Dynojet 150 User Manual

©1999-2002 Dynojet Research, Inc. All Rights Reserved.
Eddy Current Brake Installation Guide For Motorcycle Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual 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 89031, USA.
Printed in USA.
Part Number: 98226100 Version 8 (03/02)
T
ABLE OF
C
ONTENTS
List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Chapter 1 Eddy Current Brake Installation
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Removing the Dyno Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Air Brake and Manual Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Removing the Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Removing the Manual Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Removing the Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Adjusting the Brake for Right Side Installations . . . . . . . . . . . . . . . . . . . . . .1-9
Installing the Connecting Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Installing the Dyno Shaft Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Connecting the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Aligning the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Coupling the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Securing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Theta Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Adjusting the Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Drilling the Mounting Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
Installing the Theta Controller—Left Side . . . . . . . . . . . . . . . . . . . . . . . . .1-20
Installing the Theta Controller—Right Side . . . . . . . . . . . . . . . . . . . . . . .1-22
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
Replacing the Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-24
Changing the Input Power Cable Plug . . . . . . . . . . . . . . . . . . . . . . . . . . .1-26
Verifying the Eddy Current Brake Wiring Configuration . . . . . . . . . . . . . .1-26
Hood Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
Assembling the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
Installing the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
Eddy Current Brake Installation Guide
i
TABLE OF CONTENTS
Appendix A Red Head Anchor Installation
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . .A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Appendix B High Inertia Drum—Older Dyno Installation
Connecting the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Appendix C Theta Controller—Internal Fuse
Replacing the Internal Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Appendix D Mounting Templates
ii
Eddy Current Brake Installation Guide
L
IST OF
Figure 1-1: Remove the Brake Cover and Hood Keepers . . . . . . . . . . . . . .1-3
Figure 1-2: Remove the Eddy Current Brake from the Crate . . . . . . . . . . .1-4
Figure 1-3: Remove the Hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Figure 1-4: Remove the Air Brake Solenoid Wires . . . . . . . . . . . . . . . . . . . . 1-5
Figure 1-5: Remove the Brake Wires from the Breakout Board . . . . . . . . .1-5
Figure 1-6: Air Brake—Remove the Springs. . . . . . . . . . . . . . . . . . . . . . . . .1-6
Figure 1-7: Air Brake—Remove the Master Cylinder. . . . . . . . . . . . . . . . . .1-6
Figure 1-8: Air Brake—Remove the Air Cylinder . . . . . . . . . . . . . . . . . . . . .1-7
Figure 1-9: Remove the Manual Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Figure 1-10: Remove the Brake Caliper Assembly. . . . . . . . . . . . . . . . . . . .1-8
Figure 1-11: Right Side Installation Set-up . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Figure 1-12: Remove the Connecting Arm Bolts. . . . . . . . . . . . . . . . . . . . .1-9
F
IGURES
Figure 1-13: Install the Connecting Arms . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Figure 1-14: Replace the Coupler Set Screws . . . . . . . . . . . . . . . . . . . . . .1-11
Figure 1-15: Install the Dyno Shaft Coupler . . . . . . . . . . . . . . . . . . . . . . .1-11
Figure 1-16: Remove the Connecting Bolts from the Dyno. . . . . . . . . . .1-12
Figure 1-17: Connect the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . .1-12
Figure 1-18: Align the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Figure 1-19: Secure the Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Figure 1-20: Secure the Brake to the Ground . . . . . . . . . . . . . . . . . . . . . .1-14
Figure 1-21: Theta Controller—Metal Plug . . . . . . . . . . . . . . . . . . . . . . . .1-15
Figure 1-22: Theta Controller—North America 120 VAC
Dip Switch Settings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Eddy Current Brake Installation Guide
iii
LIST OF FIGURES
Figure 1-23: Theta Controller—Europe and Australia 240 VAC
Figure 1-24: Theta Controller—Drill Mounting Holes on Left Side . . . . . 1-18
Figure 1-25: Theta Controller—Drill Mounting Holes on Right Side. . . . 1-19
Figure 1-26: Theta Controller—Install on Left Side. . . . . . . . . . . . . . . . . .1-20
Figure 1-27: Theta Controller—Routing the Cables on Left Side . . . . . .1-21
Figure 1-28: Theta Controller—Install on Right Side . . . . . . . . . . . . . . . .1-22
Figure 1-29: Theta Controller—Routing the Cables on Right Side . . . . . 1-22
Figure 1-30: Theta Controller—Remove the Breakout Board Cover . . . .1-23
Figure 1-31: Theta Controller—Breakout Board Wiring and
Figure 1-32: Theta Controller—Replace the Fuse . . . . . . . . . . . . . . . . . . .1-24
Figure 1-33: Theta Controller—Determine the Type . . . . . . . . . . . . . . . .1-25
Dip Switch Settings
Jumper Settings
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Figure 1-34: Theta Controller—Input Power Cable Plug . . . . . . . . . . . . . 1-26
Figure 1-35: Theta Controller —Eddy Current Brake Wiring . . . . . . . . . .1-26
Figure 1-36: Dyno Hood Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-27
Figure 1-37: Secure Eddy Current Brake Cover to Dyno Hood . . . . . . . . 1-27
Figure 1-38: Install the New Dyno Hood . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
Figure 1-39: Secure the Hood Clamps and Brake Cover . . . . . . . . . . . . .1-28
Figure A-1: Red Head Anchor—Drill the Hole . . . . . . . . . . . . . . . . . . . . . . .A-2
Figure A-2: Red Head Anchor—Insert the Anchor. . . . . . . . . . . . . . . . . . . .A-2
Figure A-3: Red Head Anchor—Drive the Anchor Flush . . . . . . . . . . . . . . .A-3
Figure A-4: Red Head Anchor—Expand the Anchor . . . . . . . . . . . . . . . . . .A-3
Figure B-1: High Inertia Drum—Measure the Axle . . . . . . . . . . . . . . . . . . .B-1
Figure B-2: High Inertia Drum—Remove Nuts and Washers . . . . . . . . . . .B-2
Figure B-3: High Inertia Drum—Connect Brake . . . . . . . . . . . . . . . . . . . . .B-2
Figure C-1: Theta Controller—Replace Internal Fuse . . . . . . . . . . . . . . . . .C-1
iv
Eddy Current Brake Installation Guide
E
DDY
C
URRENT
C HAPTER
B
RAKE INSTALLATION
1
This document provides instructions for installing the Eddy Current Brake (retarder) optional hardware to Dynojet’s Model 150 and 200 Motorcycle Dynamometers. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
Document Part Number: 98226100
Versio n 8
Last Updated: 03-29-02

