Harley-Davidson and the Bar & Shield logo are among the trademarks of H-D Michigan, LLC.

Transcription

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2 Dynojet Research, Inc. All Rights Reserved. Harley-Davidson JUMPSTART Intallation and User Guide This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, and 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. Harley-Davidson and the Bar & Shield logo are among the trademarks of H-D Michigan, LLC. 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 08 (10/2012)

3 TABLE OF CONTENTS Warnings iii Appendix A Accessories Harley-Davidson Jumpstart Installation Introduction Conventions Used In This Manual Technical Support JUMPSTART Experience Specifications Uncrating the JUMPSTART Experience Identifying the JUMPSTART Experience Main Components JUMPSTART Experience Installation Installing the Axle Mount Assembly Installing the Mid-Section, Roller Module, and Side Decks Using the JUMPSTART Experience Loading the Motorcycle Removing the Motorcycle Maintenance Bearing Grease Axle Mounts Dress-Up Kit Installation A-2 Installing the Diamond Plate Covers to the Side Decks A-2 Installing the Diamond Plate Cover to the Roller Module A-3 Installing the Diamond Plate Cover to the Front Section A-4 Anchor Kit Installation A-5 Forklift Kit Installation A-7 Appendix B Red Head Anchor Installation Installation B-2 i

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5 WARNINGS Disclaimers Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the contents hereof and specifically disclaims any implied warranties of merchantability for any particular purpose. Dynojet reserves the right to revise this publication and to make changes from time to time in the content hereof without obligation of Dynojet to notify any person of such revision or changes. Dynojet is not responsible for damage resulting from improper installation of the Harley-Davidson JUMPSTART (the JUMPSTART experience) or from improper service rendered to the JUMPSTART experience. Dynojet is not responsible for damage incurred due to alteration of the JUMPSTART experience or components, use of unapproved parts, or abuse to the JUMPSTART experience. Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when using and servicing the JUMPSTART experience. Potential Hazards The JUMPSTART experience should be located in a well ventilated area. There is a carbon monoxide hazard with all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death. Any room used must incorporate sufficient exhaust extraction. Keep clear of the motorcycle when operating. Engine and exhaust components are hot. Use caution when working around the motorcycle. A cooling fan for the engine is recommended. Keep area behind the JUMPSTART experience clear. Never stand behind the JUMPSTART experience when in operation. Extended high speed operation may result in elevated rear tire temperature. Always have at least two people for loading and unloading the motorcycle. The JUMPSTART experience must always be used on a flat, level, and hard surface. Always secure the JUMPSTART experience to any trailer or other raised surfaces. Use the Anchor Kit P/N Always keep the area around the JUMPSTART experience clear. When the JUMPSTART experience is located on a trailer or other raised surface, there must be sufficient flat walking area around the JUMPSTART experience and railings around the elevated area. Never transport the JUMPSTART experience with a motorcycle mounted to it. Always wear proper ear and eye protection when operating the JUMPSTART experience. As with any equipment having moving parts, there are potential hazards. To use this equipment safely, the operator should become familiar with the instructions for operation of the equipment and always exercise care when using it. Do not repair or replace any part of the JUMPSTART experience or attempt any servicing unless specifically recommended in published user-repair instructions that you understand and have the skills to carry out. iii

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7 HARLEY-DAVIDSON JUMPSTART INSTALLATION Thank you for your interest in the Harley-Davidson JUMPSTART (the JUMPSTART experience). The JUMPSTART experience allows a person to experience riding a motorcycle without leaving the comfort and safety of the showroom floor. This document is designed to help you install and use the JUMPSTART experience. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: Version 8 Last Updated: This chapter is divided into the following categories: Introduction, page 2 JUMPSTART Experience Specifications, page 3 Uncrating the JUMPSTART Experience, page 5 JUMPSTART Experience Installation, page 8 Using the JUMPSTART Experience, page 15 Maintenance, page 18 1

8 HARLEY-DAVIDSON JUMPSTART INSTALLATION Introduction INTRODUCTION Thank you for your interest in the JUMPSTART experience. Before installing the JUMPSTART experience system, please take a moment to read this guide for proper installation procedures. 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 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 equipment. TECHNICAL SUPPORT For assistance, please contact Dynojet Technical Support at , Dynojet at dynosales@dynojet.com, 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 lines. 2

