©2002 Dynojet Research, Inc. All Rights Reserved.
Air Brake Installation Guide for Model 200/250 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 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: 98222103 Version 02 (03/2002)
Air Brake Installation Guide i
T
ABLE
OF
C
ONTENTS
Air Brake Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Removing the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installing the Rotor/Taper Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installing the Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Installing the Air Cylinder and Master Cylinder Assembly . . . . . . . . . . . . . . . . . 7
Installing the Spring Bolt Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installing the Air Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Wiring the Air Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Final Adjustments and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replacing the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air Brake Assembly Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air Brake Installation Guide 1
A
IR
B
RAKE
I
NSTALLATION
This document provides instructions for installing the air brake to the motorcycle
dynamometer (dyno). To ensure safety and accuracy in the procedures, perform the
procedures as they are described.
Document Part Number: 98222103
Version 2
Last Updated: 03-29-02
Air Brake Installation Guide
AIR BRAKE
Introduction
2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION
The air brake is an electro-pneumatic braking system and includes a two button
pendent.
If you purchased your dyno with an air brake assembly, the air brake will already be
installed. You will need to provide an air hose nipple to connect your shop air supply
(80 psi constant line pressure) to the dynamometer. Once air pressure is connected,
the air brake is ready to use.
Figure 1: Connect Your Shop Air Supply
CONVENTIONS USED IN THIS MANUAL
The conventions used in this manual are designed to protect both the user and the
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 89081.
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 line.
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.
connect shop air supply
INSTALLATION GUIDE
Introduction
Version 2 Air Brake Installation Guide
3
PARTS LIST
The following table lists all of the parts included in the Air Brake (P/N 102-201)
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 description quantity
197104130 Zip Tie, 4" 6
22103080 Rod, Air Brake Spring 2
22923000 Spring Guide (retainer ring) 4
36390640 Bolt, 1/2"-20 x 3/4", Hex 1
43310600 Grommet, 7/16" ID x 3/4" OD 1
61322300 Spring Bolt Mounting Plate 1
63990001 Caliper Assembly 1
63990002 Rotor/Taper Lock Assembly with Hub and Key 1
63990004 Air Cylinder Assembly 1
BR102-033 Grommet, 1"OD, 3/8ID, 3/4H, 1/8G 1
BR102-038-5 Air Hose Push Lock Fitting 1
BR102-038-6 Air Hose Bulk Head Fitting 1
BR102-038-7 Air Hose, 55" .05 55.00 inches
BR102-041 Master Cylinder 1
BR102-045 Brake Hose (installed) 1
None Copper Washers (installed) 2
BR102-046 Brake Line 1
BR102-047 Banjo Bolt (installed) 1
BR102-055 Springs, Purple (for Spring Bolt Assembly) 2
BR102-061 Bolts, 1/4"-20 x 4 1/2", Socket Head 2
DC100-104 Pendant and Cable 1
DE100-134 Screw, 8 x 1/2", Self Tapping 2
DM150-035 1/2" Cable Clamp, Nylon 2
DM150-009-005 Nut, 1/4"-20, Adjuster (for Spring Bolt Assembly) 4
Air Brake Installation Guide
AIR BRAKE
Installation
4
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INSTALLATION
This section describes the prcedures for installing the air brake.
REMOVING THE HOOD
1 Remove the four bolts securing the hood to the dyno and set aside. Prop up the
hood.
2 If present, disconnect the wires to the key switch.
3 Remove the hood from the dyno and set aside.
4 Disconnect the battery.
To prevent possible injury, disconnect the battery before performing any dyno
maintenance or installing any optional accessory.
Figure 2: Remove the Hood
key switch
INSTALLATION GUIDE
Installation
Version 2 Air Brake Installation Guide
5
INSTALLING THE ROTOR/TAPER LOCK ASSEMBLY
When upgrading from a manual brake, the rotor/taper lock assembly and caliper
assembly will already be installed. Proceed to “Installing the Air Cylinder and Master
Cylinder Assembly” on page 7.
1 Insert the key into the slot on the shaft.
2 Slide the rotor/taper lock assembly on to the shaft.
Figure 3: Install the Rotor/Taper Lock Assembly
3 Attach the dial indicator to the side of the dyno. Spin the drum and check for run
out; the tolerances are +/- .005".
4 Tighten the taper lock bolts. While tightening, adjust the bolts to keep the run out
within tolerances. Torque the taper lock bolts to 15 ft. lb.
Figure 4: Check for Run Out
key
shaft
rotor/taper lock
assembly
dial indicator
taper lock bolts
(two visible here)
Air Brake Installation Guide
AIR BRAKE
Installation
6
INSTALLING THE CALIPER ASSEMBLY
1 Tighten the two bolts shown in Figure 5.
2 Remove the four bolts and washers in the top and bottom right corners (as shown
in Figure 5) and set aside. These bolts will be used to mount the caliper assembly
in step 3.
