Motorcycle Dynamometer Installation Guide

Transcription

1 Motorcycle Dynamometer Installation Guide Dynojet Research, Inc. All Rights Reserved SD Dynojet Research, Inc. 200 Arden Drive Belgrade, MT Mendenhall Drive North Las Vegas, NV P/N Version 3

2 Copyright 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. Trademarks 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.

3 TABLE OF CONTENTS List of Figures iii Chapter 1 Dyno Installation and Setup Introduction Uncrate the Dyno Tire Carriage Pickup Card Battery Dyno Hood Ramp Assembly Electrical Diagram Chapter 2 Hardware Installation Dynoware EX+ Hardware Stack Chapter 3 Optional Accessories Optional Accessories Overview Air Brake Dual Fan Extended Carriage Mechanical Brake Monitor Arm Power Carriage Index Index-i i

4 TABLE OF CONTENTS ii

5 LIST OF FIGURES Figure 1-1: Custom Dyno Room Figure 1-2: Remove the Ramp Supports and Face Figure 1-3: Remove the Tire Carriage from the Crate Figure 1-4: Remove the Ramp Bracket from the Crate Figure 1-5: Hardware Box Contents Figure 1-6: Remove the Hood Figure 1-7: Loop Strap Placement Figure 1-8: Remove the Metal Outrigger from the Crate Figure 1-9: Secure the Metal Outrigger to the Dyno Figure 1-10: Tire Carriage Loosen the Clamps and Nut Block Figure 1-11: Tire Carriage Secure the Hand Crank Figure 1-12: Tire Carriage Install the Screw Support Bracket Figure 1-13: Attach the Pickup Card to the Bracket Figure 1-14: Align the Pickup Card Figure 1-15: Install the Battery Figure 1-16: Secure the Hood to the Dyno Figure 1-17: Ramp Assembly Figure 1-18: Electrical Diagram Figure 2-1: Dynoware EX+ Hardware Stack Figure 2-2: RPM Module Figure 2-3: Dynamometer Input/Output Module Figure 2-4: CPU Module Figure 2-5: Connecting the Dynoware EX+ Cables iii

6 LIST OF FIGURES Figure 3-6: Remove and Replace the Hood Figure 3-7: Connect Your Shop Air Supply Figure 3-8: Install the Rotor/Taper Lock Assembly Figure 3-9: Check for Run Out Figure 3-10: Caliper Assembly Mounting Bolts Figure 3-11: Secure the Caliper Assembly Figure 3-12: Adjust the Brake Pad Space Figure 3-13: Install the Air Cylinder Figure 3-14: Install the Master Cylinder Figure 3-15: Install the Metal Brake Line Figure 3-16: Install the Spring Bolt Assembly Figure 3-17: Secure the Air Hose to the Regulator Figure 3-18: Install the Bulk Head Fitting Figure 3-19: Wire Set Up 1 Terminal Strip Wiring Figure 3-20: Wire Set Up 1 Breakout Board Wiring Figure 3-21: Wire Set Up 2 Terminal Strip Wiring Figure 3-22: Wire Set Up 2 Breakout Board Wiring and Jumper Settings Figure 3-23: Air Brake Assembly Schematic Figure 3-24: Modify the Tire Stop Figure 3-25: Remove the Extension Arm Assembly from the Crate Figure 3-26: Secure the Extension Arm Assembly to the Tire Stop Figure 3-27: Install the Fan Assembly Figure 3-28: Install the Outlet Box Figure 3-29: Modify the Extension Arm Assembly Removing the Arms Figure 3-30: Modify the Extension Arm Assembly New Arm Configuration Figure 3-31: Remove the Carriage Screw Support Bracket Figure 3-32: Remove the Tire Carriage, Nut Block, and Clamps Figure 3-33: Remove the Top Cover Figure 3-34: Install the Extended Carriage Support Bracket iv

7 LIST OF FIGURES Figure 3-35: Install the Nut Block and Front Clamp Figure 3-36: Install the Screw Support Bracket Figure 3-37: Install the Rotor/Taper Lock Assembly Figure 3-38: Check for Run Out Figure 3-39: Caliper Assembly Mounting Bolts Figure 3-40: Secure the Caliper Assembly Figure 3-41: Adjust the Brake Pad Space Figure 3-42: Install the Master Cylinder and Foot Pedal Figure 3-43: Install the Metal Brake Line Figure 3-44: Install the Monitor Arm Bracket Figure 3-45: Install the Arms and Tray Figure 3-46: Remove the Hand Crank Figure 3-47: Remove the Flange Bearing Figure 3-48: Remove the Aluminum Cover Figure 3-49: Install the Motor Mount Assembly Figure 3-50: Power Carriage Secured to Dyno Version 3 v

8 LIST OF FIGURES vi

9 C HAPTER 1 DYNO INSTALLATION AND SETUP This document provides instructions for installing the Dynojet Motorcycle Dynamometer (dyno). To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: Version 3 Last Updated: This chapter is divided into the following categories: Introduction, page 1-2 Uncrate the Dyno, page 1-5 Tire Carriage, page 1-9 Pickup Card, page 1-11 Battery, page 1-12 Dyno Hood, page 1-13 Ramp Assembly, page 1-14 Electrical Diagram, page

10 CHAPTER 1 Introduction INTRODUCTION Thank you for purchasing the Dynojet Motorcycle Dynamometer. Before installing your dynamometer (dyno), please take a moment to review the items you will need to provide for your dyno. YOUR DYNO ROOM This section is not meant to imply that a dyno room is essential to repeatable results on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan, exhaust extraction, and noise reduction capabilities can add a new dimension to your shop. A proper dyno room design will help to ensure repeatable, accurate runs. A good dyno room should do the following: minimize noise provide a controlled environment for testing provide a view window for customers be designed with safety in mind Cooling Fan After building your dyno room, you will need to supply a cooling fan. The cooling fan supplies air to cool the bike s engine while supplying fresh oxygen for you and your bike to breathe. It is a common misconception that you cannot tune a bike without a large fan simulating exact road conditions; however, a good cooling fan is the only requirement for consistent diagnostics and tuning. Exhaust Extraction An exhaust fan is needed to remove exhaust gasses, especially carbon monoxide, from the dyno room. Carbon monoxide is extremely harmful to people if not removed from the room and will affect engine power when mixed with fresh air. Equalizer Box If the air coming into the dyno room is greater than the air leaving the dyno room, the room will become pressurized. A pressurized dyno room will make measured power misleading. To compensate, you need an equalizer box. The equalizer box is a baffled (to reduce noise) vent to the outside of your dyno room. The size of the equalizer box is dependent on the size of your dyno room and the size of your fans. 1-2

