©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.
TABLE OF CONTENTS Air Brake and EEC Kit Installation Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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.
AIR BRAKE AND EEC KIT Air Brake 4 5 6 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. 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. Remove the right side drum cover.
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. Remove the tire carriage by sliding the carriage under the carriage clamps toward the back of the dyno and set aside.
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.
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.
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.
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.
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 2 3 4 5 Turn off the dyno and disconnect the AC power cord from its power source. Insert the woodruff key into the dyno shaft.
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 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.
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.
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 2 3 4 Open the front panel of the control panel interface (CPI) to access the breakers and Breakout board. 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.
INSTALLATION GUIDE Air Brake CONNECTING THE SHOP AIR—200I/250I 1 2 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. 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.
AIR BRAKE AND EEC KIT Air Brake CONNECTING THE SHOP AIR—200IP/250IP 1 2 to 60 ps i clean dry air Route the air brake air hose through the access hole in the drum module upright and through the pit conduit. Connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the air hose.
INSTALLATION GUIDE Air Brake ADJUSTING THE BRAKE PAD CLEARANCE Before you tighten the bolts securing the brake caliper stop you will want to adjust the brake pad clearance. 1 Release the brakes. Note: In order for the brakes to release, power must be on, air connected, red button on pendant not lit, and the emergency stop button not depressed. 2 Insert the brake adjusting shim between the inboard brake pad and the brake rotor.
AIR BRAKE AND EEC KIT Air Brake 3 Remove the hairpin cotter and hand tighten the castle nut on the caliper assembly to clamp the brake pads against the rotor and shim. 4 5 6 Tighten the brake caliper stop bolts torquing to 26 pounds/feet. 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 8 Replace the hair pin cotter in the castle nut.
INSTALLATION GUIDE Air Brake FINAL ADJUSTMENTS AND TESTS—200I/250I 1 Replace the drum module hood, side drum cover, tire carriage, and center panel. Refer to “Replacing the Drum Module Hood, Side Drum Cover, Center Panel, and Tire Carriage—200i/250i” on page 33. Note: If you are installing the EEC Kit do not replace the drum module hood, center panel, and tire carriage until you have finished the installation process. Refer to page 20 for the 200i/250i EEC finger guard installation.
AIR BRAKE AND EEC KIT EEC Finger Guards—200i/250i EEC FINGER GUARDS—200I/250I ................................... The EEC finger guards are secured to the drum module hood and provide extra protection from the drum by regulating the distance between the drum and the chassis. The placement of the finger guards can be manually adjusted. Refer to “EEC Finger Guards—200iP/250iP” on page 23 for model 200iP/250iP dynos. Refer to “Air Brake” on page 3 for air brake installation instructions.
INSTALLATION GUIDE EEC Finger Guards—200i/250i 3 Secure the drum module hood with the EEC finger guards to the dyno using the eight 1/4-20 x 5/8-inch pan head screws removed earlier. Note: For clarity, the retarder and carriage are not shown. Do not operate the dynamometer without the EEC finger guards properly installed. The gap between the finger guards and the drum must be less than 0.64 centimeters (0.25 inches). Refer to page 22 for instructions on adjusting the gap.
AIR BRAKE AND EEC KIT EEC Finger Guards—200i/250i ADJUSTING THE EEC FINGER GUARDS Once the drum module hood is installed, the EEC finger guards will need to be adjusted. 1 2 Loosen the 1/4-20-inch pan head screws and adjust the EEC finger guards so they are 0.16 cm to 0.64 cm (0.0625 in. to 0.25 in.) from the drum. Tighten the screws. Check the EEC finger guards regularly to verify the clearance has not changed. Note: For clarity, the retarder and carriage are not shown.
INSTALLATION GUIDE EEC Finger Guards—200iP/250iP EEC FINGER GUARDS—200IP/250IP ................................... The 200iP/250iP motorcycle pit dynos also benefit from the EEC kit. The EEC finger guards provide extra protection from the drum by regulating the distance between the drum and the chassis. The placement of the finger guards can be manually adjusted. Refer to “EEC Finger Guards—200i/250i” on page 20 for model 200i/250i dynos.