9 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Specifications JUMPSTART EXPERIENCE SPECIFICATIONS The following specifications specific to the JUMPSTART experience will help you set up an area to operate the JUMPSTART experience safely. description Weight total of axle mount assembly of mid-section of roller module of side deck Width Length Height to top of roller module to top of deck to top of axle mount assembly Maximum Wheelbase Minimum Wheelbase Maximum Front Axle Height Minimum Front Axle Height Maximum Motorcycle Weight Maximum Speed specifications kg ( lbs) kg ( lbs) kg (50.00 lbs) kg ( lbs) kg (30.00 lbs) cm (56.00 in.) cm (99.00 in.) cm (5.25 in.) cm (4.00 in.) cm (20.00 in.) cm ( in.) cm ( in.) cm ( in.) cm (12.00 in.) kg ( lbs) 105 KPH (65 MPH) Axle Mount Assembly Mid-Section Axle Handle and Screw Roller Module RS012 Side Deck Figure 1: JUMPSTART Experience Overview Version 8 3

10 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Specifications cm (56.00 in.) cm (99.00 in.) cm (5.25 in.) cm (4.00 in.) cm (20.00 in.) RS011 Figure 2: JUMPSTART Experience Dimensions 4

11 HARLEY-DAVIDSON JUMPSTART INSTALLATION Uncrating the JUMPSTART Experience UNCRATING THE JUMPSTART EXPERIENCE Use the following steps to unload your JUMPSTART experience. 1 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the top of the crate. At this point, you will want to inspect the exterior of the JUMPSTART experience for any indications of damage. Report any damage immediately. 2 Remove the JUMPSTART experience parts, leaving the roller module, from the crate and set aside. 3 Remove the sides of the crate. crate top jumpstart experience parts RS014 crate side Figure 3: Uncrating the JUMPSTART Experience Parts 4 Remove the roller module from the crate. 4a Remove the 2 x 2 from the end of the crate. 4b Insert the mid-section assembly into the roller module. 4c Secure the mid-section to the roller module using two 3-inch pins. 4d Using the mid-section as a handle, lift the roller module onto its wheels and carefully roll it off of the crate bottom. crate 2 x 2 mid-section assembly 3" pin RS015 3" pin roller module Figure 4: Removing the Roller Module Version 8 5

12 HARLEY-DAVIDSON JUMPSTART INSTALLATION Uncrating the JUMPSTART Experience IDENTIFYING THE JUMPSTART EXPERIENCE MAIN COMPONENTS Use the following list to identify the JUMPSTART experience components. part description part description axle mount panel P/N axle upright assembly, right P/N cross brace, axle mount (2) P/N mid-section assembly P/N axle cup, 1.10", superlow P/N axle cup, 1.15", superlow P/N front brace, axle mount P/N washer, 1.87 x 1.25 ID x.12 Thk (4) P/N interface assembly, right P/N pin, quick release, with ring 3/8 x 3" (2) P/N interface assembly, left P/N pin, quick release, with ring 3/8 x 1.3" (2) P/N side deck assembly (2) P/N nut, 3/8-16, nylock (16) P/N axle upright assembly, left P/N

13 HARLEY-DAVIDSON JUMPSTART INSTALLATION Uncrating the JUMPSTART Experience part description part description screw, 1/4-20 x 5/8", pan-head, torx (12) P/N axle screw handle assembly (2) P/N bolt, 3/8-16 x 3", flange-hex (20) P/N roller module P/N washer, 3/8", flat (16) P/N nut, 3/8-16, hex (4) P/N DM washer, 1/2", hardened, flat, steel (2) P/N caster mount assembly with P/N , P/N (2), and P/N (8) Version 8 7

14 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Installation JUMPSTART EXPERIENCE INSTALLATION Use the following instructions to install the axle mount assembly, mid-section, and roller assembly. INSTALLING THE AXLE MOUNT ASSEMBLY You will need the following parts: Panel, Axle Mount Cross Brace, Axle Mount (2) Nut, 3/8-16, Nylock (16) Screw, 1/4-20 x 5/8", PH, Torx (12) Bolt, 3/8-16 x 3", Flange-Hex (20) Washer, 3/8", Flat (16) Right Axle Upright Assembly Front Brace, Axle Mount Interface Assembly, Right Interface Assembly, Left Left Axle Upright Assembly Axle Screw Handle Assembly (2) DM Nut, 3/8-16, Hex (4) Caster Mount Assembly 8

