Dynojet 188R User Manual

©1997-1999 Dynojet Research, Inc. All Rights Reserved.

Eddy Current Brake Installation Guide for Model 168/178/188/198 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
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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: 98232100 Version 3 (08/99)

Revision C 8/12/99 Document #98232100 1

Eddy Current Brake
Installation Guide

This manual is designed to help the user install the
Eddy Current Brake optional hardware for Dynojet’s
model 168 / 178 / 188 / 198 Dynamometers.

Uncrate

Step 1

Remove the top and sides of the crate and remov e
retarder cover.

- Remove (4) bolts that secure the retarder cov er.

- Remove the Retarder Safety Cover.

- Unclamp the retarder from the Retarder Cover.

- Remove the hardware box and the hood
extension from the crate.

2 Document #98232100

Step 2

Verify the hardware contents as follows:

- (A) Control Box

- (B) Connecting Arms (2)

- (C) Power Cable

- (D) Remote Pendant

- (E) Male Coupler (Mounted on the Retarder)

- (F) Female Coupler

- (G) Key

- (H) Coupler Bolts

- (I) Rubber Mounts (4)

- (J) Rubber Grommets (2)

- (K) Plastic Ties (4)

- (L) 3/8" Nuts, Bolts and Lockwashers for
Connecting Arms (4)

Refer to the picture below.

F

E

D

C

B

B

G

K

H

J

I

A

L

Document #98232100 3

Step 3

Remove the retarder from the crate.

- Unbolt the retarder from the crate.

- Use loop straps to lift the retarder from the
crate. Loop the straps around the top of the
retarder frame so that they cross as shown in the
pictures below.

- Lift the retarder out of the crate and place it
near the dyno.

Correct

Incorrect

4 Document #98232100

Prepare Dyno

Step 1

Unbolt the top deck and then remove it.

Step 2

Remove the brake cover (if applicable)

- Using a 9/16" socket, open or box end wrench,
remove the four bolts, (2) each side, that secure
the cover to the dyno.

Step 3

Disconnect the battery.

Document #98232100 5

Remove the Brake

Remove the existing dyno brake (if applicable).

Step 1

Remove the brake lines and master cylinder
assembly.

Brake Removal.

- Disconnect all air lines and brake lines from the
dyno.

- Disconnect brake electrical wires:

- Remove the cover on the wire terminal box

and disconnect the air valve wires from the
breakout board.

- Remove the four hex head bolts from
the air canister assembly and remove it.
The bolts come through from the other
side of the center frame section.

Remove the (4) hex
head bolts from the
other side of the
center frame section.

6 Document #98232100

Step 2

Remove the 4 bolts holding the brake pad
assembly (caliper assembly). Loosen the brake
pads and remove the assembly. Do not put the
bolts back into the dyno frame as the holes will be
used to fasten the retarder to the dyno.

Step 3

Remove the rotor.

- Loosen the set screw above the keyway in the
drum axle using a 3/16" Allen wrench.

Document #98232100 7

- Remove the (3) 5/16" bolts in the lock collar.

- Put the (3) 5/16" bolts in the three threaded
holes in the lock collar and tighten until the
collar comes loose.

- Slide the rotor and lock collar off the drum axle
and remove the key.

Step 4

Check the drum axle.

- Check the shaft for damage or rust.

(If there are any marks on the shaft, carefully file
them flush with the shaft.)

8 Document #98232100

Step 5

Put the upper and lower connecting arms on the
retarder .

- Remove the (8) 3/8" bolts from the side of the
retarder, as in the picture below.

Do not tighten the set screw in the coupler!

- Take one of the connecting arms and 4 of the
3

/8" bolts and fasten it to the bottom of the
retarder (the connecting arms are identical and
interchangeable).

Leave the bolts loose! Do Not Tighten yet.

Refer to the picture on the next page.

Document #98232100 9

- Take the other connecting arm and 4 of the 3/8"
bolts and fasten it to the top of the retarder.

Leave the bolts loose! Do Not Tighten yet.

10 Document #98232100

Step 6

Put the coupler on the dyno.

- Put a key in the keyway.

- Slide the coupler over the key on the axle.

Do not tighten the set screw in the coupler!

Document #98232100 11

Connect The Retarder to the Dyno

Step 1

Place the retarder next to the dyno so that the 8
holes in the connecting arms meet the 8 holes in
the dyno frame.

Step 2

Using eight 3/8"x3/4" bolts and washers
(supplied), bolt the connecting arms to the dyno.

Leave the bolts loose! Do Not Tighten yet.

Note: You must use the

3

/8“ x 3/4” bolts

with a

flat washer when connecting the arms to
the dyno. Failure to use the specified bolts
and washers will cause interference with
the dynamometer drum.

Note: The bolts that secure the arms to the dyno

should have blue lock tight on them.

12 Document #98232100

Step 3

Align the retarder with the dyno.

- Remove the top bolt of the torque arm so that
the middle of the retarder can swivel.

- Place a straight edge across the apex of the drum
and across the retarder. (Swivel the middle of
the retarder as necessary for clearance.)

- Measure down to the collars on the axle shaft of
the retarder (not the black bearing locking
collars!). Shim the retarder or the dyno until the
collars are 7 19/32" (19.288 cm) down from the
top of the drum on the dyno +/- 1/16" (1.58 mm).