AIR BRAKE AND EEC KIT EEC Finger Guards—200iP/250iP 4 Secure each EEC finger guard to the drum guard mount using two 1/4-20 x 5/8-inch pan head screws.
INSTALLATION GUIDE EEC Finger Guards—200iP/250iP 5 Secure the left pit cover plate with the drum guard mount to the dyno using the four 3/8-16 x 1/2-inch screws removed earlier.
AIR BRAKE AND EEC KIT EEC Finger Guards—200iP/250iP 6 Secure the upright brace to the drum module using the two screws removed earlier. Refer to Figure 7 on page 9. 7 Secure the right pit cover plate to the dyno using the four 1/4-20 x 5/8-inch pan head screws and the four 3/8-16 x 1/2-inch screws removed earlier.
INSTALLATION GUIDE EEC Finger Guards—200iP/250iP 8 Secure the right drum guard to the drum guard mount using the two 1/4-20 x 5/8-inch pan head screws and locknuts removed earlier. Do not operate the dynamometer without the EEC finger guards properly installed. The gap between the finger guards and the drum must be less than 0.64 centimeters (0.25 inches). Refer to page 28 for instructions on adjusting the gap.
AIR BRAKE AND EEC KIT EEC Finger Guards—200iP/250iP ADJUSTING THE EEC FINGER GUARDS Once the pit cover plates are installed and adjusted, the EEC finger guards will need to be adjusted. 1 2 Loosen the 1/4-20 x 5/8-inch pan head screws and adjust the EEC finger guards so they are 0.16 cm to 0.64 cm (.0625 in. to .25 in.) from the drum. Tighten the screws. Check the EEC finger guards regularly to verify the clearance has not changed.
INSTALLATION GUIDE Door Safety Switch DOOR SAFETY SWITCH ................................... Safety requirements of your local country may require that a door safety switch is installed. Be sure to follow the safety requirements specific to your country. The door safety switch requires the air brake to work. This switch is located on the dyno room door and is triggered when the pressure applied to it is released causing the air brake to lock. This prevents the dyno from being used when the door is open.
AIR BRAKE AND EEC KIT Door Safety Switch 6 Loosen the screws that hold the jumper wires in place and remove the wire. 7 Route the black and yellow wire from the safety switch through the dyno. Make sure the switch will not get caught in any moving components or chafed on any edges. 8 9 Attach the yellow wire to the 1A position on the J2 connector. Attach the black wire to the 6B position on the J4 connector.
INSTALLATION GUIDE Door Safety Switch INSTALLING THE DOOR SAFETY SWITCH—200IP/250IP 1 2 3 4 Open the CPI front panel access and turn off the main breaker. Unplug the dyno power cable. Remove the eight button-head screws securing the CPI cover and set aside. Remove the cover and set aside.
AIR BRAKE AND EEC KIT Door Safety Switch 5 Loosen the screws that hold the jumper wires in place and remove the wire. 6 Route the black and yellow wire from the door safety switch through the dyno. Make sure the switch will not get caught in any moving components or chafed on any edges. 7 8 Attach the yellow wire to the 1A position on the J2 connector. Attach the black wire to the 6B position on the J4 connector.
INSTALLATION GUIDE Replacing the Drum Module Hood, Side Drum Cover, Center Panel, and Tire Carriage—200i/250i REPLACING THE DRUM MODULE HOOD, SIDE DRUM COVER, CENTER PANEL, AND TIRE CARRIAGE—200I/250I ................................... Refer to “Replacing Pit Cover Plates and Upright Brace—200iP/250iP” on page 34 for model 200iP/250iP dynos. 1 2 3 Secure the center panel to the dyno carriage using the six 1/4-inch screws removed earlier. Refer to Figure 4 on page 6.
AIR BRAKE AND EEC KIT Replacing Pit Cover Plates and Upright Brace—200iP/250iP REPLACING PIT COVER PLATES AND UPRIGHT BRACE—200IP/250IP ................................... Refer to “Replacing the Drum Module Hood, Side Drum Cover, Center Panel, and Tire Carriage—200i/250i” on page 33 for model 200i/250i dynos. 1 2 3 Secure the upright brace to the drum module using the two screws removed earlier. Refer to Figure 7 on page 9.