©1999-2002 Dynojet Research, Inc. All Rights Reserved. Eddy Current Brake Installation Guide For Motorcycle Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual is furnished under license and may only be used or copied in accordance with the terms of such license. This manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by Dynojet.
TABLE OF CONTENTS List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Chapter 1 Eddy Current Brake Installation Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Appendix A Red Head Anchor Installation Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . .A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Appendix B High Inertia Drum—Older Dyno Installation Connecting the Eddy Current Brake . . . . . . . . . . . . . . . .
LIST OF FIGURES Figure 1-1: Remove the Brake Cover and Hood Keepers . . . . . . . . . . . . . . 1-3 Figure 1-2: Remove the Eddy Current Brake from the Crate . . . . . . . . . . . 1-4 Figure 1-3: Remove the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 1-4: Remove the Air Brake Solenoid Wires . . . . . . . . . . . . . . . . . . . . 1-5 Figure 1-5: Remove the Brake Wires from the Breakout Board . . . . . . . . . 1-5 Figure 1-6: Air Brake—Remove the Springs . . . . . .
LIST OF FIGURES Figure 1-23: Theta Controller—Europe and Australia 240 VAC Dip Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Figure 1-24: Theta Controller—Drill Mounting Holes on Left Side . . . . . 1-18 Figure 1-25: Theta Controller—Drill Mounting Holes on Right Side . . . . 1-19 Figure 1-26: Theta Controller—Install on Left Side . . . . . . . . . . . . . . . . . . 1-20 Figure 1-27: Theta Controller—Routing the Cables on Left Side . . . . . .
CHAPTER 1 EDDY CURRENT BRAKE INSTALLATION This document provides instructions for installing the Eddy Current Brake (retarder) optional hardware to Dynojet’s Model 150 and 200 Motorcycle Dynamometers. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: 98226100 Version 8 Last Updated: 03-29-02 CONVENTIONS The conventions used in this manual are designed to protect both the user and the equipment.
CHAPTER 1 Parts List PARTS LIST ................................... The following table lists all of the parts included in the Eddy Current 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.
EDDY CURRENT BRAKE INSTALLATION Preparation PREPARATION ................................... This section describes how to unpack the eddy current brake and remove the hood from your dyno. UNPACKING THE EDDY CURRENT BRAKE 1 2 3 4 5 Remove the top and sides of the crate. If you ordered a hood upgrade, remove the new hood from the crate. Remove the four bolts securing the eddy current brake cover and set aside. Remove the two bolts securing the hood clamps to the brake and set aside.
CHAPTER 1 Preparation 6 Remove the eddy current brake from the crate. Note: Dynojet recommends using a continuous nylon loop style strap to lift the eddy current brake from the crate. 6a Remove the bolts securing the eddy current brake to the crate. 6b Place the nylon loop strap around the top of the brake frame making sure it crosses as shown in Figure 1-2. 6c Using the nylon loop strap, remove the eddy current brake from the crate and place it near the dyno.
EDDY CURRENT BRAKE INSTALLATION Air Brake and Manual Brake Removal AIR BRAKE AND MANUAL BRAKE REMOVAL ................................... This section describes how to remove both the air brake and the manual brake, the brake caliper assembly, and the rotor. If you are mounting the eddy current brake on the right side of your dyno, you do not need to remove the air or manual brake. Note: Safety requirements of your local country may require that both brakes are installed.
CHAPTER 1 Air Brake and Manual Brake Removal 3 Remove the jam nuts, adjuster nuts, retainers, and springs. The springs are compressed. Use caution when removing the springs. 4 Disconnect the brake line from the master cylinder to the caliper. Note: Make sure you have disconnected all air lines and released the tension in the springs before disconnecting the brake line.
EDDY CURRENT BRAKE INSTALLATION Air Brake and Manual Brake Removal 6 7 Remove the bolt securing the spring bolt mounting plate. Remove the mounting plate and the air cylinder from the dyno frame. bolt air cylinder mounting plate Figure 1-8: Air Brake—Remove the Air Cylinder REMOVING THE MANUAL BRAKE 1 2 Disconnect the brake line from the master cylinder to the caliper. Remove the four bolts, lock washers, and flat washers that secure the master cylinder and foot pedal.
CHAPTER 1 Air Brake and Manual Brake Removal REMOVING THE BRAKE CALIPER ASSEMBLY 1 2 Remove the four bolts and washers that secure the caliper assembly. Loosen the brake pads and remove the assembly. Note: Do not put the bolts back into the dyno frame. The holes will be used to mount the eddy current brake to the dyno. 3 Loosen the set screw above the keyway in the drum axle using a 3/16-inch allen wrench.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake EDDY CURRENT BRAKE ................................... The eddy current brake can be installed on either the left or right side of the dyno. Be sure to check the dyno drum axle for damage or rust and carefully file any marks flush with the axle. ADJUSTING THE BRAKE FOR RIGHT SIDE INSTALLATIONS Make the following adjustments to the eddy current brake only if the brake will be mounted on the right side of the dyno.