Document #98232100 13

Step 4

Torque all the bolts on the connecting arms to the
dyno and to the retarder to 400 in. lbs. (45 N m)
Recheck the height as in Step 4 to ensure that
nothing has moved.

14 Document #98232100

Step 5

Couple the retarder to the dyno.

- Put the bolt back in the torque arm and tighten
to 40 in. lbs.(4.5 N m). (Swivel the middle of
the retarder as necessary.)

- Slide the coupler on the dyno over the coupler
on the retarder so that the three holes in each of
the couplers line up.

- Bolt the couplers together with three 3/8"
coupler bolts and tighten to 396-444 in. lbs.
(45-50 N m).

- Tighten the set screws in the couplers to 260­290 in. lbs. (29-33 N m).

Step 6

Bolt the retarder to the ground through the four
holes in the bottom lip. As shown below.

Document #98232100 15

Control Box Installation and Wiring

Step 1

Locate the (4) holes in the dyno frame and install
the (4) rubber mounts. Use the star washers and
screws to secure the mounts.

Step 2

Mount the Control Box to the dyno frame. Secure
the Control Box with the nuts provided. The plugs
on the Control Box should be oriented upward.

(4) rubber
mounts on the
inside of the
dyno frame.

Plug

Plug

Wire goes to
Breakout Board

16 Document #98232100

Step 3

Use a 3/8” nut to secure a wire loop to the frame
bolt. Run the wire from the Control Box through the
wire loop and then through the grommet in the
frame. Leave the nut loose, you will run another
wire through the loop later.

Step 4

Wire the Control Cable from the Control box to the
Breakout board.

- The control cable has 5 wires. They connect to
the wiring block on right side of the breakout
board labeled

“ -LOAD CONTROL - “.
The black wire connects to V-.
The red wire connects to V+.
The clear wire connects to O+.
The green wire connects to O-.
The ground wire connects to SH.

See picture below.

Jumpers

Document #98232100 17

- The jumpers circled in the picture (previous
page) may need to be changed to look like the
drawing below.

Step 5

Wire the Temperature Probe wires to the breakout
board.

- The temperature cable has 5 wires. They
connect to the wiring block on the bottom of
the breakout board labeled “ - TEMP- “.

The green wire connects to G1.
The white wire connects to W1.
The black wire connects to B1.
The red wire connects to R1.
The ground wire connects to S1.

See picture below.

18 Document #98232100

- The finished Breakout Board Wiring should
look like this:

Step 6

Run the Input Power Cable through the grommet
below the Control Box. (See picture on next page)

Control Cable

Temp Probe Cable

Data Acq. Cable

Note: The Eddy Current Brake is setup to run on

120 volts / 20 amps / 60 Hz for U.S. or 220
volts / 10 amps / 50 Hz for European

Note: The voltage source must be capable of

handling a minimum of 20 amps U.S. or
10 amps European.

Document #98232100 19

Step 7

Attach the Input Power Cable to the Control Box.

Step 8

Run the Retarder Power Cable from the Retarder
through the hole with the grommet on the side of
the Dyno.

20 Document #98232100

Note:

The Eddy Current Brake is setup to run on
120 volts / 20 amps / 60 Hz for US or 220
volt / 10 amps / 50 Hz for European.

Warning!!

The voltage source and power plug must
be capable of handling a minimum of 20
amps. US or 10 amps European.

Step 9

Attach the Retarder Power Cable to the Control Box.

Step 10

Run the Retarder Power Cable along the edge of the
frame. Secure the wire with the wire loop you were
working with earlier.

Note:

See Appendix A if you must change
the plug on the Input Power Cable.

Document #98232100 21

Install The New Retarder Cover

Step 1

Remove the (4) screws that hold the cover on the
Wire Terminal Box.

Remove the cover on the wire terminal box and
set it aside.

Step 2

Using a small flat head screwdriver, loosen the
screws that retain the Starter Remote leads, and
pull the leads out of the box.

Step 3

Remove the wire restraint from the side of the
Retarder Cover. Unscrew the restraint into two
halves, then slide the Starter Remote leads
through the two halves. Using the plastic nuts,
secure the wires / restraint to the Retarder Cover.

See picture on next page.

22 Document #98232100

Step 4

Carefully position the retarder cover to the dyno
and then reattach the starter remote wires. See
picture on previous page for wiring detail.

Step 5

Use the four bolts from the old cover to bolt the
new Retarder Cover to the dyno.

Run the Starter Remote
lead through the strain relief.

Document #98232100 23

Step 6

Use the two bolts and clips, previously removed,
to bolt the cover to the retarder.

Step 7

Install the top deck that was removed earlier.

Step 8

Use the four allen head bolts, previously
removed, to bolt the retarder cover to the hood.

24 Document #98232100

Notes:

Warning:

Never operate the dyno with these
covers removed!

Document #98226100 Appendix A - 1

Appendix A

Note:

The Eddy Current Brake is setup to run
on 120 volts / 20 amps / 60 Hz for US or
220 volt / 10 amps / 50 Hz for European.

Warning!!

The voltage source and power plug must
be capable of handling a minimum of 20
amps. US or 10 amps European.

Clear Insulation Wire-

NEUTRAL

Black Insulation Wire-

HOT

Bare Wire-

GROUND

If you must replace the power plug, be sure to adhere to the
specification abov e. The individual wire descrptions are below: