©1993-2008 Dynojet Research, Inc. All Rights Reserved. Installation Guide for In Ground Model 224 Automotive Dynamometers. 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.
TABLE OF CONTENTS Warnings Chapter 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Specifications and Operating Requirements Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Chapter 2 Installation Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Anchoring the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Installing the Eddy Current Brake . . . . .
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.
WA R N I N G S Electrostatic Discharge Precautions Electrostatic Discharge Electrostatic Discharge (ESD), or static shock, can damage electronic components within the dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade the component, resulting in a premature component failure later. To avoid ESD damage, always practice good ESD control precautions when servicing the dynamometer.
WA R N I N G S Other Potential Hazards The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for disconnect before service. The dynamometer 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 dyno room design must incorporate sufficient exhaust extraction.
CHAPTER 1 SPECIFICATIONS AND OPERATING REQUIREMENTS Thank you for purchasing Dynojet’s In Ground Model 224 Automotive Dynamometer (dyno). Dynojet’s software and dynamometers will give you the power to get the maximum performance out of vehicles you evaluate. Whether you are new to the benefits of a chassis dynamometer or an experienced performance leader, the repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer will give you the professional results you are looking for.
CHAPTER 1 Introduction INTRODUCTION ................................... Thank you for purchasing a Dynojet automotive dyno. Before installing your dyno, please take a moment to read this guide for installation instructions, dyno features, and other important information. This guide is designed to be a reference tool in your everyday work and includes the following chapters and information: SPECIFICATIONS AND OPERATING REQUIREMENTS This chapter describes the requirements and specifications for the dyno.
SPECIFICATIONS AND OPERATING REQUIREMENTS Introduction CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. example of convention RECORD # Bold description 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.
CHAPTER 1 Introduction YOUR DYNO ROOM This section is not meant to imply that a dyno room is essential to repeatable results on a Dynojet dynamometer. However, a dyno room with an engine cooling intake fan, exhaust extraction, and noise reduction capabilities can add a new dimension to your shop. A proper dyno room design will help to ensure repeatable, accurate runs.
SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS ................................... The following specifications will help in positioning your dyno in your shop or designing a dyno room.
CHAPTER 1 Dynamometer Specifications and Requirements Figure 1-1: Model 224 In Ground Dyno Dimensions 1-6 In Ground Model 224 Automotive Dynamometer Installation Guide
SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements COMPRESSED AIR The following requirements are needed for the air brake: • Clean and dry air, between 100-140 psi • shut off valve • 1/4-inch NPT pipe thread connector (to attach air to the dyno), if air hose does not have a 3/8-inch inside diameter COMPUTER SPECIFICATIONS You will need to provide a computer system to run the WinPEP software. A complete list of system requirements can be found in your WinPEP 7 User Guide.
CHAPTER 1 Dynamometer Specifications and Requirements ENVIRONMENTAL REQUIREMENTS description Temperature operating min./max storage min./max Humidity specifications 10°C/50°C (50°F/122°F) 0°C/70°C (32°F/158°F) 0 to 95% non condensing FIRE SUPPRESSION Always have adequate fire suppression or fire extinguishers in your dyno room. FORKLIFT REQUIREMENTS You will need to provide equipment capable of lifting a minimum of 2,722 kg. (6,000 lb.) to lift the dyno off the crate and into position in your dyno room.
SPECIFICATIONS AND OPERATING REQUIREMENTS Model 224 In Ground Dynamometer MODEL 224 IN GROUND DYNAMOMETER ...................................
CHAPTER 1 Dyno Electronics DYNO ELECTRONICS ................................... The standard dyno electronics package is comprised of four interconnected modules. Use the figure below to identify the modules and connectors when routing cables. A detailed description of each module along with the instructions for connecting the dyno electronics to the WinPEP 7 software can be found in your WinPEP 7 User Guide.
SPECIFICATIONS AND OPERATING REQUIREMENTS Pit Specifications PIT SPECIFICATIONS ................................... Before installing your dynamometer, prepare your pit according to the specifications provided by your salesperson. Refer to the pit dimensions (P/N 98219103) for more detailed specifications. 224 PIT REQUIREMENTS AND SPECIFICATIONS description length length with retarder depth width specifications 269.24 cm (106.00 in.) 370.84 cm (146.00 in.) 58.42 cm (23.00 in.) 134.62 cm (53.00 in.
CHAPTER 2 INSTALLATION This chapter will walk you through unpacking and installing the dynamometer. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 2 Unpacking and Inspecting the Dyno UNPACKING AND INSPECTING THE DYNO ................................... When you receive your dyno, examine the exterior of the shipping container for any visible damage. If damage is detected at this stage, contact the shipper or Dynojet before proceeding with unpacking. Use the following steps to unload your dyno. You will need to provide equipment capable of lifting a minimum of 2,722 kg. (6,000 lb.) to move the crated dyno into position in your dyno room.