Figure 5: Caliper Assembly Mounting Bolts
3 Secure the caliper assembly with the four bolts and washers removed in step 2.
Figure 6: Secure the Caliper Assembly
tighten
remove bolts and use to
mount caliper assembly
remove bolts and use to
mount caliper assembly
caliper assembly
INSTALLATION GUIDE
Installation
Version 2 Air Brake Installation Guide
7
4 Adjust the space between the brake pad and the rotor making sure the rotor is
able to spin free of contact.
Loosen the jam nut and use the adjuster nut to move the brake pads in or out.
Figure 7: Adjust the Brake Pad Space
INSTALLING THE AIR CYLINDER AND MASTER CYLINDER ASSEMBLY
1 With the air cylinder on the inside of the dyno frame and the mounting plate on
the outside, secure the air cylinder with the 1/2-20 x 3/4-inch bolt.
Figure 8: Install the Air Cylinder
jam nut adjuster nut
bolt
air cylinder
mounting plate
cut away view of
dyno side panel
Air Brake Installation Guide
AIR BRAKE
Installation
8
2 Slide the master cylinder assembly through the holes in the air cylinder and
through the dyno frame.
3 Secure the master cylinder to the air cylinder with two 1/4-20 x 4 1/2-inch socket
head mounting bolts using a 3/16-inch allen wrench.
Figure 9: Install the Master Cylinder
4 Run the metal brake line from the master cylinder to the caliper brake hose.
4a Insert a rubber grommet into the hole shown in Figure 10.
4b Run the brake line from the master cylinder through the grommet and over
to the caliper assembly.
4c Secure the brake line to the master cylinder and to the caliper brake hose.
4d Secure the brake line to the outside of the dyno frame using two nylon
loops and two 8 x 1/2-inch self tapping screws.
Figure 10: Install the Metal Brake Line
bolts
master cylinder
cut away view of dyno
side panel
air cylinder
metal brake line nylon loops secure metal brake line
to caliper brake hose
grommet
metal brake line
master
cylinder grommet brake
hose
INSTALLATION GUIDE
Installation
Version 2 Air Brake Installation Guide
9
INSTALLING THE SPRING BOLT ASSEMBLY
1 Push the mounting plate flush with the dyno cabinet.
2 Install the rear retainer, spring, front retainer, and adjuster nut. Be sure the
hardware is in this order.
Note: You may need to compress the spring to get the adjuster nut on.
The distance from the front retainer to the dyno cabinet should be 3.25 inches.
Final adjustments will be made later.
If the distance is less that 3.25 inches, us a flat blade screwdriver to unscrew the
spring rod until the proper distance is achieved.
3 Turn the adjuster nut to tighten the spring until there is enough room on the
spring rod for the jam nut.
4 While holding the adjuster nut from turning, tighten the jam nut against the
adjuster nut.
Figure 11: Install the Spring Bolt Assembly
spring
rear retainer
adjuster nut
jam nut
cut away view of dyno
side panel
spring rod
front retainer
tighten jam nut
against adjuster nut
hold adjuster nut dyno cabinet
front retainer
mounting plate
Air Brake Installation Guide
AIR BRAKE
Installation
10
INSTALLING THE AIR HOSE
1 Install the 1-inch grommet into the hole shown in Figure 12.
2 Wrap the push lock fitting with thread tape. Refer to Figure 13.
3 Insert the five foot section of air hose through the hole. Leave enough air hose
exposed and attach it to the regulator.
Figure 12: Secure the Air Hose to the Regulator
grommet
run air hose
inside dyno
attach air hose to
regulator
INSTALLATION GUIDE
Installation
Version 2 Air Brake Installation Guide
11
4 Lift the front of the dyno high enough to access the cut out on the bottom side of
the dyno.
The dyno is heavy. Use suitable methods to lift and support the dyno while
working through these steps.
5 Reach into the access hole in the bottom of the dyno and find the air hose.
6 Place the nut and washer from the bulk head fitting onto the air hose.
7 Insert the air hose through the hole in the front dyno panel and thread the bulk
head fitting onto the push lock fitting.
8 Insert the bulk head fitting into the hole. While holding the bulk head fitting from
the outside, tighten the nut from the inside.
Note: You will need to supply the couplers/fittings to attach to the bulk head
fitting. Using a quick coupler at the end is convenient if you need that air source
for other activities in the shop.