CONVENTIONS

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 1-800-992-3525, or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89031.
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.
Eddy Current Brake Installation Guide
1-1
CHAPTER 1

Parts List

PARTS LIST
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The following table lists all of the parts included in the Eddy Current Brake 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 4" Zip Tie 4
25111310 Clamp, Retarder Hood 2
61229101 Hood Assembly, M/C Retarder 1
62992001
Or
62992002
29250001 Mod-Key, 1/2 x 7/16 x 2" 1
29250002 Key, 3/8 x 3/8 x 2" (installed) 1
Retarder-Generic
Or
Retarder-Generic, European
1
32431332 Male Coupler, mounted on eddy current brake
32431333 Female Coupler Assembly with four set screws
36488101 Nut, 3/8-16, Hex, W/Tlok 5
36581270 Bolt, 3/8-16 x 3/4", W/Tlok 28
36581670 Bolt, 3/8-16 x 1", W/Tlok (for right side installation) 4
43312200 Grommet, 1-5/8OD x 1-3/8ID (one is installed) 2
61329105 Connecting Rod Sub-Assembly 2
66411002
Or
66411003
66952004 Power Cable, M/C Retarder Sub-Assembly 1
DC100-104 Pendant and Cable 1
DM150-002-007 5/16" Flat Washer 8
DM150-033 Rubber Grommet 1
(with male coupler hub, P/N 32431330, installed)
(with female coupler hub, P/N 32431331, installed)
Theta-2 Controller-120V
Or
Theta-2 Controller-240V
Red Head Anchor Kit 1
Theta Controller Mounting Hole Drill Template For Left Side Mounting 1
Theta Controller Mounting Hole Drill Template For Right Side Mounting 1
1
1
1
The following part number should be used when replacing all of the coupler pieces:
78122002 Coupler Kit
1-2
Eddy Current Brake Installation Guide
EDDY CURRENT BRAKE INSTALLATION

PREPARATION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section describes how to unpack the eddy current brake and remove the hood from your dyno.