CHAPTER 1 Eddy Current Brake 2 Loosely attach one of the connecting arms to the bottom of the eddy current brake using four 3/8-inch bolts and four 3/8-inch washers. 3 Loosely attach the remaining connecting arm to the top of the eddy current brake using four 3/8-inch bolts and four 3/8-inch washers. Note: All eight bolts need to remain loose in order to align the brake.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake INSTALLING THE DYNO SHAFT COUPLER 1 Replace the existing set screw in the key way of each coupler with the thread-lock set screws provided. Note: Replace the dyno shaft coupler set screw before installing the coupler on the shaft. set screw key way key way set screw eddy current brake coupler dyno shaft coupler Figure 1-14: Replace the Coupler Set Screws 2 3 Insert the key into the keyway. Slide the coupler over the key on the axle.
CHAPTER 1 Eddy Current Brake CONNECTING THE EDDY CURRENT BRAKE The following instructions and figures show the eddy current brake mounting to the left side of the dyno; however, the instructions are the same for both left and right side installations. Use the following instructions to install the eddy current brake to both the standard and high inertia drums. If you have a high inertia drum, refer to Appendix B for installation details.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake ALIGNING THE EDDY CURRENT BRAKE Eddy current brake and coupler alignment is very important. You must follow these instructions very carefully to ensure proper alignment and function. Dynojet will not warranty any coupler that is damaged due to improper installation. 1 2 3 4 Place a straight edge with a notch across the apex of the drum with the notch across the eddy current brake.
CHAPTER 1 Eddy Current Brake COUPLING THE EDDY CURRENT BRAKE Coupler alignment is very important. You must follow these directions very carefully to ensure proper alignment and function. Dynojet will not warranty any coupler that is damaged due to improper installation. 1 2 3 4 Slide the dyno coupler over the eddy current brake coupler so the three holes in each of the couplers line up. Secure the couplers together using three 3/8-inch bolts and tighten to 33-37 ft. lb. (45-50 N-m).
EDDY CURRENT BRAKE INSTALLATION Theta Controller THETA CONTROLLER ................................... This section describes how to install the Theta Controller, make power adjustments, and replace the fuses. ADJUSTING THE POWER Newer Theta Controllers are capable of operating at either 60 Hz or 50Hz and are able to compensate for a lower AC line voltage allowing improved performance under varying AC power conditions.
CHAPTER 1 Theta Controller 120 VAC THETA CONTROLLER (P/N 66411002) The 120 VAC Theta Controller is designed for operation in North America and Japan and is identified by a single external fuse holder. This controller is nominally calibrated for 115 to 120 VAC line voltage; in Japan, the nominal line voltage is 100 VAC and the dip switch on the Theta Controller can be set to compensate for the reduced line voltage while still providing the full output current of 20 amps.
EDDY CURRENT BRAKE INSTALLATION Theta Controller 240 VAC THETA CONTROLLER (P/N 66411003) The 240 VAC Theta Controller is identified by the two external fuse holders. The 240 VAC Theta Controller is calibrated for a nominal 230 to 240 VAC line voltage; in certain countries, line voltages of 210 to 220 VAC may be encountered and the dip switch can be set to provide full output current of 10 amps even with the reduced line voltage. Note: This controller cannot be converted to operate on 120 VAC line voltage.
CHAPTER 1 Theta Controller DRILLING THE MOUNTING HOLES Depending on the age of your dyno, you may need to drill the holes needed to mount the Theta Controller. If your dyno already has the required holes, skip these steps and continue with the installation. LEFT SIDE INSTALLATION 1 Locate the template for left side installations included with the control box. This template can also be found in Appendix D. 2 3 4 Locate the large hole on the left side of the dyno.
EDDY CURRENT BRAKE INSTALLATION Theta Controller RIGHT SIDE INSTALLATION 1 Locate the template for right side installations included with the control box. This template can also be found in Appendix D. 2 3 Place the template on the dyno. Line the template up using the existing hole and the bottom lip of the dyno frame. Mark and drill the three mounting holes to 3/16-inch (5 mm). Note: Make sure no metal chips come in contact with the electrical components.
CHAPTER 1 Theta Controller INSTALLING THE THETA CONTROLLER—LEFT SIDE The Theta Controller is mounted on the left side of the dyno regardless of which side the eddy current brake is on. The only exception is when the air brake is mounted on the left side and the eddy current brake is mounted on the right side. Refer to “Installing the Theta Controller—Right Side” on page 1-22 for more information. Be sure to set the dip switch power settings before installation.
EDDY CURRENT BRAKE INSTALLATION Theta Controller 5 Route the input power cable under and out the front of the dyno. 6 7 Insert the smaller rubber grommet as shown in Figure 1-27. Route the temperature sensor cable from the eddy current brake through the dyno to the Breakout board. Route the control cable from the Theta Controller to the Breakout board.