11 DYNO INSTALLATION AND SETUP Introduction Industrial Noise Control, Inc. Industrial Noise Control, Inc. offers a zinc-coated steel room custom built to your specifications. This room meets all dyno room requirements. For more information on building a dyno room, read the DynoSource newsletter Volume 1, No. 7 (published by Dynojet) included in your information pack. The dyno room must be clean, dry, at a minimum of 32 degrees Fahrenheit (0 degrees Celsius), and have some system of exhaust extraction. Figure 1-1: Custom Dyno Room 12 Volt Battery A motorcycle starting system is included with your Dynojet Dynamometer. You will need an automotive battery to use this feature. The dyno is designed to carry a group 24 deep cycle series battery with a minimum of 600 cold cranking amps. Motorcycle Tie-Down Straps Dynojet recommends using motorcycle tie-down straps for securing the bike on the dyno. You will need to provide the tie-down straps. Computer System You will need to provide a computer system to run the WinPEP software. system requirements recommended hardware and software Pentium P5-100 processor Pentium P5-133 or greater processor Microsoft Windows 9x 28.8 K modem or better 800 MB hard drive 1.2 gigabyte hard drive or better 16 MB of available RAM 16 MB of available RAM (32 MB for Windows 98) 800x600 (SVGA) monitor 1024x768 (SVGA) monitor 16k color video 16k color video or better 8x CD-ROM Drive 8x CD-ROM Drive 8 MB of available hard-disk space is required to install WinPEP Version 3 1-3

12 CHAPTER 1 Introduction 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 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 , or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV Visit us on the World Wide Web at where Dynojet provides state of the art technical support, on-line shopping, 3D visualizations, and press releases about our latest product line. 1-4

13 DYNO INSTALLATION AND SETUP Uncrate the Dyno UNCRATE THE DYNO Use the following steps to uncrate your dyno. You will need to provide equipment capable of lifting a minimum of 1600 lb. (725 kg.) to move the crated dyno into position in your dyno room. 1 Move the crated dyno to a clear area near your dyno room. 2 Remove the three ramp supports and the ramp face. If you ordered your dyno without a ramp, skip to step 3. Refer to Ramp Assembly on page 1-14 for ramp assembly instructions, ramp face ramp supports Figure 1-2: Remove the Ramp Supports and Face 3 Remove the top and sides of the crate. 3a Use a pry bar, or large flat screwdriver, and a hammer to loosen and remove the top of the crate. 3b Remove the crate braces and sides. 4 Remove the tire carriage. The tire carriage is fastened to the bottom of the crate. Figure 1-3: Remove the Tire Carriage from the Crate Version 3 1-5

14 CHAPTER 1 Uncrate the Dyno 5 Remove the ramp bracket. The ramp bracket is attached to the bottom of the crate. Figure 1-4: Remove the Ramp Bracket from the Crate 6 Remove the hardware box containing two outrigger bolts and lock washers, the tire carriage screw handle, and the screw support bracket. Refer to Figure 1-5. If you ordered a ramp, the hardware box will also contain six carriage bolts, six flat washers, six lock washers, and six nuts to be used in the ramp installation. Refer to Ramp Assembly on page 1-14 for ramp assembly instructions, Figure 1-5: Hardware Box Contents 1-6

15 DYNO INSTALLATION AND SETUP Uncrate the Dyno REMOVING THE DYNO FROM THE CRATE You will need to provide equipment capable of lifting a minimum of 1600 lb. (725 kg.) to lift the dyno off the crate and into position in your dyno room. You will also need a pair of straps capable of supporting 1600 lb. (725 kg.) to attach to the dyno. Dynojet recommends using single loop style straps. 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. key switch Figure 1-6: Remove the Hood 4 Remove the four screws securing the dyno to the crate base using a 9/16-inch socket, open or box end wrench. 5 Wrap the single loop straps around the dyno support frame just in front of the drum. 6 Position the straps as far to the outside of the support frame as possible. Refer to Figure 1-7 for exact placement. Note: Exact placement of the loop straps is important. Any other placement could damage the dyno. support frame in front of drum Figure 1-7: Loop Strap Placement Version 3 1-7

16 CHAPTER 1 Uncrate the Dyno 7 Lift the dyno off the crate and move into position in your dyno room. 8 Remove the metal outrigger attached to the bottom of the crate. metal outrigger Figure 1-8: Remove the Metal Outrigger from the Crate 9 Attach the metal outrigger to the dyno. The outrigger is used when strapping the bike to the dyno. 9a Slide the outrigger through the rectangular hold in the dyno frame. 9b Secure the outrigger to the dyno using two 3/8-inch bolts and lockwashers. bolt lock washer metal outrigger Figure 1-9: Secure the Metal Outrigger to the Dyno 1-8

17 DYNO INSTALLATION AND SETUP Tire Carriage TIRE CARRIAGE The tire carriage is fastened to the bottom of the crate next to the dyno. Refer to step 4 on page 1-5 for instructions on removing the tire carriage from the crate. INSTALLING THE TIRE CARRIAGE 1 Loosen the bolts securing the three carriage clamps and nut block to the top of the dyno using a 1/2-inch socket, open or box end wrench. carriage clamps nut block Figure 1-10: Tire Carriage Loosen the Clamps and Nut Block 2 Slide the carriage under the carriage clamps and the nut block until the carriage screw is touching the nut block as shown in Figure Slide the hand crank onto the end of the carriage screw. 4 Secure the hand crank to the screw shaft by tightening the set screw using a 5/32-inch allen wrench. nut block hand crank carriage screw Figure 1-11: Tire Carriage Secure the Hand Crank Version 3 1-9

18 CHAPTER 1 Tire Carriage 5 Using the hand crank, screw the carriage through the nut block. 6 Install the screw support bracket. 6a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure b Place the screw support bracket in front of the carriage screw. The two threaded holes in the bracket should face the two matching holes in the carriage. Loosely install the two 1/4 x 1/2-inch button-head screws. 6c Before tightening the screws, apply some pressure to the bracket to compress the belleville washers. The handle should still turn freely, but the turning force should now be around five to six pounds. To adjust the force needed to turn the crank handle, adjust the compression of the belleville washers. 6d Using a 5/32-inch allen wrench, tighten the two button-head screws. 7 Tighten the clamp and nut block bolts with a 1/2-inch wrench. screws belleville washers support bracket carriage screw Figure 1-12: Tire Carriage Install the Screw Support Bracket 1-10

