Dynojet Research Microphone 200Ip Users Manual Air Brake And EEC Kit Installation Guide For 200i/250i 200iP/250iP Motorcycle Dynos

2015-02-04

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©2005 Dynojet Research, Inc. All Rights Reserved.
Air Brake and EEC Kit Installation Guide for Model 200i/250i and 200iP/250iP Motorcycle
Dynamometers
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: 98123114 Version 01 (12/05)
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers i
T
ABLE
OF
C
ONTENTS
Air Brake and EEC Kit Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Air Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removing the Drum Module Hood, Side Drum Cover,
Center Panel, and Tire Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Removing the Pit Cover Plate and Upright Brace . . . . . . . . . . . . . . . . . . . . . . . 7
Installing the Air Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Routing the Air Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connecting the Shop Air—200i/250i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting the Shop Air—200iP/250iP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjusting the Brake Pad Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Final Adjustments and Tests—200i/250i . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Final Adjustments and Tests—200iP/250iP . . . . . . . . . . . . . . . . . . . . . . . . . . 19
EEC Finger Guards—200i/250i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
EEC Finger Guards—200iP/250iP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installing the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adjusting the EEC Finger Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Door Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installing the Door Safety Switch—200i/250i . . . . . . . . . . . . . . . . . . . . . . . . 29
Installing the Door Safety Switch—200iP/250iP . . . . . . . . . . . . . . . . . . . . . . . 31
Replacing the Drum Module Hood, Side Drum Cover,
Center Panel, and Tire Carriage—200i/250i . . . . . . . . . . . . . . . . . . . . . . . . . 33
Replacing Pit Cover Plates and Upright Brace—200iP/250iP . . . . . . . . . . . . 34
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers 1
A
IR
B
RAKE
AND
EEC K
IT
I
NSTALLATION
This document provides instructions for installing the air brake and EEC Kit to the
model 200i/250i and 200iP/250iP motorcycle dynamometer (dyno). This document
will walk you through installing the air brake assembly, EEC finger guards, and door
safety switch. To ensure safety and accuracy in the procedures, perform the
procedures as they are described.
Document Part Number: 98123114
Version 1
Last Updated: 12-05-05
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Introduction
2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION
The EEC Kit with Brake package consists of the EEC finger guards, air brake assembly,
and door safety switch. The air brake can also be purchased separately. The EEC finger
guards are a valuable safety device that allow you to regulate the distance between the
dyno chassis and the drum; the air brake quickly slows the drum’s rotation and locks
it for loading and unloading motorcycles; and the door safety switch provides an
added safety measure by automatically activating the dyno’s air brake when it is
triggered.
For more detailed information on the 200i/250i and 200iP/250iP motorcycle dynos,
refer to the Installation Guide for Model 200i/250i Motorcycle Dynamometers
(P/N 98220104) or the Installation Guide for Model 200iP/250iP Motorcycle Pit
Dynamometers (P/N 98229103).
CONVENTIONS USED IN THIS MANUAL
The conventions used in this manual are designed to protect both the user and the
equipment.
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet Research at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of
the art technical support, on-line shopping, 3D visualizations, and press releases
about our latest product line.
example of convention description
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
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.
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR BRAKE
The air brake is an electro-pneumatic braking system which quickly slows the drum
after a run and locks it from turning. The air brake includes the brake rotor, air brake
assembly, and the brake bracket and is easily installed onto the dyno. Use the
following instructions to install your air brake.
REMOVING THE DRUM MODULE HOOD, SIDE DRUM COVER,
CENTER PANEL, AND TIRE CARRIAGE
The following instructions are for model 200i/250i dynos. Refer to “Removing the Pit
Cover Plate and Upright Brace” on page 7 for model 200iP/250iP dynos.
Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to remove
the 1/4-inch screws. For dynos with serial numbers lower than 2030152,
Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap-On
FA5E). A standard allen key may round off in the shallow screw head.
