Dynojet Spring Applied Air Release Brake Assembly User Manual
©2006 Dynojet Research, Inc. All Rights Reserved.
Spring Applied Air Release (SAAR) Brake Assembly Installation
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: 98212104 Version 01 (06/06)
T
ABLE OF
C
ONTENTS
Spring Applied Air Release (SAAR)
Brake Assembly Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
The Hydraulic Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Preparing to Remove the Hydraulic Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removing the Hydraulic Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Installing the SAAR Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installing the Brake Weldment and Brake Shoes . . . . . . . . . . . . . . . . . . . . . 12
Installing the Air Can Mount and Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installing the Air Can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting to the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Connecting to the Shop Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fastening the Air Can . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Powering up and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Four Wheel Drive Dynos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Upgrading the Moveable 224 Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connecting the Movement Board and Shop Air . . . . . . . . . . . . . . . . . . . . . 20
Spring Applied Air Release (SAAR) Brake Assembly Installation
i
S
PRING
This document provides instructions for installing the Spring Applied Air Release
Brake Assembly (P/N 77010008) as an upgrade to model 224 Automotive
Dynamometers (dynos). To ensure safety and accuracy in the procedures, perform
the procedures as they are described.
Document Part Number: 98212104
Version 1
Last Updated: 06-21-06
A
B
RAKE
PPLIED
A
SSEMBLY INSTALLATION
AIR R
ELEASE
(SAAR)
Spring Applied Air Release (SAAR) Brake Assembly Installation
1
SPRING APPLIED AIR RELEASE (SAAR) BRAKE ASSEMBLY INSTALLATION
Introduction
INTRODUCTION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The Spring Applied Air Release (SAAR) Brake Assembly (P/N 77010008) may be used
to replace the hydraulic brake on model 224 dynamometers. This guide provides
instructions for removing the hydraulic brake and installing the SAAR brake assembly.
The SAAR brake provides braking to the dyno drum through the use of a spring
applied brake mechanism. By default, the brake shoes are pressed against the dyno
drum by the spring mechanism. Air applied to the SAAR brake moves the brake shoes
away from the drum, releasing the brake.
The SAAR brake provides the following advantages over the previous hydraulic brake:
• Vehicles are easier to load since the SAAR brake is applied when the dyno is idle
• The SAAR brake provides braking in the event of a loss of power or an air supply
failure.
• Brake maintenance is reduced as the SAAR brake does not need the filling and
bleeding required for hydraulic brakes.
For more detailed information on the 224 dyno, refer to the Installation Guide for
Model 224 Above Ground Automotive Dynamometers (P/N 98210108) or the
Installation Guide for In Ground Model 224 Automotive Dynamometers (P/N
98210100).
CONVENTIONS USED IN THIS MANUAL
The conventions used in this manual are designed to protect both the user and the
equipment.
example of convention description
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 Research 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 and press releases about our latest
product line.
Do not repair or replace any part of the dynamometer or attempt any servicing
unless specifically recommended in published user-repair instructions that you
understand and have the skills to carry out.
2
Spring Applied Air Release (SAAR) Brake Assembly Installation
SPRING APPLIED AIR RELEASE (SAAR) BRAKE ASSEMBLY INSTALLATION
77010008 Spring Applied Brake Upgrade, 224
Stock Code Description Quantity
21612112 Mount, Air Can, Upgrade, 224 1
21612400 Brake Arm, 24 4
21612900 Brake Shoe Retainer, 224 2
21612901 Brake Actuating Tube, 224 1
32904080 Hairpin Cotter, 7/16"-3/4" 4
32916144 Clevis Pin, 1/2" x 4-1/2" 2
34761003 Air Canister, Type R30 1
36582471 Bolt, 3/8-16 x 1-1/2", Flange-Hex 4
61312105 Brake Holder Weldment, 224 2
64111005 Brake Solenoid Assembly, 224-2 1
brake solenoid
assembly
3/8-16 x 1-1/2" bolt
Introduction
air canister
brake arm
brake actuating tube
air can mount
AB090
Figure 1: Spring Applied Brake Upgrade
brake shoe retainer
brake holder weldment
hairpin cotter
clevis pin
Version 1 Spring Applied Air Release (SAAR) Brake Assembly Installation
3
SPRING APPLIED AIR RELEASE (SAAR) BRAKE ASSEMBLY INSTALLATION
The Hydraulic Brake Assembly
THE HYDRAULIC BRAKE ASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When upgrading to the SAAR Brake Assembly, you will remove the previously installed
hydraulic braking system shown in Figure 2. In order to minimize your exposure to
the fluid used in the hydraulic brake assembly, you will remove the major portion of
the assembly as one piece.
Follow manufacturer precautions for handling brake fluid used in the
hydraulic braking system. Do not breathe vapors, mist, fume or dust. Do not
get in eyes, on skin or clothing. Wear protective gloves or clothing if exposure
conditions warrant. Wash thoroughly after handling. Launder contaminated
clothing before reuse. Use only with adequate ventilation.
solenoid
assembly
spring
slave cylinder
air pressure
regulator
air can
brake clevis
pin
slave cylinder
mounting
bracket
BR011
master cylinder
hydraulic line
Figure 2: Existing Hydraulic Braking System
4
Spring Applied Air Release (SAAR) Brake Assembly Installation
SPRING APPLIED AIR RELEASE (SAAR) BRAKE ASSEMBLY INSTALLATION
PREPARING TO REMOVE THE HYDRAULIC BRAKE
1 Turn off the power and unplug the dyno electronics and observe all applicable
safety procedures.
2 Shut off and release the air pressure to the air pressure regulator.
3 Remove covers as necessary to provide yourself good access to the braking
components. Refer to your dyno manuals, if necessary, to review removing the
covers. You can download copies of the manuals for your dyno from
www.dynojet.com.
4 Disconnect the 3/8-inch air hose from the fitting on the pressure regulator, or cut
off the existing air hose close to the fitting on the pressure regulator.
Note: Leave the air hose with the dyno as you will reconnect it to the new
pressure regulator for the SAAR Brake Assembly.
The Hydraulic Brake Assembly
Version 1 Spring Applied Air Release (SAAR) Brake Assembly Installation
5
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