19 DYNO INSTALLATION AND SETUP Pickup Card PICKUP CARD The pickup card is an electronic circuit board that accurately senses each drum revolution. INSTALLING THE PICKUP CARD 1 Locate the pickup card bracket on the right side of the dyno just ahead of the drum. 2 Install the new pickup card in the notch on the new bracket using two No. 8 screws and lock washers. Do not tighten, the card must be aligned first Make sure the side of the card with the optical pickup faces the back of the dyno. Refer to Figure pickup card bracket pickup card Figure 1-13: Attach the Pickup Card to the Bracket 3 Align the optical pickup card with the tab on the dyno drum axle. Once aligned, tighten the screws to secure the pickup card in place. The optical pickup is very delicate. Be careful not to damage the optical pickup during alignment. tab on dyno optical pickup Figure 1-14: Align the Pickup Card Version

20 CHAPTER 1 Battery BATTERY A bike starting system is included with your Dynojet Dynamometer. You will need to provide an automotive battery to use this system. The dyno is designed to carry a group 24 series battery with a minimum of 600 cold cranking amps. INSTALLING THE BATTERY 1 Locate the red battery cable on the inside of the dyno. 2 Place the battery in the battery carrier on the inside of the dyno so the red cable can reach the positive (+) post on the battery and the black battery cable can reach the negative (-) post. 3 Secure the red battery cable to the positive (+) battery post. 4 Secure the black battery cable to the negative (-) battery post. 5 Press the starter button to verify that the starter turns the drum correctly. To prevent possible injury, disconnect the battery before performing any dyno maintenance or installing any optional accessories. battery with positive side towards the front of the dyno Figure 1-15: Install the Battery 1-12

21 DYNO INSTALLATION AND SETUP Dyno Hood DYNO HOOD There is a door safety switch included with the European dynos only. European dyno owners will need to install this switch before reinstalling the hood. Installation instructions are included with the switch. INSTALLING THE HOOD 1 Make a final inspection of your dyno and verify that all connections are tight. 2 If you have not already done so, connect the battery. 3 Carefully place the hood on the dyno leaving it propped up. 4 Secure the wires to the key switch. Note: You must have the wires connected and the key installed to operate the dyno. The orientation of the wires on the key switch is not important. 5 Lower and secure the hood using the four bolts you removed earlier. Never operate the dyno with this cover removed. key switch Figure 1-16: Secure the Hood to the Dyno Version

22 CHAPTER 1 Ramp Assembly RAMP ASSEMBLY ramp support The ramp is assembled by bolting the ramp face, the ramp supports, and the ramp bracket together. Note: You will need to supply additional wood screws or nails to secure the ramp supports to the ramp face. 1 Using the ramp bracket as a template, mark and drill six holes in the ramp face using a 3/8-inch bit. 2 Secure the ramp face, supports, and bracket using six six-inch carriage bolts, six flat washers, six lock washers, and six nuts. 3 Make sure the supports are aligned properly with the ramp face and secure the supports to the ramp face using wood screws or nails. nut lock washer flat washer ramp bracket ramp face carriage bolt Figure 1-17: Ramp Assembly 1-14

23 DYNO INSTALLATION AND SETUP Electrical Diagram ELECTRICAL DIAGRAM Figure 1-18: Electrical Diagram Version

24 CHAPTER 1 Electrical Diagram 1-16

25 C HAPTER 2 HARDWARE INSTALLATION This chapter contains the hardware installation specifications for the DynoWare EX+ modules. This chapter is divided into the following categories: Dynoware EX+ Hardware Stack, page 2-2 Atmospheric Sensing Module, page 2-2 RPM Module, page 2-3 Dynamometer Input/Output Module, page 2-4 CPU Module, page 2-5 Connecting the DynoWare EX+ Cables, page

26 CHAPTER 2 Dynoware EX+ Hardware Stack DYNOWARE EX+ HARDWARE STACK The standard dynamometer electronics package (hardware stack) is comprised of four interconnected modules: Atmospheric Sensing Module, RPM Module, Dynamometer Input/Output Module, and the CPU Module. system expansion connector atmospheric sensing module RPM module dynamometer input/output module CPU module Figure 2-1: Dynoware EX+ Hardware Stack ATMOSPHERIC SENSING MODULE The atmospheric sensing module measures absolute pressure, air temperature, and relative humidity. These measurements are used by WinPEP to correct power and torque measurements to standard atmospheric conditions according to a DIN, SAE, or other formula. LED Indicator Description The green LED glows when the atmospheric sensing module is receiving power. The flashing amber LED indicates the module processor is operating properly. 2-2

27 HARDWARE INSTALLATION Dynoware EX+ Hardware Stack RPM MODULE The RPM module receives and processes signals from up to two inductive pickups for measurement of engine RPM. Each input has an automatic gain circuit to compensate for a wide variance of ignition systems. Figure 2-2: RPM Module LED Indicator Description The green LED glows when the RPM module is receiving power. The amber LED flashes when an RPM signal is detected. A steady flash rate, proportional to engine RPM, indicates a good RPM signal. These connectors are the inputs for both primary and secondary inductive pickup clips. Either input may be used with a primary inductive pickup or a secondary inductive pickup on a single ended coil. Both inputs can be used for a wasted spark ignition. Version 3 2-3

28 CHAPTER 2 Dynoware EX+ Hardware Stack DYNAMOMETER INPUT/OUTPUT MODULE The dynamometer input/output module sends and receives data from the dynamometer and the hand-held pendant. The module also contains a buzzer and light which are activated when either the vehicle or the dynamometer speed limit is approached. Figure 2-3: Dynamometer Input/Output Module LED Indicator Description The green LED glows when the dynamometer input/output module is receiving power. The amber LED flashes proportionally to dynamometer drum RPM. This 25-pin connector attaches to the shielded cable from the dynamometer. This 9-pin connector attaches to the hand held pendant which houses the button used to start/stop acquiring data. The pendant may also contain a brake switch. 2-4

29 HARDWARE INSTALLATION Dynoware EX+ Hardware Stack CPU MODULE The CPU module contains a 32-bit processor which acquires data from the expansion modules and communicates to the main computer running the WinPEP software. The processor queries the expansion modules to determine their identity and capabilities. Figure 2-4: CPU Module LED Indicator Description The green LED glows when the CPU module is receiving power. The blue LED is lighted when data from the modules is being acquired and saved. One of these connectors is used to communicate to the main computer. The 9-pin connector (left) attaches to the PC s RS-232 serial communications port. The 8-pin modular connector (right) provides communications according to the RS-422/485 specification. This connector provides a synchronization signal to a third party data acquisition system. This connector provides 12 volt DC power to a third party data acquisition system. This connector accepts 12 volt DC power from a power supply or battery. The adjacent LED glows bright green when power is properly connected. When this switch is on, power is supplied to all connected modules. Version 3 2-5