UNPACKING THE EDDY CURRENT BRAKE

1 Remove the top and sides of the crate. 2 If you ordered a hood upgrade, remove the new hood from the crate. 3 Remove the four bolts securing the eddy current brake cover and set aside. 4 Remove the two bolts securing the hood clamps to the brake and set aside. 5 Remove the hardware box from the crate and verify the hardware box contents.
Refer to the parts list on page 1-2.
brake cover
Preparation
hood clamps
Figure 1-1: Remove the Brake Cover and Hood Keepers
Vers ion 8 Eddy Current Brake Installation Guide
1-3
CHAPTER 1
Preparation
6 Remove the eddy current brake from the crate.
Note: Dynojet recommends using a continuous nylon loop style strap to lift the eddy current brake from the crate.
6a Remove the bolts securing the eddy current brake to the crate.
6b Place the nylon loop strap around the top of the brake frame making sure it
crosses as shown in Figure 1-2.
6c Using the nylon loop strap, remove the eddy current brake from the crate
and place it near the dyno.
Figure 1-2: Remove the Eddy Current Brake from the Crate

REMOVING THE DYNO 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 all battery wires.
key switch
1-4
Eddy Current Brake Installation Guide
Figure 1-3: Remove the Hood
EDDY CURRENT BRAKE INSTALLATION

Air Brake and Manual Brake Removal

AIR BRAKE AND MANUAL BRAKE REMOVAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This section describes how to remove both the air brake and the manual brake, the brake caliper assembly, and the rotor.
If you are mounting the eddy current brake on the right side of your dyno, you do not need to remove the air or manual brake.
Note: Safety requirements of your local country may require that both brakes are
installed. Be sure to follow the safety requirements specific to your country.

REMOVING THE AIR BRAKE

1 Disconnect all air lines from the dyno. 2 Disconnect the brake electrical wires.
Model 150 dynos: Disconnect the brake wires from the electrical block mounted on the center of the dyno frame. Refer to the DynoWare EX+ Upgrade manual for more information.
air brake
solenoid wires
loosen screws
Figure 1-4: Remove the Air Brake Solenoid Wires
Upgraded Model 150/Model 200 dynos: Disconnect the brake wires from the Breakout board located on the side of the dyno.
brake wires
Figure 1-5: Remove the Brake Wires from the Breakout Board
Vers ion 8 Eddy Current Brake Installation Guide
1-5
CHAPTER 1
Air Brake and Manual Brake Removal
3 Remove the jam nuts, adjuster nuts, retainers, and springs.
The springs are compressed. Use caution when removing the springs.
4 Disconnect the brake line from the master cylinder to the caliper.
Note: Make sure you have disconnected all air lines and released the tension in the springs before disconnecting the brake line.
cut away view of dyno
side panel
spring
adjuster nut
jam nut
retainer
Figure 1-6: Air Brake—Remove the Springs
5 Remove the two bolts securing the master cylinder to the air cylinder using a
3/16-inch allen wrench. Remove the master cylinder.
master cylinder
bolts
1-6
Eddy Current Brake Installation Guide
Figure 1-7: Air Brake—Remove the Master Cylinder
EDDY CURRENT BRAKE INSTALLATION
Air Brake and Manual Brake Removal
6 Remove the bolt securing the spring bolt mounting plate. 7 Remove the mounting plate and the air cylinder from the dyno frame.
air cylinder
Figure 1-8: Air Brake—Remove the Air Cylinder

REMOVING THE MANUAL BRAKE

1 Disconnect the brake line from the master cylinder to the caliper. 2 Remove the four bolts, lock washers, and flat washers that secure the master
cylinder and foot pedal.
The bolts run from the inside, through the master cylinder, and into the foot pedal mounting plate.
foot pedal
bolt
mounting plate
master cylinder
Figure 1-9: Remove the Manual Brake
Vers ion 8 Eddy Current Brake Installation Guide
1-7
CHAPTER 1
Air Brake and Manual Brake Removal

REMOVING THE BRAKE CALIPER ASSEMBLY

1 Remove the four bolts and washers that secure the caliper assembly. 2 Loosen the brake pads and remove the assembly.
Note: Do not put the bolts back into the dyno frame. The holes will be used to mount the eddy current brake to the dyno.
3 Loosen the set screw above the keyway in the drum axle using a 3/16-inch allen
wrench.
4 Remove the three 5/16-inch bolts in the lock collar and insert these bolts in the
three threaded holes in the lock collar. Tighten the bolts until the collar comes loose.
5 Slide the rotor and lock collar off the drum axle and remove the key.
caliper assembly
lock collar
Figure 1-10: Remove the Brake Caliper Assembly
key way
1-8
Eddy Current Brake Installation Guide
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