15 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Installation 1 Thread one axle screw handle assembly into the left and right axle upright assemblies. 2 Loosely secure the left and right axle upright assemblies to the two cross braces using sixteen 3/8 x 3-inch bolts, sixteen 3/8-inch flat washers, and sixteen 3/8-inch nylock nuts. Leave this hardware loose for now. left axle upright assembly axle screw handle assembly right axle upright assembly cross brace RS016 Figure 5: Loosely Secure the Axle Mount Uprights to the Cross Braces 3 Secure the front brace to the left and right uprights using six 1/4-20 x 5/8-inch torx screws. RS002 front brace Figure 6: Secure the Front Brace to the Left and Right Uprights Version 8 9

16 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Installation 4 Secure the caster mount assembly to the left and right uprights using four 1/4-20 x 5/8-inch torx screws. Note: If you are installing the forklift kit, refer to Forklift Kit Installation on page A-7. 5 Tighten the 3/8-inch nuts and bolts installed earlier. RS003 Figure 7: Secure the Caster Mount Assembly to the Left and Right Uprights caster mount assembly 6 Place the axle mount panel on the axle mount assembly. Secure the axle mount panel to the front of the assembly using two 1/4-20 x 5/8-inch torx screws. axle mount panel RS004 Figure 8: Secure the Axle Mount Panel to the Axle Mount Assembly 10

17 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Installation 7 Slide the left and right interface assemblies over the left and right upright tubes and over the axle mount panel. 8 Loosely secure each interface assembly using two 3/8 x 3-inch bolts and two 3/8-inch nuts. Leave this hardware loose for now. loosely secure interface assembly using bolts and nuts slide interface assembly over tube and panel RS005 Figure 9: Loosely Secure the Interface Assemblies to the Axle Mount Assembly Version 8 11

18 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Installation INSTALLING THE MID-SECTION, ROLLER MODULE, AND SIDE DECKS You will need the following parts: Quick Release Pin, 3/8 x 3" (2) Quick Release Pin, 3/8 x 1.3" (2) Mid-Section Assembly Side Deck Assembly (2) Roller Module 1 Slide the mid-section into the roller module. 2 Insert a 3/8 x 3-inch pin on each side. mid-section 3" pin RS023 roller module Figure 10: Secure the Mid-Section to the Roller Module 12

19 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Installation 3 Slide the axle mount assembly under the mid-section. Insert a 3/8 x 1.3-inch pin in each side. 4 Tighten the two 3/8-inch bolts and nuts securing each interface assembly. Verify all four pins are fully inserted and all the hardware is secure. axle mount assembly tighten interface assembly hardware 1.3" pin mid-section RS007 Figure 11: Secure the Axle Mount Assembly to the Mid-Section Version 8 13

20 HARLEY-DAVIDSON JUMPSTART INSTALLATION JUMPSTART Experience Installation 5 Place the side decks on the mid section. Verify the pins on the side decks engage the holes on the mid-section. side deck RS008 Figure 12: Place the Side Decks on the Mid-Section 14

21 HARLEY-DAVIDSON JUMPSTART INSTALLATION Using the JUMPSTART Experience USING THE JUMPSTART EXPERIENCE Before using the JUMPSTART, Dynojet recommends you make routine checks of the JUMPSTART. Verify the side deck pins are secure and engage the holes on the mid-section. Replace any worn or missing pins. Refer to the Side Deck Standoff Replacement Technical Bulletin (P/N ). Check the condition of the axle cups regularly. Replace worn axle cups. Verify the rollers are clear of any debris. Verify the rollers are free to rotate and do not contact the floor or ground. The JUMPSTART experience must always be used on a flat, level, and hard surface. Always secure the JUMPSTART experience to any trailer or other raised surfaces. Use the Anchor Kit P/N Always keep the area around the JUMPSTART experience clear. When the JUMPSTART experience is located on a trailer or other raised surface, there must be sufficient flat walking area around the JUMPSTART experience and railings around the elevated area. Never transport the JUMPSTART experience with a motorcycle mounted to it. Use the following steps to load a motorcycle on the JUMPSTART experience. You will need the following parts: Axle Cup, 1.10" Axle Cup, 1.15" Washer, 1.87 x 1.25 ID x.12 Thk (4) Washer, 1/2", Hardened, Flat, Steel (2) LOADING THE MOTORCYCLE 1 The roller module should be on a smooth, hard surface. 2 Turn the axle screws until they are in the fully out position. 3 Place a 1/2-inch washer on the axle screw. 4 Select an axle cup appropriate for the motorcycle axle and for the motorcycle axle nut. Place the axle cups on the appropriate axle screw. Note: Use the center hole of the axle cup for most bikes. Refer to Figure 13. Note: Axle cups for older models are available. Contact Dynojet for more information. 5 To protect painted forks, place a washer (P/N ) between the axle cup and the motorcycle fork. Version 8 15

