©2002-2004 Dynojet Research, Inc. All Rights Reserved. Proportional Air Brake Installation Guide. 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 Proportional Air Brake Installation Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROPORTIONAL AIR BRAKE INSTALLATION This document provides instructions for installing the proportional air (prop air) brake system with the model T-3000 electronic pressure regulator (EPR) to the model 248 automotive dynamometer (dyno). Appendix A includes instructions for replacing and wiring the old EPR with the model T-3000 EPR. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
PROPORTIONAL AIR BRAKE Installation INSTALLATION ................................... This section describes the procedures to remove the standard air brake system, install the proportional air brake system, and wire the Breakout board. PARTS LIST The following table lists all of the parts included in the Proportional Air 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.
INSTALLATION GUIDE Installation REMOVING THE STANDARD AIR BRAKE SYSTEM 1 2 3 4 5 6 Turn off the power on the dyno electronics. Shut off and release the air pressure to the air pressure regulator. Remove the two black wires from the wiring block labeled BRAKE on the Breakout board. Remove the yellow and black wires from the wiring block labeled PRESS on the Breakout board. Disconnect the 3/8-inch air hose from the fitting on the air brake control switch.
PROPORTIONAL AIR BRAKE Installation INSTALLING THE PROPORTIONAL AIR BRAKE SYSTEM 1 2 Install the DIN rail. 1a Clamp the DIN rail to the right post 14-inches down from the top of the dyno frame. 1b Using a center punch, mark two mounting holes in the middle of the top and bottom slots. Remove the clamp and rail. 1c Drill and tap the mounting holes for 1/4-inch UNC bolts. 1d Secure the DIN rail to the dyno using two 1/4-inch button-head allen bolts.
INSTALLATION GUIDE Installation 3 4 Install the temperature sensor. 3a Clamp the temperature sensor bracket to the left post 24-inches down from the top of the dyno frame. 3b Using a center punch, mark the bracket mounting holes in the middle of both slots. Remove the clamp and bracket. 3c Drill and tap the mounting holes for 1/4-inch UNC bolts. 3d Loosely attach the bracket to the dyno using two 1/4-inch button-head allen bolts. Do not tighten the bolts.
PROPORTIONAL AIR BRAKE Installation 5 6 7 Attach the air line labeled OUT from the EPR to the three-way valve on the prop air regulator assembly. Push the hose in and hand tighten the fitting. Attach the air line labeled IN from the EPR to the brass four-way fitting on the prop air regulator assembly. Note: Pull on both hoses to ensure they are secure. If there is movement, tighten the fitting. Connect your shop air to the dyno. Dynojet recommends using an air filter/dryer.
INSTALLATION GUIDE Installation WIRING THE BREAKOUT BOARD When attaching cables, refer to Figure 6 for cable location and Figure 7 for Breakout board wiring information. Refer to page 9 for four wheel drive wiring instructions. 1 2 3 Attach the data acquisition cable coming from the optical pickup card on the dyno to the Breakout board. The data acquisition cable has four wires which connect to the wiring block labeled DRUM 1.
PROPORTIONAL AIR BRAKE Installation temperature sensor cable data acquisition cable EPR cable air pressure switch wire brake solenoid wires Figure 6: Routing Cables—Breakout Board 6 The Breakout board jumper settings are preset, however, verify jumpers J1 and J2 are set for the proportional air brake as shown in Figure 7.
INSTALLATION GUIDE Wiring—Four Wheel Drive WIRING—FOUR WHEEL DRIVE ................................... This section provides instructions for wiring the electronic pressure regulator (EPR) and Breakout board for four wheel drive applications. WIRING THE EPR Attach the four wires from the EPR cable to the new EPR.
PROPORTIONAL AIR BRAKE Wiring—Four Wheel Drive WIRING THE BREAKOUT BOARD 1 2 Attach the cable coming from the EPR to the Breakout board. The EPR cable wires connect to the wiring block labeled LOAD CONTROL. • Blue wire connects to V- • Orange wire connects to V+ • White wire connects to O+ • Green wire connects to O- The Breakout board jumper settings are preset, however, verify jumpers J1 and J2 are set for the four wheel drive proportional air brake as shown in Figure 9.
APPENDIX A REPLACING THE EPR WITH THE MODEL T-3000 EPR This appendix provides instructions for replacing the existing electronic pressure regulator (EPR) with the model T-3000 EPR. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIXA Replacing the EPR REPLACING THE EPR ................................... This section describes how to transfer over to and wire the new EPR. 1 2 Turn off the power on the dyno electronics. Disconnect the main air supply from the brake assembly.
R E P L A C I N G T H E E P R W I T H T H E M O D E L T- 3 0 0 0 E P R Replacing the EPR 3 Remove the two air lines and the muffler from the old EPR. Note: If the labels marking the air input and air output are no longer on the two air lines, re-label the lines. Left is input and middle is output. 4 Transfer the air lines and the muffler to the new EPR. Holding the new EPR in the same orientation as the old one (controls at the bottom), the air lines and muffler hookup the same.
APPENDIXA Replacing the EPR 6 Attach the cable coming from the new EPR to the Breakout board. The EPR cable has four wires which connect to the wiring block labeled LOAD CONTROL. • Black wire connects to V- • Red wire connects to V+ • White wire connects to O+ • Silver or ground (shield) wire connects to SH Refer to page 10 when wiring the Breakout board for four wheel drive applications.
R E P L A C I N G T H E E P R W I T H T H E M O D E L T- 3 0 0 0 E P R Replacing the EPR 8 Rotate the old EPR until it pops off the DIN rail. 9 Hook one side of the new EPR on the DIN rail and rotate it toward the DIN rail until it snaps into place. 10 Connect the main air supply to the brake assembly. The air will set the brakes. 11 Turn on the power to the dyno electronics. This will release the brakes.
APPENDIXA Wiring the EPR WIRING THE EPR ................................... Refer to these wiring instructions only if your EPR is not pre wired. If your EPR is not wired, attach the wires from the EPR cable to the new EPR.
