2006 Dynojet Research, Inc. All Rights Reserved. Spring Applied Air Release (SAAR) Brake Assembly Installation

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2 2006 Dynojet Research, Inc. All Rights Reserved. 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: Version 01 (06/06)

3 TABLE OF CONTENTS Spring Applied Air Release (SAAR) Brake Assembly Installation Introduction Technical Support The Hydraulic Brake Assembly Preparing to Remove the Hydraulic Brake Removing the Hydraulic Brake Assembly Installing the SAAR Brake Assembly Installing the Brake Weldment and Brake Shoes Installing the Air Can Mount and Tube Installing the Air Can Connecting to the Breakout Board Connecting to the Shop Air Fastening the Air Can Powering up and Testing Four Wheel Drive Dynos Upgrading the Moveable 224 Dyno Connecting the Movement Board and Shop Air i

SPRING APPLIED AIR RELEASE (SAAR) BRAKE ASSEMBLY INSTALLATION This document provides instructions for installing the Spring Applied Air Release Brake Assembly (P/N 77010008) as an upgrade to model

5 SPRING APPLIED AIR RELEASE (SAAR) BRAKE ASSEMBLY INSTALLATION This document provides instructions for installing the Spring Applied Air Release Brake Assembly (P/N ) 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: Version 1 Last Updated:

6 Introduction INTRODUCTION The Spring Applied Air Release (SAAR) Brake Assembly (P/N ) 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 ) or the Installation Guide for In Ground Model 224 Automotive Dynamometers (P/N ). 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 , or write to Dynojet Research 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 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

7 Introduction Spring Applied Brake Upgrade, 224 Stock Code Description Quantity Mount, Air Can, Upgrade, Brake Arm, Brake Shoe Retainer, Brake Actuating Tube, Hairpin Cotter, 7/16"-3/4" Clevis Pin, 1/2" x 4-1/2" Air Canister, Type R Bolt, 3/8-16 x 1-1/2", Flange-Hex Brake Holder Weldment, Brake Solenoid Assembly, brake solenoid assembly 3/8-16 x 1-1/2" bolt air can mount air canister brake arm brake shoe retainer brake holder weldment hairpin cotter brake actuating tube AB090 clevis pin Figure 1: Spring Applied Brake Upgrade Version 1 3

8 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. air pressure regulator air can mounting bracket BR011 master cylinder hydraulic line solenoid assembly spring slave cylinder brake clevis pin slave cylinder Figure 2: Existing Hydraulic Braking System 4

9 The Hydraulic Brake Assembly 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 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. Version 1 5

10 The Hydraulic Brake Assembly 5 On standard dynos the brake control wiring is connected to the breakout board. The breakout board is located on the dyno as shown in Figure 3. Disconnect the two wires from the wiring block labeled BRAKE on the Breakout board, as shown in Figure 3. These two wires connect the brake solenoid. It should now be disconnected. Note: If you are installing the upgrade on a four-wheel drive dyno, see Four Wheel Drive Dynos on page 20 for the connections of the brake solenoid to the movement board. Never operate the dynamometer when the brake is not functioning. breakout board AD167 BRAKE disconnect brake assembly wiring Figure 3: Disconnect the Hydraulic Brake Control Wiring from the Breakout Board 6

11 The Hydraulic Brake Assembly REMOVING THE HYDRAULIC BRAKE ASSEMBLY 1 Remove the four springs holding the brake head pivot pin to the brake frame rail. disconnect air hose or cut air hose close to solenoid BR012 brake head pivot pin brake frame rail remove four springs Figure 4: Remove the Springs 2 Use a large flat blade screw driver or small pry bar to pry the brake shoe retainer out of the brake holder. pry the brake shoe retainer out of the brake holder brake holder BR019 Figure 5: Remove the Brake Shoe Retainer Version 1 7

12 The Hydraulic Brake Assembly 3 Remove the brake shoes from the assembly by sliding them to the outside. Set the brake shoes aside to be reused with the SAAR Brake Assembly. BR015 slide brake shoes toward the outside and remove Figure 6: Remove the Brake Shoes 4 Remove the cotter pin from the brake clevis pin on both brakes. cotter pin remove cotter pin slide brake clevis pin BR022 BR020 BR021 Figure 7: Remove the Cotter Pins Holding the Brake Hanger Pivots 8

13 The Hydraulic Brake Assembly 5 Slide the brake clevis pin into the square recesses provided. The brake clevis pin will only slide in one direction. You may need to slide your brake clevis pin opposite to the direction shown in Figure 8 if your brake clevis pin faces the other way. After you remove the hydraulic brake assembly, you will reach in to remove the pivot pins from inside the square recesses. BR016 slide brake clevis pin into square recess Figure 8: Slide the Brake Clevis Pin into the Square Recess Version 1 9