22 HARLEY-DAVIDSON JUMPSTART INSTALLATION Using the JUMPSTART Experience The surfaces of the axle mount sliders should be clean and dry. DO NOT LUBRICATE. The thread of the axle mount should be clean and dry or only lightly oiled. Do not use heavy grease. axle screw in fully out position flat washer axle cup axle screw RS033 center hole of the axle cup Figure 13: Installing the Axle Cups 6 Verify the motorcycle's tires are inflated to the factory specified pressure. 7 Clean any rocks or debris from the tread of the rear tire. 8 Load the motorcycle by riding or pushing it onto the JUMPSTART experience until the rear tire is cradled in the rollers. The rider will need to hold the bike vertically. Always have at least two people for loading and unloading the motorcycle. 9 Guide both axle cups to the motorcycle axle and nut. With the handle straight out, turn the axle screws until the cups have engaged the motorcycle axle. Note: To protect painted forks, place a washer (P/N ) between the axle cup and the motorcycle fork. 16

23 HARLEY-DAVIDSON JUMPSTART INSTALLATION Using the JUMPSTART Experience 10 Pivot both handles 90 degrees. Give each screw a half turn and then another half turn alternating side to side. 11 The motorcycle should now be stable. Give the handle bar a push; the axle mounts should not slide at all. If they do, tighten each screw another quarter turn and recheck. Check the axle screws for tightness between each use. handle, 90 degrees handle, straight RS010 Figure 14: Securing the Motorcycle to the JUMPSTART Experience REMOVING THE MOTORCYCLE 1 Have the rider hold the bike steady. 2 Loosen both axle screws until the axle cups are clear of the axle. 3 Along with the rider, push the bike backwards off the JUMPSTART experience. Version 8 17

24 HARLEY-DAVIDSON JUMPSTART INSTALLATION Maintenance MAINTENANCE This section covers maintenance items for the JUMPSTART experience. BEARING GREASE The bearings are greased during manufacture; therefore, the JUMPSTART will not require grease upon delivery. Begin regular lubrication after usage as described in this section. Grease every two or three months of regular use. Higher frequency use and higher speed use will require more frequent lubrication. Each bearing should receive 0.1oz (3ml) of recommended grease. Do not over grease the bearings, damage can result. The bearing grease zerks can be accessed on the underside of the module by turning the module over. Recommended Grease: grease specification description thickener Lithium complex oil Petroleum thickness NLGI 2 operating temperature -29 C to 93 C, intermittent to 121 C (-20 F to 200 F, intermittent to 250 F) examples Mobil Mobilith AW-2 AXLE MOUNTS The surfaces of the axle mount sliders should be clean and dry. DO NOT LUBRICATE. The thread of the axle mount should be clean and dry or only lightly oiled. Do not use heavy grease. 18

25 A PPENDIX A ACCESSORIES This appendix discusses the various optional accessories that are available for the Harley-Davidson JUMPSTART (the JUMPSTART experience) to meet your individual needs. All of these options can be added at the factory at the time of original JUMPSTART experience purchase, or purchased separately and added at any time thereafter. For more information about these accessories, please contact Dynojet s Product Specialists at for pricing and availability. Installation instructions for these options can be found in this appendix. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This appendix is divided into the following categories: Dress-Up Kit Installation, page A-2 Anchor Kit Installation, page A-5 Forklift Kit Installation, page A-7 A-1

26 APPENDIX A Dress-Up Kit Installation DRESS-UP KIT INSTALLATION Use the following instructions to install the Dress-Up Kit (P/N ) to the JUMPSTART experience. INSTALLING THE DIAMOND PLATE COVERS TO THE SIDE DECKS You will need the following parts: Diamond Plate Cover, Side Deck (2) Screw, 1/4-20 x 3/4", Button-Head (8) 1 Remove the four screws (discard) and, if present, the four nuts (save) securing each side deck support. 2 Place the diamond plate cover on the side deck. 3 Secure each cover and support using four 1/4-20 x 3/4-inch button-head screws and the nuts removed earlier (if needed). diamond plate cover side deck RS024 Figure A-1: Install the Diamond Plate Covers Side Decks A-2