30 CHAPTER 2 Dynoware EX+ Hardware Stack CONNECTING THE DYNOWARE EX+ CABLES Attach the following cables using the cables that came in the DynoWare package. Refer to Figure 2-5 for cable placement locations. Attach the 9-pin shielded serial cable to the RS-232 socket on the CPU module and a free COM (serial communications) port on the PC. A 9-pin to 25-pin adapter may be required at the PC. Attach the 25-pin shielded cable from the dynamometer to the Dynamometer Input/Output module. Attach the 9-pin connector from the hand-held pendant to the Dynamometer Input/Output module. Attach the 3-pin plug from the power supply to the CPU module with the flat side facing down. Note: The DynoWare EX+ hardware stack must be mounted in your shop so as to be easily seen while making dyno runs. primary inductive pickup socket 25-pin socket 9-pin, hand help pendant 9-pin, RS-232 socket 3-pin power plug Figure 2-5: Connecting the Dynoware EX+ Cables 2-6

31 C HAPTER 3 OPTIONAL ACCESSORIES This chapter discusses the various optional accessories that are available for the Dynojet Dynamometer (dyno). For more information about these accessories, please contact Dynojet s Product Specialist s at for pricing and availability. This chapter is divided into the following categories: Optional Accessories Overview, page 3-2 Removing and Replacing the Hood, page 3-3 Air Brake, page 3-4 Dual Fan, page 3-17 Extended Carriage, page 3-24 Mechanical Brake, page 3-29 Monitor Arm, page 3-34 Power Carriage, page

32 CHAPTER 3 Optional Accessories Overview OPTIONAL ACCESSORIES OVERVIEW Depending on your current configuration, there are various optional accessories that can be added to your Dynojet Dynamometer to meet your individual needs. All of these options can be added from the factory at the time of original dyno purchase, or purchased separately and added at any time thereafter. A brief description of these accessories follows. Installation instructions for some of these options can be found in this chapter. Complete installation instruction manuals may also be found by browsing the Manuals folder on your WinPEP installation CD.Visit the Dynojet web site for more information about dynamometer accessories and ordering information. Air or Mechanical Brake The air brake is an electro-pneumatic braking system while the mechanical brake is a foot actuated hydraulic brake. Both brakes can be utilized to quickly slow the drum after a run is complete. This is especially useful for two-stroke applications when engine compression cannot be used to slow the drum. Both brakes can greatly speed up the testing process. Refer to Air Brake on page 3-4 or Mechanical Brake on page 3-29 for installation instructions. Dual Fan The dual fan supplies air to cool the bike s engine. Refer to Dual Fan on page 3-17 for installation instructions. Eddy Current Brake The eddy current brake is perfect for engine break-in, durability testing, and fuel injection mapping. Refer to your WinPEP CD for installation instructions. Extended Carriage The extended carriage option increases the maximum wheel base (measured from the front of the front wheel to the center of the rear wheel) from 84 inches to 102 inches for testing raked cruisers and drag bikes. Refer to Extended Carriage on page 3-24 for installation instructions. Fat Boy Adapter The Fat Boy adapter is necessary when strapping a Harley- Davidson Fat Boy, or any other bike with a solid front wheel, to the carriage of the dyno. Adapter includes a second ratchet, ratchet strap, double-hook strap, and necessary fastening hardware. Refer to your WinPEP CD for installation instructions. High Inertia Drum The high inertia drum is suggested when testing bikes that produce more than 250 horsepower at the rear wheel. The extra inertia built into this special drum adjusts the run time to be equivalent to that of a standard drum with an average-power motorcycle. Mobile Base The mobile base is essential for shops that require maximum flexibility and mobility. The mobile base allows the dyno to be relocated in a matter of minutes. Refer to your WinPEP CD for installation instructions. Monitor Arm This articulated arm and platform supports the monitor, keyboard, and mouse in a convenient position for operation while seated on the motorcycle. Refer to Monitor Arm on page 3-34 for installation instructions. 3-2

33 OPTIONAL ACCESSORIES Optional Accessories Overview Power Carriage The power carriage replaces the standard hand crank with an electrically powered tire carriage allowing you to easily adjust for various wheel base distances with the press of a button. This option is ideal for dynos that are recessed where the hand crank is difficult to access. The power carriage will also reduce the time spent making adjustments for various length motorcycles. Refer to Power Carriage on page 3-37 for installation instructions. RPM Pickup The secondary RPM pickup attaches to a spark plug wire to acquire an RPM signal for the hardware stack. Trailer Package The trailer package is a simple and attractive way to make your dyno portable. Each bolt-on kit includes independent suspension, tires, fenders, tow hitch, lights, and a license plate bracket. The trailer package is not available for model 250 dynos. Refer to the WinPEP CD for installation instructions. REMOVING AND REPLACING THE HOOD Many of the procedures and instructions in this chapter require you to remove and replace the hood. Refer to the following steps for removing and replacing the hood. 1 Remove the hood. 1a Remove the four bolts securing the hood to the dyno and set aside. Prop up the hood. 1b If present, disconnect the wires to the key switch. 1c Remove the hood from the dyno and set aside. 1d Disconnect all battery wires. 2 Replace the hood. 2a Connect the battery. 2b Carefully place the hood on the dyno, leaving it propped up. 2c 2d Secure the wires to the key switch, if present. Lower and secure the hood using the four bolts removed earlier. key switch Figure 3-6: Remove and Replace the Hood Version 3 3-3

34 CHAPTER 3 Air Brake AIR BRAKE The air brake is an electro-pneumatic braking system and includes a two button pendent. The air brake can be utilized to quickly slow the drum after a run is complete. This is especially useful for two-stroke applications when engine compression cannot be used to slow the drum. The air brake can also greatly speed up the testing process. When upgrading from a mechanical brake, you will no longer use the sample button; you will need to use the new two button pendant (P/N DC ). The new pendant attaches to the same nine-pin terminal on your hardware stack. 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. connect shop air supply Figure 3-7: Connect Your Shop Air Supply To prevent possible injury, disconnect the battery before performing any dyno maintenance or installing any optional accessory. 3-4

