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©2005 Dynojet Research, Inc. All Rights Reserved. Air Brake and EEC Kit Installation Guide for Model 200i/250i and 200iP/250iP Motorcycle Dynamometers 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
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TABLE OF CONTENTS Air Brake and EEC Kit Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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AIR BRAKE AND EEC KIT INSTALLATION This document provides instructions for installing the air brake and EEC Kit to the model 200i/250i and 200iP/250iP motorcycle dynamometer (dyno). This document will walk you through installing the air brake assembly, EEC finger guards, and door safety switch. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: 98123114 Version 1 Last Updated: 12-05-05 1 Air Brake and EEC Kit Installatio
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AIR BRAKE AND EEC KIT Introduction INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The EEC Kit with Brake package consists of the EEC finger guards, air brake assembly, and door safety switch. The air brake can also be purchased separately. The EEC finger guards are a valuable safety device that allow you to regulate the distance between the dyno chassis and the drum; the air brake quickly slows the drum’s rotation and locks it for loading and unloading mot
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INSTALLATION GUIDE Air Brake AIR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The air brake is an electro-pneumatic braking system which quickly slows the drum after a run and locks it from turning. The air brake includes the brake rotor, air brake assembly, and the brake bracket and is easily installed onto the dyno. Use the following instructions to install your air brake. REMOVING THE DRUM MODULE HOOD, SIDE DRUM COVER, CENTER PANEL, AND TIRE CARRIAGE
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AIR BRAKE AND EEC KIT Air Brake 4 Remove the six 1/4-20 x 5/8-inch pan head screws securing the right side drum cover to the dyno and set aside. 5 Remove the two 1/4-20 x 5/8-inch pan head screws securing the top of the right side drum cover to the dyno and set aside. 6 Remove the right side drum cover. top screw right side drum cover side screw Figure 2: Removing the Right Side Drum Cover 4 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
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INSTALLATION GUIDE Air Brake 7 Remove the four 1/4-20 x 5/8-inch pan head screws securing the bearing bracket to the tire carriage and set aside. 8 Using the hand crank, unscrew the bearing bracket and the carriage screw and set aside. 9 Remove the tire carriage by sliding the carriage under the carriage clamps toward the back of the dyno and set aside. tire carriage carriage clamp carriage screw bolt bearing bracket hand crank Figure 3: Removing the Tire Carriage 5 Version 1 Air Brake
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AIR BRAKE AND EEC KIT Air Brake 10 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps and shims and set aside. 11 Remove the three carriage clamps and shims and set aside. 12 Remove the two 5/16-inch bolts and washers securing the nut block and shim and set aside. 13 Remove the nut block and shim and set aside. 14 Remove the six 1/4-20 x 5/8-inch pan head screws securing the center panel to the dyno carriage and set aside. 15 Remove the center panel and set aside.
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INSTALLATION GUIDE Air Brake REMOVING THE PIT COVER PLATE AND UPRIGHT BRACE The following instructions are for model 200iP/250iP dynos. Refer to “Removing the Drum Module Hood, Side Drum Cover, Center Panel, and Tire Carriage” on page 3 for model 200i/250i dynos. Never operate the dynamometer with the pit cover plates removed. Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to remove the 1/4-inch screws. For dynos with serial numbers lower than 2030152, Dynojet recommends
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AIR BRAKE AND EEC KIT Air Brake 4 Remove the four 1/4-20 x 5/8-inch pan head screws and the four 3/8-16 x 1/2-inch screws securing the right pit cover plate to the dyno chassis and set aside. 5 Remove the right pit cover plate and set aside. screw right pit cover plate Figure 6: Removing the Right Pit Cover Plate 8 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
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INSTALLATION GUIDE Air Brake 6 Remove the two 1/4-20 x 5/8-inch pan head screws securing the upright brace to the drum module and set aside. 7 Remove the brace and set aside. Note: For clarity, the pit is not shown. upright brace screw Figure 7: Removing the Upright Brace 9 Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
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AIR BRAKE AND EEC KIT Air Brake INSTALLING THE AIR BRAKE ASSEMBLY The following instructions are for both the model 200i/250i above ground and 200iP/250iP pit motorcycle dynamometers. If you are not installing the air brake skip this section and refer to “EEC Finger Guards—200i/250i” on page 20, “EEC Finger Guards—200iP/250iP” on page 23, and “Door Safety Switch” on page 29. 1 Turn off the dyno and disconnect the AC power cord from its power source. 2 Insert the woodruff key into the dyno sha
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INSTALLATION GUIDE Air Brake 6 Secure the brake bracket to the drum module frame using two 5/8-11 x 1.25-inch 12-point bolts torquing to 112 foot-pounds. Note: For clarity, the side drum module hood is not shown. brake bracket bolt Figure 9: Securing the Brake Bracket 7 Place the brake assembly on the brake bracket. air brake assembly Figure 10: Securing the Air Brake Assembly 11 Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
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AIR BRAKE AND EEC KIT Air Brake 8 Secure the brake assembly with two clevis pins. 8a Push the top clevis pin through the front of the assembly. top clevis pin Figure 11: Inserting the Top Clevis Pin 8b Push the bottom clevis pin through the back of the drum module frame and the air brake assembly (drum side). 8c Secure the top clevis pin with a hair pin cotter. top hairpin cotter top clevis pin bottom clevis pin Figure 12: Inserting the Bottom Clevis Pin and Top Hairpin Cotter 12 Air Brake and
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INSTALLATION GUIDE Air Brake 8d Secure the bottom clevis pin with a hairpin cotter. hairpin cotter bottom clevis pin Figure 13: Securing the Bottom Clevis Pin with a Hairpin Cotter 9 Loosely secure the brake caliper stop to the brake bracket using two 3/8-16 x 3/4-inch bolts with lock washers and two 5/16-inch flat washers. Note: For clarity, the drum, parts of the dyno frame, and the air brake assembly spring are not shown. brake bracket brake caliper stop Figure 14: Securing the Brake
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AIR BRAKE AND EEC KIT Air Brake ROUTING THE AIR BRAKE CABLE Before proceeding with the rest of the air brake installation it is necessary to connect the shop air and check the brake pad clearance. 1 Open the front panel of the control panel interface (CPI) to access the breakers and Breakout board. 2 Route the air brake cable from the air brake solenoid to the CPI. Note: The CPI end of the air brake cable splits in two. 3 Connect the cable with the two black wires to the Breakout board wirin
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INSTALLATION GUIDE Air Brake CONNECTING THE SHOP AIR—200I/250I 1 Route the air hose from the air brake through the access hole in the drum module upright, under the carriage frame brace, and connect to the bulkhead fitting at the front of the dyno. 2 You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the dynamometer. bulkhead fitting air hose access hole air pump Figure 16: Conn
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AIR BRAKE AND EEC KIT Air Brake CONNECTING THE SHOP AIR—200IP/250IP 1 Route the air brake air hose through the access hole in the drum module upright and through the pit conduit. 2 Connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the air hose. to 60 psi clean dry air air brake pit conduit air hose access hole Figure 17: Connecting the Air Hose—200iP/250iP 16 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamo
