside of the middle pit cover using four 1/4-20 x 5/8-inch pan-head torx screws. pit cover drum guard mounting bracket Figure 1-18: Install the Drum Guard Mounting Bracket Version

32 CHAPTER 1 Pit Cover Installation 2 Loosely install the middle pit cover to the dyno drum guard mounting bracket using four 1/4-20 x 1/2-inch screws removed earlier. 3 Place the middle pit cover on the dyno drum module uprights and align the middle pit cover with the existing dyno pit cover. 4 Loosely install the middle pit cover to the dyno drum module uprights using the four 3/8-16 x 1/2-inch screws removed earlier. 5 Loosely install the middle pit cover to the ipx drum module uprights using two 3/8-16 x 1/2-inch button-head flange screws. middle pit cover Figure 1-19: Install the Middle Pit Cover to the Dyno and ipx Drum Module 1-24

33 MODEL 200IPX/250IPX UPGRADE Pit Cover Installation 6 Place the right pit cover on the ipx drum module uprights and align the right pit cover with the middle pit cover. 7 Loosely install the right pit cover to the drum guard mounting bracket using four 1/4-20 x 5/8-inch pan-head torx screws. 8 Loosely install the right pit cover to the ipx drum module uprights using four 3/8-16 x 1/2-inch button-head flange bolts. 9 Center the drum guard mounting bracket over the drum. Verify the drum does not contact the mounting bracket. 10 Tighten all screws. right pit cover Figure 1-20: Install the Right Pit Cover to the ipx Drum Module Version

34 CHAPTER 1 Pit Cover Installation 11 Install each drum guard to the drum guard mounting bracket using four 1/4-20 x 5/8-inch pan-head torx screws and four 1/4-20 nuts. Note: Verify the drum does not contact the drum guards. drum guards Figure 1-21: Install the Drum Guards 1-26

35 MODEL 200IPX/250IPX UPGRADE Pit Cover Installation 12 Place the drum safety cover over the drum. This cover has two pins to keep it in place. Risk of injury. Never run a motorcycle on the dyno without this cover in place. drum safety cover Figure 1-22: Install the Drum Safety Cover Version

36 CHAPTER 1 Ground Hook Installation GROUND HOOK INSTALLATION Using Figure 1-23 as a guide, place the ground hooks in a location that works best for your dyno application. You will need the following parts: Ground Hook/D-Ring (4) D-Ring Bracket (4) Washer, 3/8", Splitlock, Steel (8) Anchor, Redhead, 3/8" (8) DM Washer, 5/16", Flat (8) DM Bolt, 3/8-16 x 1", Hex (8) 1 Using the ground hook as a template, mark and drill each hole needed to secure the ground hooks to the floor. 2 Install the Red Head anchors. Refer to Appendix A for installation instructions. 3 Secure each ground hook to the floor using two 3/8-16 x 1-inch hex bolts, two 5/16-inch flat washers, and two 3/8 lock washers. Figure 1-23: Ground Hook Placement 1-28

37 C HAPTER 2 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 WinPEP CD or at This chapter is divided into the following categories: Loading the Vehicle, page 2-2 Connecting the RPM Pickup, page 2-4 Pre-Run Inspection, page 2-7 Making a Test Run, page 2-9 Preventative Maintenance, page

38 CHAPTER 2 Loading the Vehicle LOADING THE VEHICLE Use the following steps to load a vehicle on the dyno. For detailed information on loading a motorcycle on the dyno, refer to your motorcycle dyno installation guide. Risk of injury. Always wear proper eye and ear protection when operating the dyno. 1 Verify your computer is running. Set the dyno brake on by pressing the red button on the hand held pendant. 2 Turn the carriage screw handle (or use the control panel to run the power carriage) until the carriage is all the way out. 3 Drive the vehicle onto the dyno and align the vehicle straight with the dyno. 4 Stop the vehicle when the drive axle is centered on the drum. adjust carriage all the way out center drive axle on dyno drum Figure 2-1: Loading the Vehicle 2-2