Never operate the dynamometer with the drum module hood removed.
1 Turn off the dyno and disconnect the AC power cord from its power source. Refer
to the Installation Guide for Model 200i and 250i Motorcycle Dynamometers
(P/N 98220104) for more information.
2 Remove the eight 1/4-20 x 5/8-inch pan head screws securing the drum module
hood to the dyno and set aside.
3 Remove the drum module hood and set aside.
Note: For clarity, the retarder and carriage are not shown.
Figure 1: Removing the Drum Module Hood
drum module hood
screw
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
4
4 Remove the six 1/4-20 x 5/8-inch pan head screws securing the right side drum
cover to the dyno and set aside.
5 Remove the two 1/4-20 x 5/8-inch pan head screws securing the top of the right
side drum cover to the dyno and set aside.
6 Remove the right side drum cover.
Figure 2: Removing the Right Side Drum Cover
top screw
side screw
right side drum cover
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
5
7 Remove the four 1/4-20 x 5/8-inch pan head screws securing the bearing bracket
to the tire carriage and set aside.
8 Using the hand crank, unscrew the bearing bracket and the carriage screw and set
aside.
9 Remove the tire carriage by sliding the carriage under the carriage clamps toward
the back of the dyno and set aside.
Figure 3: Removing the Tire Carriage
hand crank
carriage screw
bolt
carriage clamp
tire carriage
bearing bracket
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
6
10 Remove the two 5/16-inch bolts and washers securing each of the carriage clamps
and shims and set aside.
11 Remove the three carriage clamps and shims and set aside.
12 Remove the two 5/16-inch bolts and washers securing the nut block and shim and
set aside.
13 Remove the nut block and shim and set aside.
14 Remove the six 1/4-20 x 5/8-inch pan head screws securing the center panel to the
dyno carriage and set aside.
15 Remove the center panel and set aside.
Figure 4: Removing the Center Panel
screw
center panel
carriage
clamp
washer
bolt
shim
nut block
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
7
REMOVING THE PIT COVER PLATE AND UPRIGHT BRACE
The following instructions are for model 200iP/250iP dynos. Refer to “Removing the
Drum Module Hood, Side Drum Cover, Center Panel, and Tire Carriage” on page 3
for model 200i/250i dynos.
Never operate the dynamometer with the pit cover plates removed.
Dynojet recommends using a T30 Torx driver (Snap-On PFTx30E) to remove
the 1/4-inch screws. For dynos with serial numbers lower than 2030152,
Dynojet recommends using a hardened 5/32-inch hex driver (such as Snap-On
FA5E). A standard allen key may round off in the shallow screw head.
1 Turn off the dyno and disconnect the AC power cord from its power source. Refer
to the Installation Guide for Model 200iP/250iP Motorcycle Pit Dynamometers
(P/N 98229103) for more information.
2 Remove the two 1/4-20 x 5/8-inch pan head screws and locknuts securing the
right drum guard to the drum guard mount using a 5/32-inch allen tool or a #30
torx tool and set aside.
3 Remove the right drum guard and set aside.
Figure 5: Removing the Right Drum Guard
FRONTOFDYNO
PD072
screw
right drum guard
right pit cover plate
locknut
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
8
4 Remove the four 1/4-20 x 5/8-inch pan head screws and the four 3/8-16 x 1/2-inch
screws securing the right pit cover plate to the dyno chassis and set aside.
5 Remove the right pit cover plate and set aside.
Figure 6: Removing the Right Pit Cover Plate
screw
right pit cover plate
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
9
6 Remove the two 1/4-20 x 5/8-inch pan head screws securing the upright brace to
the drum module and set aside.
7 Remove the brace and set aside.
Note: For clarity, the pit is not shown.
