©2002 Dynojet Research, Inc. All Rights Reserved. 020214SD Mobile Base Installation Guide Dynojet Research, Inc.
Copyright 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. Dynojet assumes no responsibility or liability for any error or inaccuracies that may appear in this manual.
TABLE OF CONTENTS List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Chapter 1 Mobile Base Installation Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Preparation . . . .
TA B L E O F C O N T E N T S ii Mobile Base Installation Guide
LIST OF FIGURES Figure 1-1: Remove the Brake Cover and Hood Clamps . . . . . . . . . . . . . . 1-3 Figure 1-2: Remove the Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Figure 1-3: Remove the Temperature Sensor Wires . . . . . . . . . . . . . . . . . . 1-4 Figure 1-4: Remove the Eddy Current Brake Cables . . . . . . . . . . . . . . . . . . 1-5 Figure 1-5: Remove the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES Figure 1-22: Attach the Temperature Sensor Wires to the Breakout Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 Figure 1-23: Secure the Input Power Cable and Cable Tie . . . . . . . . . . . 1-16 Figure 1-24: Modified Hood Measurements . . . . . . . . . . . . . . . . . . . . . . . 1-17 Figure 1-25: Install the Modified Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17 Figure 1-26: Ground Hook Placement . . . . . . . . . . . . . . . . . . . .
CHAPTER 1 MOBILE BASE INSTALLATION This document provides instructions for installing the mobile base to Dynojet’s Model 250 Dynamometer (dyno). To ensure safety and accuracy in the procedures, perform the procedures as they are described. This manual will walk you through the installation procedures, wiring, and how to secure your dyno using anchors and ground hooks.
CHAPTER 1 PARTS LIST The following table lists all of the parts included in the mobile base 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.
MOBILE BASE INSTALLATION Preparation PREPARATION ................................... You will need to provide equipment capable of lifting a minimum of 1600 lb (725 kg) to lift the dyno. You will also need a pair of straps capable of supporting the weight of the dyno. Several types of straps or chains can be used to lift the dyno; Dynojet recommends using a continuous nylon loop style strap. Dynojet recommends you remove the fan assembly, if you have one installed, before beginning installation.
CHAPTER 1 Preparation 4 Remove the four bolts securing the hood to the dyno and prop up the hood. 5 6 7 Disconnect the wires to the key switch if present. Remove the hood from the dyno and set aside. Disconnect the battery. key switch Figure 1-2: Remove the Hood REMOVING THE EDDY CURRENT BRAKE 1 Remove the following cables and wiring. 1a Remove the four screws securing the Breakout board and cover. Set the cover and screws aside. 1b Disconnect the temperature sensor cable from the Breakout board.
MOBILE BASE INSTALLATION Preparation 1c Remove the temperature sensor cable from the dyno. 1d Disconnect the input power cable from the Theta Controller. 1e Disconnect the brake power cable from the Theta Controller. 1f Remove the large rubber grommet from the hole in the dyno and remove the brake power cable from the dyno.
CHAPTER 1 Installation INSTALLATION ................................... You will need to provide equipment capable of lifting a minimum of 1600 lb (725 kg) to lift the dyno. You will also need a pair of straps capable of supporting the weight of the dyno. Several types of straps or chains can be used to lift the dyno; Dynojet recommends using a continuous nylon loop style strap. MOVING THE DYNO TO THE MOBILE BASE FRAME 1 Place the mobile base frame on blocks as shown in Figure 1-6.
MOBILE BASE INSTALLATION Installation 3 Loosely attach the mobile base frame to the dyno using six 7/16-14 x 1-inch bolts, twelve 7/16-inch flat washers, six 7/16-inch lock washers, and six 7/16-inch nuts. Refer to Figure 1-8a and Figure 1-8b. Note: Be sure the bolts are inserted from the bottom of the mobile base frame. 4 Line up the mobile base frame with the dyno and lower the dyno onto the frame.
CHAPTER 1 Installation MOVING THE BRAKE TO THE MOBILE BASE FRAME 1 Using a fork lift and nylon loop straps, move the eddy current brake onto the mobile base frame. Figure 1-9: Place the Brake on the Mobile Base Frame 2 3 4 5 Slide the brake up to the dyno. Loosen the bolts on the brake connecting arms to allow the arms to move. There are four bolts on each arm. Line up the connecting arms with the dyno and loosely attach the arms to the dyno using the bolts and washers you removed earlier.