CHAPTER 1 Theta Controller INSTALLING THE THETA CONTROLLER—RIGHT SIDE 1 Install the Theta Controller using four No. 8 screws and washers. The screws will mount from the inside of the dyno. Figure 1-28: Theta Controller—Install on Right Side 2 3 4 5 Attach the input power cable to the Theta Controller and route the input power cable along the side of the dyno. Attach the eddy current brake cable to the Theta Controller. Note: Make sure the brake power cable is clear of the coupler.
EDDY CURRENT BRAKE INSTALLATION Theta Controller WIRING 1 Remove the four screws securing the Breakout board and cover. Set the cover aside. Breakout board and cover Figure 1-30: Theta Controller—Remove the Breakout Board Cover 2 Attach the temperature cable to the Breakout board. The temperature cable has five wires which connect to the wiring block labeled TEMP.
CHAPTER 1 Theta Controller REPLACING THE FUSE Older Theta Controllers have an internal fuse. Refer to Appendix C for more information on replacing an internal fuse. Hazardous voltage. To avoid risk of electrical shock, disconnect the power cord to the Theta Controller before replacing the fuse. Do not remove the cover. No user serviceable parts inside. 1 2 3 Remove the Theta Controller from the dyno. Refer to Figure 1-26 or Figure 1-28.
EDDY CURRENT BRAKE INSTALLATION Theta Controller To determine whether you have a 120 volt or 240 volt Theta Controller, look at the serial number/fuse(s) on the Theta Controller. If the serial number begins with an “E”, and the control box has dual fuses, then it is a 240 volt unit; if the serial number does not begin with an “E” and the control box has a single fuse, then it is a 120 volt unit.
CHAPTER 1 Theta Controller CHANGING THE INPUT POWER CABLE PLUG If the input power cable is not provided with a power plug, you must install the correct power plug for your country. The input power cable plug must connect to a properly grounded outlet and be easily accessible so that it may be disconnected. Do not wire the input power cable directly into the power panel. Refer to Figure 1-34 for individual wire descriptions.
EDDY CURRENT BRAKE INSTALLATION Hood Upgrade HOOD UPGRADE ................................... Use the following instructions to assemble and install the hood upgrade or to attach the eddy current brake cover to your existing hood. ASSEMBLING THE HOOD 1 Verify that the dyno hood side panel is on the correct side for your eddy current brake. You may have to remove the side panel and move it to the opposite side for your particular installation.
CHAPTER 1 Hood Upgrade INSTALLING THE HOOD 1 2 3 4 Verify the bolts and the set screws on the couplers are tight. Connect the battery. Carefully place the hood on the dyno leaving it propped up. Secure the key switch, if present. Lower and secure the hood using the four bolts removed earlier. Verify the hood is not pinching or contacting any cables or wires. Figure 1-38: Install the New Dyno Hood 5 6 Secure the hood clamps to the brake using the two bolts you removed earlier.
APPENDIX A 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.
APPENDIXA 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.
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 A-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.
APPENDIX B HIGH INERTIA DRUM—OLDER DYNO INSTALLATION Older high inertia dynos may not have threaded mounting holes for the eddy current brake. You will need to use nuts to secure the brake to the dyno. This appendix contains instructions for mounting the eddy current brake to the older high inertia dyno. CONNECTING THE EDDY CURRENT BRAKE ................................... 1 Verify the axle length. 1a Measure the axle from the bearing on the starter side to the end of the axle.
APPENDIXB 2 3 If not already removed, remove the four bolts in the dyno frame from the positions shown in Figure B-2. Remove the four nuts and washers from the positions shown in Figure B-2 leaving the bolts in place.
APPENDIX C THETA CONTROLLER—INTERNAL FUSE Older Theta Controllers have the fuse located inside the theta control box. This appendix contains instructions to replace the internal fuse. REPLACING THE INTERNAL FUSE ................................... Hazardous voltage. To avoid risk of electrical shock, disconnect the power cord to the Theta Controller before replacing the fuse. 1 Remove the six screws that secure the cover to the base of the Theta Controller.
APPENDIXC For continued protection against risk of fire, replace only with a fuse of the same type and having the same electrical rating. To determine whether you have a 120 volt or 240 volt early style Theta Controller, look at the serial number on the Theta Controller. If it begins with an “E”, then it is a 240 volt unit; if it does not begin with an “E”, then it is a 120 volt unit.
APPENDIX D MOUNTING TEMPLATES Depending on the age of your dyno, you may need to drill the holes needed to mount the Theta Controller. This appendix contains the templates needed to locate and place the mounting holes for both left and right side installations.
THETA CONTROLLER MOUNTING HOLE DRILL TEMPLATE FOR LEFT SIDE MOUNTING EXISTING HOLES 8.75IN (222mm) DRILL 3/16" (5mm) 4 PLACES UP 4.
THETA CONTROLLER MOUNTING HOLE DRILL TEMPLATE FOR RIGHT SIDE MOUNTING DRILL 3/16" (5MM) HOLES IN THREE LOCATIONS EXISTING HOLE P:\Templates\ right theta template 12/13/01