39 BASIC DYNO OPERATION Loading the Vehicle 5 When the vehicle is positioned properly on the dyno, shut the engine off. If the vehicle has an automatic transmission, place it in park. If the vehicle has a manual transmission, place it in gear. 6 Attach two tie-down straps from the ground hooks to the rear of the vehicle. 7 Attach two tie-down straps from the ground hooks to the front of the vehicle. Note: If you are running an all wheel drive ATV, use differential jacks to get the front wheels off the dyno. Note: When running an ATV, you may need to increase the tire pressure so the tire does not come in contact with the decking. 8 Tighten the four tie-down straps evenly making sure the drive wheels remain centered on the drum. Never perform a dyno run if the tie-down straps are not in place or they are damaged. Figure 2-2: Loading the Vehicle Top View Version 1 2-3

40 CHAPTER 2 Connecting the RPM Pickup CONNECTING THE RPM PICKUP Your Dynojet dynamometer includes a primary wire inductive pickup and two secondary wire inductive pickups. These small clothespin like inductive pickups are used to sense RPM. An RPM pickup is required if you want to view torque graphs. Generally you will use one secondary wire inductive pickup on a spark plug wire. Vehicles with wasted spark ignition systems may require two secondary inductive pickups. On a wasted spark ignition, typically one coil will be connected to two spark plug wires. Attach one secondary pickup to each of these wires. If the pickups are connected to two plug wires that do not fire at the same time, an erratic RPM readout may occur. The primary wire inductive pickup senses RPM pulses from the coil. Although this pickup location generally works better, it is harder to find the correct location to connect the RPM pickup. Note: If a pickup is not being used, disconnect it from the dyno electronics to prevent any stray pick up of signals. Inductive pickups are very fragile. The ferrite core can easily be damaged and is not covered under warranty. Dropping, snapping, vibration, and heat can all damage the ferrite core. The dyno electronics RPM module contains the electronics that sense the RPM pulses. An auto-gain circuit looks at only the peak voltage of the vehicle s spark, ignoring the lower voltages to help reduce electronic noise problems. Wasted spark ignition systems will produce a lower voltage level on the exhaust stroke than the compression stroke. By definition of the auto-gain circuit, lower voltage spark levels will be ignored, missing every other spark the vehicle would produce. RPM PICKUP DESCRIPTIONS RPM pickup Secondaries (Non- wasted spark system) Secondaries (Wasted spark ignition system) Primary pickup description Use one secondary pickup. Unplug the other pickup from the RPM module and set the degrees between plug fires to 720 in WinPEP 7. Use two secondary pickups. Attach one pickup on each spark plug wire on the same coil and set the degrees between plug fires to 360 in WinPEP 7. Attach the primary wire pickup to the primary side of the coil. Set the degrees between plug fires by taking 720 (four cycle engines) or 360 (two cycle engines) divided by the number of coils. For example, the number of degrees between plug fires on a four cylinder four cycle engine with dual coils (where each coil fires two cylinders) is 720/4 x 2 =

41 BASIC DYNO OPERATION Connecting the RPM Pickup CONNECTING THE SECONDARY INDUCTIVE PICKUP The secondary inductive pickup cannot be in contact with, or it s connecting wire be crossing, other engine electrical wires or stray RF interference may result. The inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration. Do not drop the inductive pickup or snap the pickup closed. Use extreme care in handling and placement of the pickups. 1 Clip the secondary inductive pickup around one spark plug wire. Note: On a wasted spark ignition system, two secondary inductive pickup wires may be needed. 2 Route the inductive pickup cable clear of devices that produce electronic noise (spark plug wires, coil wire, coil etc.) to the dyno electronics RPM module. Note: Inductive pickup placement is important. Position the inductive pickup so that it is not making contact with any other spark plug wires. Separate the spark plug wire from the spark plug wire bundle for proper operation. Note: You must ground the vehicle to the dyno for the electronics to function properly. coil connect secondary inductive pickup on the coil wire Figure 2-3: Connecting the Secondary Inductive Pickup connect secondary inductive pickup on the coil wires coil Figure 2-4: Connecting the Secondary Inductive Pickup Version 1 2-5