14 The Hydraulic Brake Assembly 6 Remove four lower bolts holding the slave cylinders and brake head assembly to the brake frame rail. 7 Remove the four bolts holding the master cylinder bracket to the dyno, supporting the hydraulic brake assembly during the final removal of the bolts. master cylinder bracket BR017 remove four bolts slave cylinder slave cylinder remove bolts and washers Figure 9: Remove Bolts 10

15 The Hydraulic Brake Assembly 8 The hydraulic brake assembly should now be completely free. Remove it from the dyno. 9 Extract the brake clevis pins from the square recesses and set them aside.. Note: You will reuse the brake shoes and the two clevis pins. The other parts can be appropriately discarded. BR018 remove hydraulic brake assembly Figure 10: Remove the Hydraulic Brake Assembly Version 1 11

16 Installing the SAAR Brake Assembly INSTALLING THE SAAR BRAKE ASSEMBLY The following instructions are for installing the Spring Applied Air Brake Assembly on a 224 above-ground or pit dyno. In the next steps you will: attach the brake holder weldment using the brake clevis pin you removed from the hydraulic brake assembly bolt the mounting bracket to the dyno slide the tube into place mount the air can assembly make the final connections Note: If you have a 4 wheel drive dyno model or , refer to additional instructions for Four Wheel Drive Dynos on page 20. INSTALLING THE BRAKE WELDMENT AND BRAKE SHOES 1 Slide the brake clevis pins into the square recesses as shown in Figure 11. Face the head end of the pivot toward the outside, so that the brake clevis pin is partially inside the recess and then slide the clevis pin partially into the mounting bracket. The hole on the end of the brake clevis pin, which is designed to accept the hairpin cotter, should be pointed toward the center of the dyno. Do not fully insert the brake clevis pin until after you slide the brake weldment into position 2 Position the brake weldment so that the holes on the arms are aligned to accept the brake clevis pin. slide brake clevis pin into position BR024 brake holder weldment brake arms Figure 11: Slide Brake Weldment into Position 12

17 Installing the SAAR Brake Assembly 3 Insert the brake clevis pin through the holes as shown in Figure Install the hairpin cotter. 5 Use the same method to install the remaining brake weldment with arms, pivot, and hairpin cotter. head end of brake clevis pin BR025 insert hairpin cotter Figure 12: Connect the Brake Weldment and Arms using the Brake Clevis Pin 6 Slide the brake shoe into position and thread the brake shoe retainer into position. (Now is a good time to check for wear and use new brake shoes if necessary, P/N ) brake shoe retainer brake shoe retainer installed brake shoe installed brake shoe BR031 Figure 13: Install the Brake Shoes Version 1 13

18 Installing the SAAR Brake Assembly INSTALLING THE AIR CAN MOUNT AND TUBE 1 Install the air can mount using the four 3/8"-16 x 1-1/2" flange bolts provided four 3/8"-16 x 1-1/2" flange bolts BR027 air can mount air can assembly Figure 14: Attach the Air Can Mount to the Dyno 14

19 Installing the SAAR Brake Assembly 2 Slide the tube through the brake arms. 3 Rotate the tube so that the center hole is oriented vertically. BR028 slide tube through arms orienting the hole vertically Figure 15: Slide the Tube into Place Version 1 15

20 Installing the SAAR Brake Assembly INSTALLING THE AIR CAN 1 Thread the pipe fitting which extends from the solenoid subassembly into the threaded hole on the top of the air can. Apply pipe thread sealer to the fitting if sealer is not already present. 2 Align the solenoid assembly so that it is parallel to the two bolts that extend from the bottom of the air can as shown in Figure 17. solenoid assembly AB093 threaded hole in air can threaded pipe fitting air can align solenoid assembly with these two studs Figure 16: Attach the Solenoid Subassembly to the Air Can 3 Remove and set aside the two 5/8" lockwashers and nuts for the air can. 4 Remove and set aside the 5/8" nut from the long threaded rod at the bottom of the air can. BR030 5/8" lockwashers and nuts 5/8" nut Figure 17: Prepare the Air Can Assembly 16

21 Installing the SAAR Brake Assembly 5 While lowering the air can through the hole in the tube, align the air can studs with the holes in the bracket. Note: The rod will not extend all of the way through the tube until the electronics are connected and air pressure is applied to the air can. 6 Loosely attach the air can to the bracket using the two 5/8" nuts and lockwashers removed earlier. Keeping the nuts loose will allow for adjustment while extending the air can rod the remaining distance through the tube. The power and air connections are necessary to finish connecting the brake assembly. air can studs washer and upper nut will be tightened down onto tube after lower nut is fastened use 5/8" lockwashers and nuts to attach air can to bracket insert air can rod into hole through tube BR029 Figure 18: Install the Air Can Version 1 17