Figure 7: Removing the Upright Brace
upright brace
screw
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
10
INSTALLING THE AIR BRAKE ASSEMBLY
The following instructions are for both the model 200i/250i above ground and
200iP/250iP pit motorcycle dynamometers. If you are not installing the air brake skip
this section and refer to “EEC Finger Guards—200i/250i” on page 20, “EEC Finger
Guards—200iP/250iP” on page 23, and “Door Safety Switch” on page 29.
1 Turn off the dyno and disconnect the AC power cord from its power source.
2 Insert the woodruff key into the dyno shaft.
3 Slide the brake rotor with taper lock onto the shaft and align it, so that the taper
lock touches the bearing lock collar on the dyno shaft.
4 Set up a dial indicator on the disc braking surface to measure the run-out. The
maximum allowable run-out is +/- 0.005 inches.
5 Tighten the three bolts in a clockwise rotation to help minimize the run out,
torquing to 15 foot-pounds.
Note: If necessary, readjust the taper lock and brake rotor to ensure the run-out is
less than +/- 0.005 inches.
Note: For clarity, only the drum module is shown.
Figure 8: Securing the Brake Rotor
bearing lock
collar
bolt
washer
taper lock
brake rotor
woodruff key
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
11
6 Secure the brake bracket to the drum module frame using two 5/8-11 x 1.25-inch
12-point bolts torquing to 112 foot-pounds.
Note: For clarity, the side drum module hood is not shown.
Figure 9: Securing the Brake Bracket
7 Place the brake assembly on the brake bracket.
Figure 10: Securing the Air Brake Assembly
brake bracket
bolt
air brake assembly
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
12
8 Secure the brake assembly with two clevis pins.
8a Push the top clevis pin through the front of the assembly.
Figure 11: Inserting the Top Clevis Pin
8b Push the bottom clevis pin through the back of the drum module frame and
the air brake assembly (drum side).
8c Secure the top clevis pin with a hair pin cotter.
Figure 12: Inserting the Bottom Clevis Pin and Top Hairpin Cotter
top clevis pin
bottom clevis pin
top hairpin cotter
top clevis pin
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
13
8d Secure the bottom clevis pin with a hairpin cotter.
Figure 13: Securing the Bottom Clevis Pin with a Hairpin Cotter
9 Loosely secure the brake caliper stop to the brake bracket using two
3/8-16 x 3/4-inch bolts with lock washers and two 5/16-inch flat washers.
Note: For clarity, the drum, parts of the dyno frame, and the air brake assembly
spring are not shown.
Figure 14: Securing the Brake Caliper Stop
Note: Before proceeding with the rest of the air brake installation it is necessary
to connect the shop air and check the brake pad clearance.
bottom clevis pin
hairpin cotter
brake caliper stop brake bracket
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
14
ROUTING THE AIR BRAKE CABLE
Before proceeding with the rest of the air brake installation it is necessary to connect
the shop air and check the brake pad clearance.
1 Open the front panel of the control panel interface (CPI) to access the breakers
and Breakout board.
2 Route the air brake cable from the air brake solenoid to the CPI.
Note: The CPI end of the air brake cable splits in two.
3 Connect the cable with the two black wires to the Breakout board wiring block
labeled Brake.
4 Attach the 4-pin connector to port P7 on the CPI board.
Figure 15: Routing the Air Brake Cable
P7 on the
CPI board
brake wiring block
on breakout board
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
15
CONNECTING THE SHOP AIR—200I/250I
1 Route the air hose from the air brake through the access hole in the drum module
upright, under the carriage frame brace, and connect to the bulkhead fitting at the
front of the dyno.
2 You will need to provide an air hose nipple (1/4-inch NPT) to connect your clean,
dry shop air supply (60 psi, 415 kilopascal, max constant line pressure) to the
dynamometer.
Figure 16: Connecting the Air Hose—200i/250i
air pump
air hose
bulkhead fitting
access hole
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
16
CONNECTING THE SHOP AIR—200IP/250IP
1 Route the air brake air hose through the access hole in the drum module upright
and through the pit conduit.