27 ACCESSORIES Dress-Up Kit Installation INSTALLING THE DIAMOND PLATE COVER TO THE ROLLER MODULE You will need the following parts: Screw, 1/4-20 x 3/4", Button-Head (4) Diamond Plate Cover, Roller Module 1 Remove and discard the four screws securing the center panel to the roller module. 2 Place the diamond plate cover on the roller module. 3 Secure the cover and center panel to the roller module using four 1/4-20 x 3/4-inch button-head screws. Note: Verify the center cover is centered between the rollers and does not contact either roller. 1/4-20 x 3/4" screw diamond plate cover roller module RS025 Figure A-2: Install the Diamond Plate Cover Roller Module Version 8 A-3

28 APPENDIX A Dress-Up Kit Installation INSTALLING THE DIAMOND PLATE COVER TO THE FRONT SECTION You will need the following parts: Diamond Plate Cover, Front Section Screw, 1/4-20 x 3/4", Button-Head (2) 1 Remove and discard the two outer screws securing the caster mount assembly to the left and right uprights. 2 Place the diamond plate cover over the caster mount assembly. 3 Secure the cover and the caster mount assembly using two 1/4-20 x 3/4-inch button-head screws. RS026 caster mount assembly diamond plate cover Figure A-3: Install the Diamond Plate Cover Front Section A-4

29 ACCESSORIES Anchor Kit Installation ANCHOR KIT INSTALLATION Use the following instructions to install the Anchor Kit (P/N ) to the JUMPSTART experience. The anchor kit can be used to secure the JUMPSTART experience to concrete or to a trailer. You will need the following parts: Anchor Foot (4) Nut, 3/8-16, Nylock (4) Bolt, 3/8-16 x 3", Flange-Hex (4) Washer, 3/8", Hardened, Flat (4) Washer, 3/8", Splitlock, Steel (4) Anchor, Redhead, 3/8" (4) Redhead Anchor Installation Tool DM Washer, 5/16", Flat (4) DM Bolt, 3/8-16 x 1", Hex (4) 1 Lift the roller module for access to the underside of the module. 2 Remove the inner bolt, washer, and nut securing each wheel bracket. 3 Place an anchor bracket on each side of the roller module and secure with the bolt, washer, and nut removed earlier. Note: Figure A-4 is shown without the roller module cover for clarity. RS027 anchor bracket Figure A-4: Install the Anchor Brackets Roller Module Version 8 A-5

30 APPENDIX A Anchor Kit Installation 4 Remove the front section cover. 4a Remove the two 1/4-20 screws securing the cover to the front of the assembly. For more information, refer to Figure 8 on page b Remove the four 3/8-inch bolts and nuts securing the cover to the interface assemblies. 5 Remove the 3/8 x 3-inch bolt, washer, and nut from the cross brace on each side as shown in Figure A-5. 6 Using the hardware removed in step 5, secure the anchor bracket to each side of the cross brace as shown in Figure A-5. 7 Mark and drill each hole needed to secure the roller module and the front section to the floor or trailer. 8 Using the Red Head anchors, secure the roller module and front section to the floor. Refer to Appendix B for installation instructions. OR Using four 3/8-16 x 3-inch bolts, four 3/8-inch washers, and four 3/8-inch nuts, secure the roller module and front section to the trailer. Note: It is recommended to secure the JUMPSTART experience to a frame member of the trailer. 9 Replace the front section cover. front section cover RS028 anchor bracket Figure A-5: Install the Anchor Brackets Front Section A-6

31 ACCESSORIES Forklift Kit Installation FORKLIFT KIT INSTALLATION Use the following instructions to install the Forklift Kit (P/N ) to the JUMPSTART experience. You will need the following parts: Spacer (4) Nut, 3/8-16, Nylock (6) Bolt, 3/8-16 x 2", Hex (2) Bolt, 3/8-16 x 4", Hex (6) Washer, 3/8", Flat (16) P Forklift Bar (2) DM Nut, 3/8-16, Hex (2) DM Bolt, 3/8-16 x 1", Hex (4) You will also need the following JUMPSTART experience parts: Panel, Axle Mount Quick Release Pin, 3/8 x 3" (2) Screw, 1/4-20 x 5/8", PH, Torx (2) Bolt, 3/8-16 x 3", Flange-Hex (4) Mid-Section Assembly Interface Assembly, Right Interface Assembly, Left Roller Module DM Nut, 3/8-16, Hex (4) 1 Remove three 3/8 x 3-inch bolts, three 3/8-inch flat washers, and three 3/8-inch nylock nuts from each side of the axle mount assembly as shown in Figure A-6. RS039 Figure A-6: Remove Bolts, Flat Washers, and Nylock Nuts from Axle Mount Assembly Version 8 A-7

