Dynojet 200/250 Air Brake Installation guide

Brand: Dynojet

Model: 200/250 Air Brake

Type: Installation guide

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

ABLE

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

RAKE

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

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

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

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

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

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

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

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

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

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

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

Dynojet 200/250 Air Brake Installation guide

Dynojet 200/250 Air Brake Installation guide

Dynojet 200/250 Air Brake Installation guide

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