2 Connect your clean, dry shop air supply (60 psi, 415 kilopascal, max constant line
pressure) to the air hose.
Figure 17: Connecting the Air Hose—200iP/250iP
air brake
pit conduit
air hose
to 60 ps i
cl ean dry air
access hole
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
17
ADJUSTING THE BRAKE PAD CLEARANCE
Before you tighten the bolts securing the brake caliper stop you will want to adjust
the brake pad clearance.
1 Release the brakes.
Note: In order for the brakes to release, power must be on, air connected, red
button on pendant not lit, and the emergency stop button not depressed.
2 Insert the brake adjusting shim between the inboard brake pad and the brake
rotor.
Figure 18: Adjusting the Brake Pad Clearance
brake adjusting shim
inboard brake pad
rotor
brake caliper stop bolts
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Air Brake
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3 Remove the hairpin cotter and hand tighten the castle nut on the caliper assembly
to clamp the brake pads against the rotor and shim.
4 Tighten the brake caliper stop bolts torquing to 26 pounds/feet.
5 Loosen the castle nut and remove the shim.
6 Adjust the clearance between the outboard brake pad and rotor. Loosen the castle
nut to increase the clearance.
There should be equal space on both sides of the rotor.
7 Replace the hair pin cotter in the castle nut.
8 Cycle the brake to verify the brake pads release far enough so they do not touch the
rotor. If the pads touch the rotor during a run, the information provided by the
dyno will be inaccurate.
Figure 19: Tightening the Castle Nut
remove hairpin cotter
adjust castle nut
outboard brake pad
INSTALLATION GUIDE
Air Brake
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
19
FINAL ADJUSTMENTS AND TESTS—200I/250I
1 Replace the drum module hood, side drum cover, tire carriage, and center panel.
Refer to “Replacing the Drum Module Hood, Side Drum Cover, Center Panel, and
Tire Carriage—200i/250i” on page 33.
Note: If you are installing the EEC Kit do not replace the drum module hood,
center panel, and tire carriage until you have finished the installation process.
Refer to page 20 for the 200i/250i EEC finger guard installation. Refer to page 29
for door safety switch installation instructions.
2 Verify the dyno is set up properly, the dyno electronics is powered up and
operational, and the air supply is connected properly.
3 Use the emergency stop button or the red brake button on the pendant to activate
and deactivate the brake. Listen for air leaks and double check all connections.
4 Verify the brake pads release far enough so they do not touch the rotor. There
should be equal pad clearance on both sides of the rotor. If the pads touch the
rotor during a run, the information provided by the dyno will be inaccurate.
FINAL ADJUSTMENTS AND TESTS—200IP/250IP
1 Replace the pit cover plates and upright brace. Refer to “Replacing Pit Cover
Plates and Upright Brace—200iP/250iP” on page 34.
Note: If you are installing the EEC Kit do not replace the pit cover plates until you
have finished the installation process. Refer to page 23 for the 200iP/250iP EEC
finger guard installation. Refer to page 29 for door safety switch installation
instructions.
2 Verify the dyno is set up properly, the dyno electronics is powered up and
operational, and the air supply is connected properly.
3 Use the emergency stop button or the red brake button on the pendant to activate
and deactivate the brake. Listen for air leaks and double check all connections.
4 Verify the brake pads release far enough so they do not touch the rotor. There
should be equal pad clearance on both sides of the rotor. If the pads touch the
rotor during a run, the information provided by the dyno will be inaccurate.
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
EEC Finger Guards—200i/250i
20
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EEC FINGER GUARDS—200I/250I
The EEC finger guards are secured to the drum module hood and provide extra
protection from the drum by regulating the distance between the drum and the
chassis. The placement of the finger guards can be manually adjusted.
Refer to “EEC Finger Guards—200iP/250iP” on page 23 for model 200iP/250iP dynos.
Refer to “Air Brake” on page 3 for air brake installation instructions.