Figure 13: Install the Bulk Head Fitting
cut away view of
front dyno panel
bulk head fitting
(outside dyno)
push lock fitting
with thread tape
washer
nut
air hose
(inside dyno)
bulk head fitting
install complete
push lock fitting
Air Brake Installation Guide
AIR BRAKE
Installation
12
WIRING THE AIR VALVE ASSEMBLY
The wires that attach to the air valve assembly can be attached in two different places
depending on your dyno’s set up. Wire Set Up 1 is generally for older dynos while
Wire Set Up 2 is for newer dynos.
WIRE SET UP 1
This wire set up is used in older dynos that have an exposed (not in a black box)
terminal strip with only eight terminals. If your terminal strip is in a box and has
sixteen terminals, refer to Wire Set Up 2 on page 13.
1 Attach the air hose to the coupler and adjust the regulator to 80 psi.
2 Run the two black wires from the air valve to the top two terminals on the left
side, refer to Figure 14.
3 Wire the two black extension leads to the top two terminals on the right side.
Figure 14: Wire Set Up 1—Terminal Strip Wiring
4 Remove the four screws securing the Breakout board and cover. Set the screws
and cover aside.
5 Attach the extension leads to the Breakout board. Orientation of the wires is not
important.
6 Replace the Breakout board cover using the four screws removed earlier.
Figure 15: Wire Set Up 1—Breakout Board Wiring
black leads from
the air valve extension leads to
the Breakout board
two black terminal
strip wires
Breakout board
and cover
INSTALLATION GUIDE
Installation
Version 2 Air Brake Installation Guide
13
WIRE SET UP 2
This wire set up is used in newer dynos where the terminal strip is housed in a black
box and has sixteen terminals. If your terminal strip is not in a box and has only eight
terminals, refer to Wire Set Up 1 on page 12.
1 Attach the air hose to the coupler and adjust the regulator to 80 psi.
2 Remove the cover from the black box.
3 Run the wires from the air valve through the hole on the side of the black box.
4 Attach the air valve wires to the terminal strip as shown in Figure 16. The black
and yellow leads for the Breakout board have been pre wired to the terminal strip
at Dynojet.
Figure 16: Wire Set Up 2—Terminal Strip Wiring
5 Secure the cover to the black box.
6 Remove the four screws securing the Breakout board and cover. Set the screws
and cover aside.
7 Attach the black and yellow leads from the terminal strip to the Breakout board.
Orientation of the wires is not important.
8 Verify the jumper settings on the Breakout board.
9 Replace the Breakout board cover using the four screws removed earlier.
Figure 17: Wire Set Up 2—Breakout Board Wiring And Jumper Settings
hole air valve wire
air valve wire
black and yellow leads
to breakout board
black
yellow
Breakout board
and cover
Air Brake Installation Guide
AIR BRAKE
Installation
14
FINAL ADJUSTMENTS AND TESTS
1 Verify the dyno is set up properly, the hardware stack is powered up and
operational, and the air supply is connected properly.
2 Verify the brake is off; the red light on the pendant should be off.
3 Fill the master cylinder with DOT 5 brake fluid.
4 Open the bleeder valve on the caliper assembly and use the red brake button on
the pendant to activate the brake. You should see fluid and air being purged from
the bleeder valve. Repeat this procedure until the system is completely bled.
5 If you find you are not getting sufficient brake performance, adjust the spring rod
nuts to increase the spring pressure.
5a Loosen the jam nut.
5b Place the jam nut flush with the end of the spring rod and insert a
screwdriver into the slot on the end of the spring rod.
5c Tighten the adjuster nut until the springs begin to overcome the force of the
air pushing against them.
5d Once the adjuster nut is in place, snug the jam nut up to the adjuster nut.
5e Test the brake several more times to verify the brake pads return far enough
to clear the rotor.
6 Use the red brake button on the pendant to activate and deactivate the brake.
Listen for air leaks and double check all connections.
7 Adjust the clearance between the pads and the rotor by loosening the jam nut and
turning the adjuster nut on the caliper assembly. There should be equal space on
both sides of the rotor. Refer to Figure 7 for more information on the caliper
assembly jam and adjuster nuts.
Note: Cycle the brake to verify the brake pads release far enough and do not
touch the rotor. If the pads touch the rotor during a run, the information
provided by the dyno will be inaccurate.
INSTALLATION GUIDE
Installation
Version 2 Air Brake Installation Guide
15
REPLACING THE HOOD
1Connect the battery.
2 Carefully place the hood on the dyno, leaving it propped up.
3 Secure the wires to the key switch, if present.
4 Lower and secure the hood using the four bolts removed earlier.
Figure 18: Replace the Hood
AIR BRAKE ASSEMBLY SCHEMATIC
Figure 19: Air Brake Assembly Schematic
key switch
/