MOBILE BASE INSTALLATION Installation 6 Install the reinforcement brace. 6a Remove and discard the two bolts on the brake and the two bolts on the dyno. 6b Loosely secure the reinforcement brace using four 3/8-16 x 1-inch bolts with thread lock and four 3/8-inch washers (two on the brake side and two on the dyno side). For better clarity, the coupler is not shown in Figure 1-11.
CHAPTER 1 Installation INSTALLING THE WHEELS TO THE MOUNTING BRACKETS 1 Install the wheel with the brake to the rear wheel mounting bracket using four 3/8-16 x 1-inch bolts, eight 5/16-inch flat washers, and four 3/8-inch nylock nuts. Do this for both rear wheel mounting brackets. Be sure to use the wheels with the brake for the rear wheel mount assemblies.
MOBILE BASE INSTALLATION Installation INSTALLING THE REAR WHEEL MOUNT ASSEMBLIES 1 Remove and discard the three existing bolts from the brake and the dyno; these bolts are too short. remove and discard remove and discard existing bolts on dyno existing bolts on brake Figure 1-15: Remove the Existing Bolts 2 3 Secure one wheel mount to the dyno and one wheel mount to the brake using three 3/8-16 x 1-inch bolts with thread lock and three 3/8-inch washers.
CHAPTER 1 Installation TIGHTENING ALL THE BOLTS 1 2 3 4 5 Tighten the bolts securing the connecting arms to the dyno (four on each arm). Refer to Figure 1-10. Tighten the four bolts securing the reinforcement brace. Refer to Figure 1-11. Tighten the two bolts securing the rear wheel to the mobile base frame. Do this for both rear wheels. Refer to Figure 1-16. Tighten the three bolts securing the rear wheel to the brake and the three bolts securing the rear wheel to the dyno. Refer to Figure 1-16.
MOBILE BASE INSTALLATION Eddy Current Brake EDDY CURRENT BRAKE ................................... This section describes how to align the eddy current brake with the dyno, align the couplers, and attach the cables from the eddy current brake to the Theta Controller and Breakout board. For more information about the eddy current brake, refer to the Eddy Current Brake Installation Guide (P/N 98226100). ALIGNING THE EDDY CURRENT BRAKE Eddy current brake and coupler alignment is very important.
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 removed earlier and tighten to 33-37 ft. lb. (45-50 N-m).
MOBILE BASE INSTALLATION Eddy Current Brake ATTACHING THE CABLES 1 2 3 4 5 Using a fork lift, or other suitable means, remove the dyno from the blocks. Route the input power cable under and out the front of the dyno. Attach the input power cable to the Theta Controller. Route the brake power cable through the dyno as shown in Figure 1-21 and attach the cable to the Theta Controller. Secure the rubber grommet in the hole.
CHAPTER 1 Eddy Current Brake 6 Attach the temperature sensor cable to the Breakout board. The temperature sensor cable has five wires which connect to the wiring block labeled TEMP. • Green wire connects to G1 • White wire connects to W1 • Black wire connects to B1 • Red wire connects to R1 • Ground wire connects to S1 7 8 Replace the Breakout board cover and secure the Breakout board and cover to the dyno frame using the four screws you removed earlier.
MOBILE BASE INSTALLATION Final Installation FINAL INSTALLATION ................................... This section describes how to modify your hood, install the ground hooks, and secure your dyno for use. MODIFYING AND INSTALLING THE HOOD The hood will need to be modified in order to fit over the mobile base rear wheels. 1 Using the measurements in Figure 1-24, make the necessary cuts in the hood.
CHAPTER 1 Final Installation INSTALLING THE GROUND HOOKS 1 Locate the dyno in your dyno room and place the eye of each ground hook approximately thirty-six inches from the eye of each dyno wheel. ground hook eye on wheel Figure 1-26: Ground Hook Placement 2 Install the Red Head Anchors using the hardware included with the ground hook kit. Refer to Appendix A for Red Head Anchor installation instructions. Use the ground hooks as a pattern to place the anchors.
MOBILE BASE INSTALLATION Final Installation SECURING THE DYNO 1 Secure the dyno to the ground hooks using tie down straps. Note: Crossing the straps in the back will increase stability. 2 Remember to reinstall the fan if you removed it earlier.
CHAPTER 1 Final Installation 1-20 Mobile Base Installation Guide
APPENDIX A RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi-Set™II Anchors used to secure ground hooks to concrete. The anchors and ground hooks will be used to secure the mobile base dynamometer. 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. Refer to page 1-18 for instructions on installing the ground hooks.
APPENDIX A 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.