42 CHAPTER 2 Connecting the RPM Pickup CONNECTING THE PRIMARY INDUCTIVE PICKUP The primary inductive pickup cannot be in contact with, or it s connecting wire be crossing, other engine electrical wires or stray RF interference may result. The inductive pickups contain a fragile Ferrite Core that is sensitive to engine heat and vibration. Do not drop the inductive pickup or snap the pickup closed. Use extreme care in handling and placement of the pickups. 1 Clip the primary inductive pickup around the wire to the primary side of the coil. 2 Route the primary wire cable clear of devices that produce electronic noise to the dyno electronics RPM module. Note: You must ground the vehicle to the dyno for the electronics to function properly. coil connect primary inductive pickup on the negative side of the coil Figure 2-5: Connecting the Primary Inductive Pickup 2-6

43 BASIC DYNO OPERATION Pre-Run Inspection PRE-RUN INSPECTION Perform a vehicle inspection before making a run. Check the following: Check the radiator coolant (if applicable) and oil levels. Check the fuel source. Rotate the drum and check for rocks caught in the tire tread that could fly out. For motorcycles, check the chain and the chain master link. Make sure it is lubricated and adjusted to the proper tension. Check the tire pressure and tire speed rating. Improperly inflated tires or exceeding the maximum speed rating can result in premature wear or severe tire damage. Make sure the tire has no major deficiencies (cracks in sidewalls, tread life, etc.). Note: When running an ATV, you may need to increase the tire pressure so the tire does not come in contact with the decking. Visually inspect the vehicle. Make sure it is in safe running order. Make sure ear protection and safety glasses are used when the dyno is being operated. Check the tie-down straps to make sure that they are tight and secured. Check the drive tires to be sure that they are aligned correctly on the dynamometer s drums. Keep all rotating components clear at all times. Only the operator should be near the dyno or the vehicle during the test. Never allow any person(s) to stand behind the dyno or vehicle when it is being operated. Perform any other safety inspections appropriate to running your vehicle on the dyno. Never allow any person(s) to stand behind the dyno or vehicle when it is being operated. Only the operator should be near the dyno or the vehicle during the test. Version 1 2-7

44 CHAPTER 2 Pre-Run Inspection BEFORE STARTING THE ENGINE Connect an exhaust hose or hoses (if dual exhaust) on the vehicle, make sure the hose fits over the tail pipe, is not plugged or kinked and the hose is vented correctly out of the dyno room. Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death. Operate machine in well ventilated area. ENGINE WARM UP Warm the vehicle s engine and drivetrain before beginning testing. Consistent engine temperatures will assure your runs are repeatable. AFTER ENGINE WARM UP Always leave the vehicle in neutral (automatic transmission) or in first gear (manual transmission), with the engine off, and make sure the park brake and the dyno brake are on when you get off the vehicle on the dyno. Fix any fuel, oil, or coolant leaks that may have shown up after engine warm up and check the carburetor for leaks. Any loud or unusual engine noises or excessive exhaust smoke should be resolved before continuing. 2-8

45 BASIC DYNO OPERATION Making a Test Run MAKING A TEST RUN Dyno runs provide safe, reliable road testing right in the shop. The dyno allows you to measure, record, and diagnose performance problems quickly. The dyno combined with WinPEP 7 produces consistent, easily interpretable power graphs. Use the following instructions to ensure repeatable and accurate measurements. 1 Verify the vehicle is secured properly. 2 Place the vehicle in a low gear and release the dyno brake using the hand held pendant. 3 Slowly accelerate the vehicle to 20 m.p.h. 4 Test the tachometer operation. 4a Rev the engine. The gauges on the computer screen should be moving. If the tachometer is moving but not registering the correct RPM values, the number of degrees of revolution of the crank shaft (the plug fires number) is incorrect. 4b Stop the vehicle, return to the MakeRun Configuration dialog box, and enter the correct value for the plug firing order. 5 Press the red brake button to apply 100% braking and slow down the vehicle. Using the vehicle s own brakes to slow or stop the drum at speeds over 30 m.p.h. can severely over heat the brake parts. Dynojet dynamometers with the air brake or eddy current brake accessory can be used to slow the vehicle and drum to a full stop at any speed. The vehicle s brakes should be used in an emergency stop situation only. 6 Shut the engine off and put the vehicle in gear (manual transmission) or park (automatic transmission). 7 Set the vehicle s parking brake and leave the dyno brake on. 8 Perform a final inspection. Verify the drive tire s alignment on the dyno drums. Make any adjustments to the tie-down straps as needed. Perform any other safety checks that you deem appropriate to your particular situation. You are now ready to make a high speed run on the dyno. Refer to your WinPep 7 User Guide for more detailed instructions. Version 1 2-9