22 Installing the SAAR Brake Assembly CONNECTING TO THE BREAKOUT BOARD 1 Connect the two black wires from the solenoid to the two terminals on the breakout board labelled BRAKE (one to each terminal). 2 If you have a 4 wheel drive dyno model or , refer to additional instructions for Four Wheel Drive Dynos on page 20. connect the two black wires from the brake solenoid to the breakout board BRAKE Figure 19: Connect the Brake Solenoid Wires to the Breakout Board CONNECTING TO THE SHOP AIR 1 Connect shop air to the fitting on the brake air can pressure regulator. See Figure 22 on page 21 if you are installing the brake on a four-wheel drive dyno. 2 Adjust the air pressure by pulling up on the regulator knob and turning counterclockwise to decrease the pressure to 30 psi (clockwise to increase). Note: The Spring Applied Brake should be operated at 100 psi, but you will start with the pressure lower while connecting the air can to aid in lining up the parts. pull up on regulator knob and adjust pressure to 30 psi 0 AB092 pressure gauge should read 30 psi Figure 20: Adjust the Air Pressure 18

23 Installing the SAAR Brake Assembly FASTENING THE AIR CAN 1 Check to make sure that the area is clear and that the dyno can be operated safely. 2 Power up the dyno electronics. Keep hands and fingers clear when operating dyno. 3 Use the pendant to turn the brake to the OFF position. This will apply air pressure to the brake s air can to extend the rod, allowing you to fit the rod through the bottom of the hole in the brake actuating tube. 4 Gradually increase the air pressure to 100 psi by pulling up on the regulator knob and turning it clockwise. As you are doing this, guide the air can rod through the hole in the brake actuating tube. 5 Torque the upper two nuts fastening the air can to the mounting bracket to 110 ft-lbs. 6 Adjust the nut on the bottom of the air can rod until the brake shoes are 6mm/.25" away from the dyno drum. 7 Tighten the upper nut on the air can rod down onto the brake actuating tube to sandwich the tube between the two nuts. 8 Torque the lower nut to 110 ft-lbs. Your brake should now be completely installed. connect the two black wires from the brake solenoid to the breakout board connect to shop air torque nuts to 110 ft-lbs air can rod upper nut BR032 torque lower nut to 110 ft-lbs Figure 21: Apply Air Pressure to Extend Air Can Rod into Brake Actuating Tube POWERING UP AND TESTING 1 Verify that the pressure gauge on the Spring Applied Air Brake shows 100 psi. 2 Use the pendant to turn the brake ON. 3 Ensure that the brake shoes are making contact with the dyno s drum and that the drum will not rotate. Adjust the brake if necessary using the nuts on the air can rod. Version 1 19

24 Four Wheel Drive Dynos FOUR WHEEL DRIVE DYNOS The instructions in the following sections describe the differences for installing the SAAR Brake Assembly on four-wheel drive dynos. The SAAR Brake Assembly may be used to upgrade the braking on model and four-wheel drive dynos. The dyno has a stationary 248 dyno and a moveable 224 dyno. When upgrading this model, you will leave the existing air applied brake on the stationary 248 dyno and only upgrade the moveable 224 dyno. The model dyno uses a stationary 224 dyno along with a moveable 224 dyno that can be positioned to accommodate for the wheelbase of the vehicle being tested.when upgrading a model , both 224 dynos must have the SAAR Brake Assembly upgrade. To upgrade the stationary dyno, follow the directions in the previous sections of the manual. UPGRADING THE MOVEABLE 224 DYNO Moveable 224 dynos use a control box containing the dyno movement board and other movement components. The wiring to the brake solenoid is connected to the movement board in the control box and not the breakout board, as in the standard installation instructions. In general, when installing a SAAR brake on a moveable 224 dyno, follow the instructions in the manual, except when disconnecting and connecting the brake control wiring and air. Use the steps that follow to connect the brake wiring to the movement board and to connect the air supply to the SAAR brake. CONNECTING THE MOVEMENT BOARD AND SHOP AIR The movement board is located inside the control box as shown in Figure Disconnect one black wire and one white wire from the movement board terminals labelled BRK2 that connect the existing brake solenoid. 2 Route the wires for the new brake solenoid through the opening in the control box and connect the two black wires to the terminals labelled BRK 2 on the movement board. (Connect one to each terminal, the order does not matter as the solenoid will operate correctly with either polarity.) 3 Connect the air hose to the solenoid, replacing the hose if necessary. 4 Continue the installation with step #2, Connecting to the Shop Air on page

25 Four Wheel Drive Dynos control box connect the two black wires from the brake solenoid to the terminals labelled BRK 2 on movement board connect air hose to solenoid, replace hose if needed BR033 RAIL OUT IN BRK 2 BRK 1 BRK IN +12V GNDCOM IN OUT -- PRES SW movement board Figure 22: Connect from Solenoid to the Movement Board in the Control Box Version 1 21

Maintenance Guide For Model 224, Model 224 with 4WD, Model 424x, and Model 248 Automotive Dynamometers.

2004-2008 Dynojet Research, Inc. All Rights Reserved. Maintenance Guide For Model 224, Model 224 with 4WD, Model 424x, and Model 248 Automotive Dynamometers. This manual is copyrighted by Dynojet Research,