35 OPTIONAL ACCESSORIES Air Brake PARTS LIST The following table lists all of the parts included in the Air Brake (P/N ) 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 Zip Tie, Rod, Air Brake Spring Spring Guide (retainer ring) Bolt, 1/2-20 x 3/4, Hex Grommet, 7/16 ID x 3/4 OD Spring Bolt Mounting Plate Caliper Assembly Rotor/Taper Lock Assembly with Hub and Key Air Cylinder Assembly 1 BR Grommet, 1 OD, 3/8ID, 3/4H, 1/8G 1 BR Air Hose Push Lock Fitting 1 BR Air Hose Bulk Head Fitting 1 BR Air Hose, inches BR Master Cylinder 1 BR Brake Hose (installed) 1 None Copper Washers (installed) 2 BR Brake Line 1 BR Banjo Bolt (installed) 1 BR Springs, Purple (for Spring Bolt Assembly) 2 BR Bolts, 1/4 x 4 1/2, Socket Head 2 DC Pendant and Cable 1 DE Screw, 8 x 1/2, Self Tapping 2 DM /2 Cable Clamp, Nylon 2 DM Nut, 1/4, Adjuster (for Spring Bolt Assembly) 4 Version 3 3-5

36 CHAPTER 3 Air Brake 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 Insert the key into the slot on the shaft. 2 Slide the rotor/taper lock assembly on to the shaft. key shaft rotor/taper lock assembly Figure 3-8: 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. dial indicator taper lock bolts (two visible here) Figure 3-9: Check for Run Out 3-6

37 OPTIONAL ACCESSORIES Air Brake INSTALLING THE CALIPER ASSEMBLY 1 Tighten the two bolts shown in Figure Remove the four bolts and washers in the top and bottom right corners (as shown in Figure 3-10) and set aside. These bolts will be used to mount the caliper assembly in step 3. remove bolts and use to mount caliper assembly tighten remove bolts and use to mount caliper assembly Figure 3-10: Caliper Assembly Mounting Bolts 3 Secure the caliper assembly with the four bolts and washers removed in step 2. caliper assembly Figure 3-11: Secure the Caliper Assembly Version 3 3-7

38 CHAPTER 3 Air Brake 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. jam nut adjuster nut Figure 3-12: 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. cut away view of dyno side panel air cylinder bolt mounting plate Figure 3-13: Install the Air Cylinder 3-8

39 OPTIONAL ACCESSORIES Air Brake 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 x 4 1/2-inch socket head mounting bolts using a 3/16-inch allen wrench. cut away view of dyno side panel master cylinder bolts air cylinder Figure 3-14: 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 b 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. grommet master cylinder grommet metal brake line nylon loops secure metal brake line to caliper brake hose brake hose metal brake line Figure 3-15: Install the Metal Brake Line Version 3 3-9

40 CHAPTER 3 Air Brake 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. hold adjuster nut dyno cabinet tighten jam nut against adjuster nut front retainer cut away view of dyno side panel mounting plate front retainer adjuster nut spring rod rear retainer spring jam nut Figure 3-16: Install the Spring Bolt Assembly 3-10

41 OPTIONAL ACCESSORIES Air Brake INSTALLING THE AIR HOSE 1 Install the 1-inch grommet into the hole shown in Figure Wrap the push lock fitting with thread tape. Refer to Figure Insert the five foot section of air hose through the hole. Leave enough air hose exposed and attach it to the regulator. run air hose inside dyno attach air hose to regulator grommet Figure 3-17: Secure the Air Hose to the Regulator Version

42 CHAPTER 3 Air Brake 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. cut away view of front dyno panel air hose (inside dyno) bulk head fitting (outside dyno) nut washer push lock fitting with thread tape push lock fitting bulk head fitting install complete Figure 3-18: Install the Bulk Head Fitting 3-12

43 OPTIONAL ACCESSORIES Air Brake 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 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 Wire the two black extension leads to the top two terminals on the right side. black leads from the air valve extension leads to the Breakout board Figure 3-19: 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. two black terminal strip wires Breakout board and cover Figure 3-20: Wire Set Up 1 Breakout Board Wiring Version

44 CHAPTER 3 Air Brake 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 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 The black and yellow leads for the Breakout board have been pre wired to the terminal strip at Dynojet. hole air valve wire black and yellow leads to breakout board air valve wire Figure 3-21: 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. yellow black Breakout board and cover Figure 3-22: Wire Set Up 2 Breakout Board Wiring and Jumper Settings 3-14

45 OPTIONAL ACCESSORIES Air Brake 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 3-41 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. 8 Replace the hood. Refer to Removing and Replacing the Hood on page 3-3. Version

46 CHAPTER 3 Air Brake AIR BRAKE ASSEMBLY SCHEMATIC Figure 3-23: Air Brake Assembly Schematic 3-16

47 OPTIONAL ACCESSORIES Dual Fan DUAL FAN The dual fan supplies air to cool the bike s engine. This section will walk you through the fan installation procedures and adjusting the extension arm assembly when a power carriage is installed. The fan extension arm assembly comes ready to mount to the tire carriage on the dyno. However, if you have a power carriage installed on your dynamometer, you will need to make adjustments to the extension arm assembly before mounting the assembly to the dyno. Refer to Modifying the Extension Arm Assembly (For Power Carriage Only) on page To prevent possible injury, disconnect the battery before performing any dyno maintenance or installing any optional accessory. PARTS LIST The following table lists all of the parts included in the Dual Fan 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 Or Dual Fan Assembly (complete assembly) Or Dual Fan Assembly-220V (complete assembly) Dual Fan Mounting Bracket and Extension Arm Assembly Washer, 1.87 x 1.25 IDx.12Thk (Poly Washer) Bolt, 3/8"-16 x 1-1/2", Hex Nut, 3/8"-16, Nylock Washer, 3/8", Splitlock, Stl 4 DE & Outlet Box and Mounting Bracket 1 1 Version

48 CHAPTER 3 Dual Fan MODIFYING THE TIRE STOP Older dynos may not have the four holes on the tire stop needed to mount the extension arm assembly; you will need to modify the tire stop before continuing with the fan installation instructions. Refer to Figure 3-24 for hole size and placement. Figure 3-24: Modify the Tire Stop 3-18