46 CHAPTER 2 Preventative Maintenance PREVENTATIVE MAINTENANCE This section contains basic preventative maintenance and troubleshooting information for the wheel clamp and CPI fuses. 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 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. Check all air fittings for leaks monthly. Correct any leaks found. Once per month verify that the drum brake pressure gauge reads 55 to 65psi (380 to 450kPa). Adjust regulator if pressure is out of specification. 2-10

47 A PPENDIX 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 B 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 , or 1300 North Michael Drive, Wood Dale, IL A-1

48 APPENDIX A Installation INSTALLATION Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number. catalog number drill bit size minimum hole depth setting tool catalog number Carbon Steel RM-38/RL-38 (9.5 mm) 1/2-inch 1 5/8-inch (41.2 mm) 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. 2 Insert the anchor. Figure A-1: Red Head Anchor Drill the Hole anchor Figure A-2: Red Head Anchor Insert the Anchor A-2

49 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 1 A-3

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51 INDEX A accessories 1-5 B battery hazards iv blower extension cord 1-22 brake pads 2-10 brake pressure 2-10 C cable cover installing 1-15 removing 1-8 cable track, moving 1-12 certification 1-2 chassis specifications 1-3 compliance testing 1-2 connector plate 1-20 conventions 1-2 crate, removing parts 1-17 D dimensions 1-4 disclaimers iii document part number 1-1 driveline 1-19 drum guard 1-26 drum guard mounting bracket 1-23 drum module connector plate 1-20 driveline 1-19 installing 1-19 woodruff key 1-19 drum safety cover 1-27 dyno, specifications 1-3 E electrostatic discharge iv end cap installing 1-15 removing 1-8 ESD precautions iv H hazards v height 1-3 I inspection 2-7 J junction box installing 1-14 removing 1-13 junction box cover installing 1-15 removing 1-8 L left blower assembly installing 1-16 removing 1-13 length 1-3 loading the vehicle 2-2 M maintenance 2-10 making a run 2-9 middle pit cover 1-24 monitor arms installing 1-16 removing 1-11 Index-i

52 INDEX monitor support installing 1-14 removing 1-13 monitor tray installing 1-16 removing 1-11 P pit dimensions 1-6 pit covers drum guard 1-26 drum guard mounting bracket 1-23 drum safety cover 1-27 middle pit cover 1-24 right pit cover 1-25 power, disconnecting 1-7 pre-run inspection 2-7 preventative maintenance 2-10 primary inductive pickup 2-6 R red head anchor contact information A-1 installation A-2 setting tool A-3 warnings A-1 right blower assembly installing 1-21 removing 1-13 right blower mount installing 1-21 removing 1-13 right pit cover 1-25 right side drum cover, removing 1-10 RPM pickup connecting 2-4 primary inductive pickup 2-6 secondary inductive pickup 2-5 S secondary inductive pickup 2-5 setting tool A-3 specifications chassis 1-3 length, height, width, weight 1-3 T technical support 1-2 testing the dyno 2-9 tie-down straps 2-3 TUV certification 1-2 U upright bar installing 1-20 removing 1-16 using the dyno 2-9 W warnings iii weight 1-3 width 1-3 woodruff key 1-19 Index-ii