INSTALLING THE EEC FINGER GUARDS
If you are not installing the EEC finger guards skip this section and refer to “Door
Safety Switch” on page 29 for door safety switch installation instructions.
1 Remove the drum module hood. Refer to “Removing the Drum Module Hood,
Side Drum Cover, Center Panel, and Tire Carriage” on page 3.
2 Secure each EEC finger guard to the drum module hood using two
1/4-20 x 5/8-inch pan head screws.
Figure 20: Securing the EEC Finger Guards to the Drum Module Hood
drum module hood
screw
finger guard
INSTALLATION GUIDE
EEC Finger Guards—200i/250i
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
21
3 Secure the drum module hood with the EEC finger guards to the dyno using the
eight 1/4-20 x 5/8-inch pan head screws removed earlier.
Note: For clarity, the retarder and carriage are not shown.
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less than
0.64 centimeters (0.25 inches). Refer to page 22 for instructions on adjusting
the gap.
Figure 21: Replacing the Drum Module Hood
screw
drum module hood
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
EEC Finger Guards—200i/250i
22
ADJUSTING THE EEC FINGER GUARDS
Once the drum module hood is installed, the EEC finger guards will need to be
adjusted.
1 Loosen the 1/4-20-inch pan head screws and adjust the EEC finger guards so they
are 0.16 cm to 0.64 cm (0.0625 in. to 0.25 in.) from the drum. Tighten the screws.
2 Check the EEC finger guards regularly to verify the clearance has not changed.
Note: For clarity, the retarder and carriage are not shown.
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less than
0.64 centimeters (0.25 inches).
Figure 22: Adjusting the EEC Finger Guard Clearance
adjust clearance
adjust screw
INSTALLATION GUIDE
EEC Finger Guards—200iP/250iP
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
23
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EEC FINGER GUARDS—200IP/250IP
The 200iP/250iP motorcycle pit dynos also benefit from the EEC kit. The EEC finger
guards provide extra protection from the drum by regulating the distance between
the drum and the chassis. The placement of the finger guards can be manually
adjusted.
Refer to “EEC Finger Guards—200i/250i” on page 20 for model 200i/250i dynos. Refer
to “Air Brake” on page 3 for air brake installation instructions.
INSTALLING THE EEC FINGER GUARDS
If you are not installing the EEC finger guards skip this section and refer to “Door
Safety Switch” on page 29 for door safety switch installation instructions.
1 Remove the right pit cover plate. Refer to “Removing the Pit Cover Plate and
Upright Brace” on page 7.
2 Remove the four 3/8-16 x 1/2-inch screws securing the left pit cover plate to the
dyno chassis and set aside.
3 Remove the left pit cover plate.
Note: The drum guard mount is attached to the left pit cover plate.
Figure 23: Removing the Left Pit Cover Plate
screw
left pit cover plate
drum guard mount
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
EEC Finger Guards—200iP/250iP
24
4 Secure each EEC finger guard to the drum guard mount using two
1/4-20 x 5/8-inch pan head screws.
Figure 24: Securing the Finger Guards to the Drum Guard Mount
screw
left pit cover plate
finger guard
drum guard mount
INSTALLATION GUIDE
EEC Finger Guards—200iP/250iP
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
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5 Secure the left pit cover plate with the drum guard mount to the dyno using the
four 3/8-16 x 1/2-inch screws removed earlier.
Figure 25: Securing the Left Pit Cover Plate to the Dyno
screw
left pit cover plate
drum guard mount
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
EEC Finger Guards—200iP/250iP
26
6 Secure the upright brace to the drum module using the two screws removed
earlier. Refer to Figure 7 on page 9.
7 Secure the right pit cover plate to the dyno using the four 1/4-20 x 5/8-inch pan
head screws and the four 3/8-16 x 1/2-inch screws removed earlier.