49 OPTIONAL ACCESSORIES Dual Fan INSTALLING THE EXTENSION ARM ASSEMBLY The fan extension arm assembly comes ready to mount to the tire stop on the dyno. Note: If you have a power carriage installed on your dyno, you will need to make adjustments to the extension arm assembly before mounting the assembly to the dyno. Refer to Modifying the Extension Arm Assembly (For Power Carriage Only) on page Remove the two screws securing the extension arm assembly to the crate and remove the assembly. remove screws clip zip tie securing poly washer before installing fan Figure 3-25: Remove the Extension Arm Assembly from the Crate 2 Secure the main bracket on the extension arm assembly to the tire stop using four 3/8-16 x 1-1/2-inch bolts and four 3/8-inch washers. Note: If you modified the tire stop, you will also need to use four 3/8-inch nylock nuts. bolt washer main bracket tire stop Figure 3-26: Secure the Extension Arm Assembly to the Tire Stop Version

50 CHAPTER 3 Dual Fan INSTALLING THE FAN ASSEMBLIES Repeat the following steps for each fan assembly. 1 Place a poly washer between the stud and the extension arm. Note: The poly washer is secured to the extension arm with a zip tie. Clip the zip tie before installing the fan assembly. Refer to Figure Insert the stud on the fan assembly into the extension arm. 3 If not already installed, secure the hand knobs to the extension arm and to the fan base. Note: Your hand knobs may be different than the hand knobs shown in the following figures. fan assembly poly washer hand knob extension arm Figure 3-27: Install the Fan Assembly 3-20

51 OPTIONAL ACCESSORIES Dual Fan INSTALLING THE OUTLET BOX The outlet box mounts to the main bracket on the extension arm assembly. Install the outlet box the same way for dynos with or without a power carriage installed. 1 Remove the two button-head screws from the front of the main bracket. 2 Secure the outlet box bracket to the main bracket using the two button-head screws you just removed. Note: Extra button-head screws are included in the hardware bag if needed. 3 Plug the power cord into a 120 volt (North America) or 240 volt (Europe and Australia) power source. Note: When using the dual fan assembly in conjunction with an eddy current brake (retarder), make sure the dual fan assembly is plugged into a separate circuit than the retarder. The current draw at 120 volts is 17 amps and at 240 volts is 8 1/2 amps. 4 Activate the fans by flipping the toggle switch on the motors. The fans are independent of one another; each fan can be turned on and off individually. Note: Be sure the fans are free and clear of any obstruction. The fans can run at any time once the cord is plugged into a power source. outlet box and bracket screw Figure 3-28: Install the Outlet Box Version

52 CHAPTER 3 Dual Fan MODIFYING THE EXTENSION ARM ASSEMBLY (FOR POWER CARRIAGE ONLY) When the fan assembly is used with a power carriage, the following modifications must be made to the extension arm assembly before mounting the extension arm assembly to the dyno. Note: These modifications should be made only when a power carriage is installed. 1 Remove the four hand knobs from the extension arms. 2 Remove arm A, including the poly washer, and set aside. 3 Remove the bolt, lock washer, flat washer, and spacer securing arm B to the main bracket, including the poly washer, and set aside. Note: Arm B is the only arm with a threaded stud. arm A hand knob bolt lock washer flat washer spacer poly washer hand knob hand knob arm A arm B threaded stud poly washer arm B hand knob Figure 3-29: Modify the Extension Arm Assembly Removing the Arms 3-22

53 OPTIONAL ACCESSORIES Dual Fan 4 Flip arm A over, place the poly washer on the stud, and insert into the main bracket from the top. 5 Flip arm B over, place the poly washer on the stud, and insert into arm A from the bottom. Secure Arm B using the bolts, washers, and spacers removed earlier. Note: Arm B is the only arm with a threaded stud. 6 Replace the four hand knobs removed earlier. 7 Continue with Installing the Extension Arm Assembly on page 3-19, Installing the Fan Assemblies on page 3-20, and Installing the Outlet Box on page 3-21 to complete the fan installation. hand knob arm A hand knob threaded stud hand knob arm B main bracket arm A arm B hand knob Figure 3-30: Modify the Extension Arm Assembly New Arm Configuration Version

54 CHAPTER 3 Extended Carriage EXTENDED CARRIAGE The extended carriage option increases the maximum wheel base (measured from the front of the front wheel to the center of the rear wheel) from 84 inches to 102 inches for testing raked cruisers and drag bikes. PARTS LIST To prevent possible injury, disconnect the battery before performing any dyno maintenance or installing any optional accessory. The following table lists all of the parts included in the Extended Carriage 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 Nut, 3/8"-16, Nylock Screw, 1/4-20 x 1/2", Button-head 2 DM Nut, 5/16" 4 DM Washer, 3/8", Flat 12 DM Nut Block 1 DM Carriage Screw Support Bracket 1 DM Bolt, 3/8 x 1", Hex 6 EXT Extended Carriage Support Bracket 1 EXT DM Carriage and Tire Stop 1 DM Small Leveling Shim 1 DM Large Leveling Shim 1 DM Bolt, 5/16 x 1 1/2" 4 DM Washer, 5/16", Lock

55 OPTIONAL ACCESSORIES Extended Carriage REMOVING THE TIRE CARRIAGE 1 Using a 5/32-inch allen wrench, remove the two button-head screws securing the carriage screw support bracket and remove the bracket. carriage screw support bracket Figure 3-31: Remove the Carriage Screw Support Bracket 2 Unscrew the carriage until it is free from the nut block. Slide the carriage off the dyno. 3 Using a 1/2-inch wrench, remove the bolts (discard bolts) and washers securing the nut block and front clamp to the dyno cover and set aside. 4 Using a 1/2-inch wrench, remove the bolts and washers securing the two rear clamps to the dyno cover and set aside. nut block slide carriage off dyno rear clamps nut block front clamp carriage screw Figure 3-32: Remove the Tire Carriage, Nut Block, and Clamps Version

56 CHAPTER 3 Extended Carriage INSTALLING THE EXTENDED CARRIAGE SUPPORT BRACKET 1 Remove the eight screws securing the top cover to the dyno and set aside. Remove the cover and set aside. Removing the cover will make installing the extended carriage support bracket less difficult. cover Figure 3-33: Remove the Top Cover 2 Loosely attach the extended carriage support bracket to the front of the dyno using six 3/8 x 1-inch bolts, twelve 3/8-inch flat washers, and six 3/8-inch nylock nuts. Be sure the bolts are installed from the inside of the dyno. Figure 4 shows a cut away view of the extended carriage support bracket, dyno frame, and three of the six mounting bolts. extended carriage support bracket Figure 3-34: Install the Extended Carriage Support Bracket 3-26