32 APPENDIX A Forklift Kit Installation 2 Secure each fork lift bar with two spacers to the axle mount assembly using three 3/8 x 4-inch bolts, six 3/8-inch flat washers, and three 3/8-inch nylock nuts. Note: Place a washer between the floor and the rear part of the fork lift bar to lift it slightly while the bolts are tightened. Tighten these bolts to 31 ft. lb. RS044 spacers fork lift bar place a washer here to lift the fork lift bar Figure A-7: Secure the Forklift Bar and Spacers 3 Place the axle mount panel on the axle mount assembly. Secure the axle mount panel to the front of the assembly using two 1/4-20 x 5/8-inch torx screws. 4 Slide the left and right interface assemblies over the left and right upright tubes and over the axle mount panel. 5 Loosely secure each interface assembly using two 3/8 x 3-inch bolts and two 3/8-inch nuts. Leave this hardware loose for now. axle mount panel interface assembly RS045 Figure A-8: Install the Axle Mount Panel and Interface Assemblies A-8

33 ACCESSORIES Forklift Kit Installation 6 Slide the mid-section into the roller module. 7 Insert a 3/8 x 3-inch pin on each side. mid-section 3" pin RS023 roller module Figure A-9: Secure the Mid-Section to the Roller Module 8 Remove the two most forward button-head flange bolts from each side of the roller module as shown in Figure A-10. roller module RS042 Figure A-10: Remove the Button-Head Flange Bolts from the Roller Module Version 8 A-9

34 APPENDIX A Forklift Kit Installation 9 Slide the axle mount assembly under the mid-section. 10 Secure each side of the mid-section to the axle mount assembly using one 3/8-16 x 2-inch bolt and one 3/8-inch nut. 11 Secure the forklift bars to the roller module on each side using two 3/8-16 x 1-inch bolts two 3/8-inch flat washers. 12 Tighten the two 3/8-inch bolts and nuts securing each interface assembly. The JUMPSTART can now be moved as a complete unit with a forklift. Certified forklift operators only. Follow all OSHA forklift operation guidelines. Do not move the JUMPSTART with a motorcycle loaded. 13 When you are not moving the JUMPSTART with a forklift, replace the side decks on the mid-section. Refer to Figure 12 on page secure the mid-section to the axle mount assembly RS046 secure the fork lift bar to the roller module Figure A-11: Secure the Forklift Bars and Mid-Section A-10

35 A PPENDIX B RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi-Set II Anchors. The anchors will be used to secure the dyno to concrete. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Be sure to read and understand the warnings included in this appendix. WARNINGS Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors. ITW Ramset/Red Head Multi-Set II Anchors are designed to operate properly only when installed with ITW Ramset/Red Head brand Setting Tools. The use of a 24 to 40 ounce hammer is recommended for expanding Multi-Set II anchors. The use of carbide drill bits manufactured with ANSI B drill bit diameter requirements is recommended for installation of this anchor. Not recommended for use in lightweight masonry material such as block or brick. Use of core drills is not recommended to drill holes for use with this anchor. Not recommended for use in new concrete which has not had sufficient time to cure. Anchor spacing and edge distance requirements (anchor installation locations) are the responsibility of the engineer of record. CONTACT INFORMATION FOR ITW RAMSET/RED HEAD Contact ITW Ramset/Red Head at , or 1300 North Michael Drive, Wood Dale, IL B-1

36 APPENDIX B Installation INSTALLATION Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number. catalog number drill bit size minimum hole depth setting tool catalog number Carbon Steel RM-38/RL-38 (9.5 mm) 1/2-inch 1 5/8-inch (41.2 mm) RT-138 Use the following instructions to install the Red Head anchors. 1 Drill the hole in the concrete the same outside diameter as the anchor being used to any depth exceeding minimum embedment. 2 Insert the anchor. Figure B-1: Red Head Anchor Drill the Hole anchor Figure B-2: Red Head Anchor Insert the Anchor B-2

37 RED HEAD ANCHOR INSTALLATION Installation 3 Using a hammer, drive the anchor flush with the surface of the concrete, or below the surface if the hole depth exceeds minimum embedment. Figure B-3: Red Head Anchor Drive the Anchor Flush 4 Using a hammer, expand the anchor with the setting tool. The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor. Note: Use only Ramset/Red Head setting tools to insure proper installtion. setting tool Figure B-4: Red Head Anchor Expand the Anchor Version 8 B-3

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