Figure 26: Securing the Right Pit Cover Plate to the Dyno
right pit cover plate
screw
INSTALLATION GUIDE
EEC Finger Guards—200iP/250iP
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
27
8 Secure the right drum guard to the drum guard mount using the two
1/4-20 x 5/8-inch pan head screws and locknuts removed earlier.
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less than
0.64 centimeters (0.25 inches). Refer to page 28 for instructions on adjusting
the gap.
Figure 27: Securing the Drum Guard to the Drum Guard Mount
FRONTOFDYNO
PD072
screw
drum guard mount
locknut
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
EEC Finger Guards—200iP/250iP
28
ADJUSTING THE EEC FINGER GUARDS
Once the pit cover plates are installed and adjusted, the EEC finger guards will need
to be adjusted.
1 Loosen the 1/4-20 x 5/8-inch pan head screws and adjust the EEC finger guards so
they are 0.16 cm to 0.64 cm (.0625 in. to .25 in.) from the drum. Tighten the
screws.
2 Check the EEC finger guards regularly to verify the clearance has not changed.
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less than
0.64 centimeters (0.25 inches).
Figure 28: Adjusting the EEC Finger Guard Clearance
adjust screw
adjust clearance
INSTALLATION GUIDE
Door Safety Switch
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
29
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DOOR SAFETY SWITCH
Safety requirements of your local country may require that a door safety switch is
installed. Be sure to follow the safety requirements specific to your country. The door
safety switch requires the air brake to work. This switch is located on the dyno room
door and is triggered when the pressure applied to it is released causing the air brake
to lock. This prevents the dyno from being used when the door is open.
Components attached to and within the dynamometer operate with potentially
lethal voltages. To provide the greatest assurance of safety, the AC power
cord(s) must be disconnected from the power source before servicing electrical
components or wiring. Disconnect all power cords before servicing electrical
components for the greatest assurance of safety.
INSTALLING THE DOOR SAFETY SWITCH—200I/250I
1 Turn off the main breaker inside the power distribution assembly door.
2 Unplug the dyno power cable.
3 Remove the tire carriage and center panel. Refer to “Removing the Drum Module
Hood, Side Drum Cover, Center Panel, and Tire Carriage” on page 3.
4 Remove the three screws securing the power distribution assembly cover and set
aside.
5 Remove the power distribution assembly cover and set aside.
Figure 29: Removing the Power Distribution Assembly Cover
power distribution
assembly cover
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Door Safety Switch
30
6 Loosen the screws that hold the jumper wires in place and remove the wire.
7 Route the black and yellow wire from the safety switch through the dyno.
Make sure the switch will not get caught in any moving components or chafed on
any edges.
8 Attach the yellow wire to the 1A position on the J2 connector.
9 Attach the black wire to the 6B position on the J4 connector.
Figure 30: Wiring the Safety Switch
10 Replace the power distribution assembly cover using the screws removed earlier.
11 The door safety switch needs to be mounted at the entry of the dyno room.
12 Plug the dyno into the power outlet.
13 Turn on the main breaker inside the power distribution assembly door.
14 Open the door safety switch by allowing the plunger to extend.
The air brake should be applied holding the drum and the status light on the
Control Panel will be flashing.
15 Depress the safety switch and the air brake will release and the status light will be
on steady.
black wire to 6B
on J4 connector
yellow wire to 1A
on J2 connector
remove
jumper
wire
INSTALLATION GUIDE
Door Safety Switch
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
31
INSTALLING THE DOOR SAFETY SWITCH—200IP/250IP
1 Open the CPI front panel access and turn off the main breaker.
2 Unplug the dyno power cable.
3 Remove the eight button-head screws securing the CPI cover and set aside.
4 Remove the cover and set aside.
Figure 31: Accessing the CPI
PD027
cover
front panel access
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Door Safety Switch
32
5 Loosen the screws that hold the jumper wires in place and remove the wire.
6 Route the black and yellow wire from the door safety switch through the dyno.
Make sure the switch will not get caught in any moving components or chafed on
any edges.