57 OPTIONAL ACCESSORIES Extended Carriage 3 Using a straight edge, line the top of the support bracket with the top of the dyno chassis. 4 Tighten all six mounting bolts to 30 ft. lb. 5 Install the top cover on the dyno using the eight screws removed earlier. Refer to Figure Install the two rear clamps to the dyno cover using the bolts and washers removed earlier. Refer to Figure Using the original shim and the large shim included with the kit, loosely attach the nut block to the front of the extended carriage support bracket using two 5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock washers, and two 5/16-inch nuts. 8 Using the original shim and the small shim included with the kit, loosely attach the front clamp to the front of the extended carriage support bracket using two 5/16 x 1 1/2-inch bolts, the flat washers you removed earlier, two 5/16-inch lock washers, and two 5/16-inch nuts. nut block front clamp Figure 3-35: Install the Nut Block and Front Clamp Version

58 CHAPTER 3 Extended Carriage INSTALLING THE EXTENDED CARRIAGE 1 Slide the extended carriage through the nut block and clamps until the carriage screw contacts the nut block. Be sure the slide plate is under the rear carriage clamps. 2 Screw the carriage through the nut block. 3 Install the screw support bracket. 3a Place the belleville washers over the end of the carriage screw. It is important the belleville washers are installed in the configuration shown in Figure b Place the screw support bracket in front of the carriage screw. The two threaded holes in the bracket should face the two matching holes in the carriage. Loosely install the two 1/4 x 1/2-inch button-head screws. 3c Before tightening the screws, apply some pressure to the bracket to compress the belleville washers. The handle should still turn freely, but the turning force should now be around five to six pounds. To adjust the force needed to turn the crank handle, adjust the compression of the belleville washers. 3d Using a 5/32-inch allen wrench, tighten the two button-head screws. 4 Tighten the bolts in the nut block and the three carriage clamps. screws support bracket belleville washers carriage screw Figure 3-36: Install the Screw Support Bracket 3-28

59 OPTIONAL ACCESSORIES Mechanical Brake MECHANICAL BRAKE The mechanical or manual brake is a foot actuated hydraulic brake. The mechanical brake can be utilized to quickly slow the drum after a run is complete. This is especially useful for two-stroke applications when engine compression cannot be used to slow the drum. The brake can also greatly speed up the testing process. The following installation instructions are for the model 200 dyno; however, the mechanical brake may be installed on model 100 and 150 dynos with proper modification. Contact Dynojet Technical Support for more information about model 100 and 150 dyno modifications PARTS LIST To prevent possible injury, disconnect the battery before performing any dyno maintenance or installing any optional accessory. The following table lists all of the parts included in the Mechanical 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 Caliper Assembly Rotor with Hub, Taper Lock, and Key 1 BR Mechanical Brake Pedal Assembly 1 BR Brake Spring Plug 1 Rubber Boot 1 BR Grommet 1" OD, 3/8" ID 1 BR Master Cylinder 1 BR Brake Line 1 DE Screw, #8 x 1/2, Self Tapping 2 DM /2" Cable Clamp, Nylon 2 DM Washer, 3/8" Flat 4 DM Washer, 3/8" Lock 4 DM Bolt, 3/8 x 1 1/4", Hex 2 DM Bolt, 3/8 x 1", Hex 2 Version

60 CHAPTER 3 Mechanical Brake INSTALLING THE ROTOR/TAPER LOCK ASSEMBLY 1 Remove the hood. Refer to Removing and Replacing the Hood on page Insert the key into the slot on the shaft. 3 Slide the rotor/taper lock assembly on to the shaft. key shaft rotor/taper lock assembly Figure 3-37: Install the Rotor/Taper Lock Assembly 4 Attach the dial indicator to the side of the dyno. Spin the drum and check for run out; the tolerances are +/-.005". 5 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. dial indicator taper lock bolts (two visible here) Figure 3-38: Check for Run Out 3-30

61 OPTIONAL ACCESSORIES Mechanical Brake INSTALLING THE CALIPER ASSEMBLY 1 Tighten the two bolts shown in Figure Remove the four bolts and washers in the top and bottom right corners (as shown in Figure 3-39) and set aside. These bolts will be used to mount the caliper assembly in step 3. remove bolts and use to mount caliper assembly tighten remove bolts and use to mount caliper assembly Figure 3-39: Caliper Assembly Mounting Bolts 3 Secure the caliper assembly with the four bolts and washers removed in step 2. caliper assembly Figure 3-40: Secure the Caliper Assembly Version

62 CHAPTER 3 Mechanical Brake 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. jam nut adjuster nut Figure 3-41: Adjust the Brake Pad Space INSTALLING THE MASTER CYLINDER AND FOOT PEDAL 1 Position the master cylinder to the inside of the dyno frame and slip the rubber boot on from the outside. The rubber boot slips over the piston sleeve on the master cylinder. 2 Mount the foot pedal to the outside of the dyno frame. The bolts should run from the inside, through the master cylinder, and into the threaded foot pedal mounting plate. Note: Use the two 3/8 x 1-inch bolts on the top and the two 3/8 x 1 1/4-inch bolts on the bottom. All bolts get a lock washer and flat washer. foot pedal master cylinder 3/8 x 3/4-inch bolts for top 3/8 x 1 1/4-inch bolts for bottom Figure 3-42: Install the Master Cylinder and Foot Pedal 3-32

63 OPTIONAL ACCESSORIES Mechanical Brake 3 Remove the plunger from the pedal brake assembly. Slip the plunger into the rubber boot and then reattach it to the pedal brake arm. 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 b 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. grommet master cylinder grommet metal brake line nylon loops secure to caliper brake hose metal brake line plunger Figure 3-43: Install the Metal Brake Line 5 Fill the master cylinder with DOT 5 brake fluid. 6 Open the bleeder valve on the caliper assembly and cycle the brake to expel air. You should see fluid and air being purged from the bleeder valve. Repeat this procedure until the system is completely bled. 7 Adjust the clearance between the pads and the rotor by loosening the jam nut and turning the adjuster nut. There should be equal space on both sides of the rotor. Refer to Figure 3-41 for more information on the jam and adjuster nuts. 8 Replace the hood. Refer to Removing and Replacing the Hood on page 3-3. Version