7 Attach the yellow wire to the 1A position on the J2 connector.
8 Attach the black wire to the 6B position on the J4 connector.
Figure 32: Wiring the Door Safety Switch
9 Replace the CPI cover using the screws removed earlier.
10 The door safety switch needs to be mounted at the entry of the dyno room.
11 Plug the dyno into the power outlet.
12 Turn on the main breaker inside the power distribution assembly door.
13 Open the door safety switch by allowing the plunger to extend.
The air brake should be applied holding the drum and the status light on the
Control Panel will be flashing.
14 Depress the door safety switch and the air brake will release and the status light
will be on steady.
black wire to 6B
on J4 connector
yellow wire to 1A
on J2 connector
remove
jumper
wire
INSTALLATION GUIDE
Replacing the Drum Module Hood, Side Drum Cover, Center Panel, and Tire Carriage—200i/250i
Version 1 Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
33
REPLACING THE DRUM MODULE HOOD, SIDE DRUM COVER,
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTER PANEL, AND TIRE CARRIAGE—200I/250I
Refer to “Replacing Pit Cover Plates and Upright Brace—200iP/250iP” on page 34 for
model 200iP/250iP dynos.
1 Secure the center panel to the dyno carriage using the six 1/4-inch screws
removed earlier. Refer to Figure 4 on page 6.
2 Secure the three carriage clamps and shims using two 5/16-inch bolts and washers
each. Refer to Figure 4 on page 6.
3 Secure the nut block and shim using two 5/16-inch bolts and washers. Refer to
Figure 4 on page 6.
4 Replace the tire carriage by sliding it under the carriage clamps. Refer to Figure 3
on page 5.
5 Slide the carriage screw and the bearing bracket toward the nut block until the
carriage screw is touching the nut block. Refer to Figure 3 on page 5.
6 Secure the bearing bracket to the carriage using four 1/4-20 x 5/8-inch pan head
screws. Refer to Figure 3 on page 5.
7 Using the hand crank, screw the carriage through the nut block and into the
screw support bracket. Refer to Figure 3 on page 5.
8 Secure the right side drum cover to the dyno frame using the six 1/4-20 x 5/8-inch
pan head screws removed earlier. Refer to Figure 2 on page 4.
9 Secure the top of the right side drum cover to the dyno using the two
1/4-20 x 5/8-inch pan head screws removed earlier. Refer to Figure 2 on page 4.
10 Secure the drum module hood to the dyno using the eight 1/4-20 x 5/8-inch pan
head screws removed earlier. Refer to Figure 1 on page 3.
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less than
0.64 centimeters (0.25 inches). Refer to page 22 for instructions on adjusting
the gap.
Air Brake and EEC Kit Installation Guide for 200i/250i and 200iP/250iP Motorcycle Dynamometers
AIR BRAKE AND EEC KIT
Replacing Pit Cover Plates and Upright Brace—200iP/250iP
34
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING PIT COVER PLATES AND UPRIGHT BRACE—200IP/250IP
Refer to “Replacing the Drum Module Hood, Side Drum Cover, Center Panel, and Tire
Carriage—200i/250i” on page 33 for model 200i/250i dynos.
1 Secure the upright brace to the drum module using the two screws removed
earlier. Refer to Figure 7 on page 9.
2 Secure the right pit cover plate to the dyno using the eight
1/4-20 x 5/8-inch pan head screws removed earlier. Refer to Figure 26 on page 26.
3 Secure the right drum guard to the drum guard mount using the two
1/4-20 x 5/8-inch pan head screws removed earlier. Refer to Figure 27 on page 27.
Do not operate the dynamometer without the EEC finger guards properly
installed. The gap between the finger guards and the drum must be less than
0.64 centimeters (0.25 inches). Refer to page 28 for instructions on adjusting
the gap.

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