64 CHAPTER 3 Monitor Arm MONITOR ARM PARTS LIST This articulated arm and platform supports the monitor, keyboard, and mouse in a convenient position for operation while seated on the motorcycle. The arm can be mounted on either side of the dynamometer. The following table lists all of the parts included in the Monitor Stand 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 Monitor Arm Tray Bushing, 1" x 2", 10 Gauge, Stl Plastic Cap, 1-3/4" x 1/2", Black Nut, 1/2-13, Hex Screw, 1/2-13 x 1-1/2", Sh-Cap Washer, 3/8", Splitlock, Stl Washer, 1/2", Splitlock, Stl Washer, 1/2", Flat, Stl Monitor Arm Monitor Arm Base Monitor Arm Upright 1 DM Washer, 3/8" Flat 1 DM Bolt, 3/8-16 x 1 1/4", Hex

65 OPTIONAL ACCESSORIES Monitor Arm INSTALLING THE MONITOR ARM BRACKET 1 Drill a 1/2-inch hole through the aluminum deck plate as shown in Figure Use the existing hole under the deck plate as a guide. 2 Fasten the top of the monitor arm bracket to the dyno using a 3/8-inch bolt, 3/8-inch lock washer, and 3/8-inch flat washer. Note: Do not tighten. 3 Secure the bottom of the bracket to the dyno using two 1/2-inch bolts, four 1/2-inch washers, two 1/2-inch lock washers, and two 1/2-inch nuts. 4 Fully tighten all three bracket bolts. 3/8-inch bolt drill hole monitor arm bracket 1/2-inch bolt Figure 3-44: Install the Monitor Arm Bracket Version

66 CHAPTER 3 Monitor Arm INSTALLING THE ARMS AND TRAY 1 Place a bushing on the pin of the first arm and insert the arm into the upright. Both arms are identical and interchangeable. 2 Place a bushing on the pin of the second arm and insert the arm into the first arm. 3 Place a bushing on the pin of the tray and insert the tray into the second arm. 4 Insert a plastic cap in both ends of each arm. 5 Check for clearance between the monitor arm and motorcycle, walls, ceiling, etc. Note: Dynojet does not recommend placing the computer CPU on the monitor/keyboard tray since vibration can cause damage to the computer. tray bushing plastic cap second arm first arm upright Figure 3-45: Install the Arms and Tray 3-36

67 OPTIONAL ACCESSORIES Power Carriage POWER CARRIAGE The power carriage replaces the standard hand crank with an electrically powered tire carriage allowing you to easily adjust for various wheel base distances with the press of a button. This option is ideal for dynos that are recessed where the hand crank is difficult to access. The power carriage will also reduce the time spent making adjustments for various length motorcycles. The power carriage motor is preset to be installed with the carriage screwed in all the way. Do not run the motor prior to installing it on your dyno. PARTS LIST To prevent possible injury, disconnect the battery before performing any dyno maintenance or installing any optional accessory. The following table lists all of the parts included in the Power Carriage 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 Screw, 1/4-20 x 3/4 Button-Head Bolt, 1/4-20 x 1, Hex Washer, 1/4, Splitlock, STL 2 REMOVING THE HAND CRANK 1 Remove the hand crank from the tire carriage. 1a Screw the carriage all the way in. 1b Loosen the set screw on the hand crank and remove the hand crank. set screw hand crank Figure 3-46: Remove the Hand Crank Version

68 CHAPTER 3 Power Carriage 2 Using a 5/32-inch allen wrench, loosen the two set screws in the lock collar and remove it from the screw shaft. 3 Using a 7/16-inch wrench, remove the two bolts securing the flange bearing. 4 Pry the flange bearing from the carriage screw shaft with a flat screwdriver and set aside. Note: Clean the shaft with a fine grit emery cloth to remove any remaining thread lock residue. This will make it easier to slide the motor assembly and flange bearing on the shaft. set screw on lock collar (only one visible) shaft flange bearing bolts Figure 3-47: Remove the Flange Bearing INSTALLING THE POWER CARRIAGE 1 Remove the two button-head screws securing the aluminum cover to the motor mount assembly and set aside. button-head screws aluminum cover Figure 3-48: Remove the Aluminum Cover motor mount assembly 3-38

69 OPTIONAL ACCESSORIES Power Carriage 2 Slide the motor mount assembly and flange bearing, removed earlier, over the screw shaft. Make sure the flex coupling is on the shaft. Note: The flange bearing must be facing as shown in Figure 3-49 so the grease zerk is accessible. 3 Secure the motor mount assembly and flange bearing to the carriage using two 1/4 x 1-inch bolts and lock washers. Note: Dynojet recommends using a 1/4-inch ratchet drive with universal joint and a 7/16-inch shallow socket to secure the flange bearing bolts. 4 Using a 1/8-inch allen wrench, tighten the flex coupling set screw. grease zerk flex coupling set screw flex coupling screw shaft flange bearing flange bearing bolts motor mount assembly Figure 3-49: Install the Motor Mount Assembly Version

70 CHAPTER 3 Power Carriage 5 Secure the aluminum cover with the two screws you removed earlier. 6 Plug the power cord into a 120 volt power source. Note: For European and 240 volt applications, a step down transformer must be used to provide 120 volts. 7 Using the pendant, move the power carriage through the entire range of motion making sure there is no binding or jamming. Note: When operating the power carriage with a bike on the dyno, make sure the bike is in neutral. aluminum cover pendant Figure 3-50: Power Carriage Secured to Dyno 3-40

71 INDEX A air brake 3-2, adjustments and tests 3-15 air cylinder 3-8 air hose 3-11 air valve 3-13 caliper 3-7 master cylinder 3-8 purchased with dyno 3-4, 3-5 rotor/taper lock 3-6 spring bolt 3-10 wire set up wire set up air cylinder 3-8 air hose 3-11 air valve 3-13 air vavle wire set up wire set up atmospheric sensing module 2-2 B battery 1-12 belleville washers 1-10, 3-28 C caliper air brake 3-7 mechanical brake 3-31 carriage clamps 1-9, 3-25, 3-27 conventions 1-4 CPU module 2-5 D document part number 1-1 dual fan 3-2, extension arm assembly 3-19 fan assembly 3-20 main bracket 3-19 modify tire stop 3-18 outlet box 3-21 parts list 3-17 power requirements 3-21 with power carriage 3-22 dynamometer input/output module 2-4 DynoWare EX atmospheric sensing module 2-2 cables 2-6 CPU module 2-5 dynamometer input/output module 2-4 RPM module 2-3 E eddy current brake 3-2 electrical diagram 1-15 engine cooling fan 3-2 European door safety switch 1-13 extended carriage 3-2, belleville washers 3-28 carriage clamps 3-25, 3-27 nut block 3-25, 3-27 parts list 3-24 remove tire carriage 3-25 screw support bracket 3-28 shims 3-27 support bracket 3-26 Index-i