INSTALLATION Unpacking and Inspecting the Dyno part description car tie down, 2" x 10’ (4) P/N 500-C10 car tie down, hi-perf, 2" x 10’ (2) P/N 500-C10W/S part description primary inductive pickup P/N DE100-110L bolt, 3/8-16 x 1", hex (4) P/N DM150-019-012 The following parts are included in the 224 Pit Cover Set P/N 81923001: top deck, side (2) P/N 21216502P top deck, end (2) P/N 61245100 bolt, 3/8-16 x 1.
CHAPTER 2 Dyno Installation DYNO INSTALLATION ................................... This section will walk you through removing the dyno from the crate and installing the dyno in the pit. REMOVING THE DYNO FROM THE CRATE You will need to provide equipment capable of lifting a minimum of 2,722 kg. (6,000 lb.) to move the crated dyno into position in your dyno room. You will also need a pair of straps capable of supporting the same weight.
INSTALLATION Dyno Installation 7 Place the drum module in the pit as shown. Note: If you have an eddy current brake (retarder), refer to the pit dimensions (P/N 98219103) for more detailed specifications. pit inside pit wall 30.48 cm (12.00 in.) 25.40 cm (10.00 in.
CHAPTER 2 Dyno Installation ANCHORING THE DYNO Dynojet recommends you secure your dyno to the pit floor in your dyno room using concrete anchors. You will need the following parts: 1 2 3 4 5 6 • 36923100 Washer, 3/8", Hardened, Flat, Steel (4) • 37513200 Anchor, Redhead, 3/8" (4) • 37518200 Redhead Anchor Installation Tool • DM150-019-012 Bolt, 3/8-16 x 1", Hex (4) Using the mounting feet as a template, mark and drill each hole needed to secure the four dyno feet to the floor.
INSTALLATION Cable Routing CABLE ROUTING ................................... Use the following instructions to route the cables. You will need to route the cables before installing the pit covers. CONNECTING THE DYNO ELECTRONICS AND SHOP AIR You will need the following parts: 1 • 318110301 Power Cord • 42924250 25-pin Cable • 53415040 Power Supply • 76199003N Dyno Electronics Route the 25-pin cable from the Breakout board, through one of the PVC conduits in the pit, and to the dyno electronics.
CHAPTER 2 Cable Routing ALIGNING THE OPTICAL PICKUP CARD TAB The optical pickup card is an electronic circuit board that accurately senses each drum revolution. The pickup card is recessed into the side of your dyno. The optical pickup card comes installed, the cable routed, and ready to use, but should be checked for alignment before the drum is turned. Should the pickup cable become disconnected, refer to Figure 2-5 for routing instructions and page 2-9 for wiring instructions.
INSTALLATION Cable Routing WIRING THE BREAKOUT BOARD 1 Attach the pickup card cable to the Breakout board. This cable may already be connected. The pickup card cable has four wires which connect to the wiring block labeled DRUM 1. 2 3 4 • Red wire connects to R1 • Black wire connects to B1 • White wire connects to W1 • Ground (shield) wire connects to S1 Attach the brake solenoid cable to the Breakout board. The brake signal cable has two wires which connect to the wiring block labeled BRAKE.
CHAPTER 2 Pit Cover Installation PIT COVER INSTALLATION ................................... Before installing the pit covers, be sure you have routed any cables and connected your shop air. If you ordered the CE drum guards, install them before securing the pit covers. Refer to the CE Package Installation Manual (P/N 98295112). Note: If you did not order the pit cover set, you will not have pit covers. You will need the following parts: • • • • 21216502P Side Pit Cover (2) 36582034 Bolt, 3/8-16 x 1.
INSTALLATION Pit Cover Installation 2 Install the side pit covers to the dyno and the end pit covers using seven 3/8-16 x 1.25" button-head flange bolts each.
CHAPTER 2 Ground Hook Installation GROUND HOOK INSTALLATION ................................... Using Figure 2-9 as a guide, place the ground hooks in a location that works best for your dyno application.
CHAPTER 3 BASIC DYNO OPERATION The Dynojet Dynamometer gives you the state of the art technology, durability, and accuracy that you need. Dynojet’s advanced engineering delivers the precise horsepower measurements a technician needs to make quick and accurate evaluations of engine performance and drive train problems. This chapter includes instructions for basic dyno operation. For more detailed instructions, refer to the WinPep 7 User Guide. This manual can also be found on your WinPep CD or at www.
CHAPTER 3 Loading the Vehicle LOADING THE VEHICLE ................................... Use the following steps to load a vehicle on the dyno. You will need the following parts: part description short axle strap, 10M #, 21" (4) P/N 30AS21 part long axle strap, 10M #, 6" (4) P/N 30AS72 1 2 3 description car tie-down, high performance, 2" x 10" (2) P/N 500-C10W car tie-down, 2" x 10" (4) P/N 500-C10 Verify your computer is running.
BASIC DYNO OPERATION Loading the Vehicle 6 7 Secure the non-drive wheels using the provided tire chocks. Do not use tire chocks for four wheel drive vehicles on four wheel drive dynos. Attach the tie-down straps. Rear Wheel Drive • Attach two tie-down straps from secure anchor points to the rear of the vehicle. Attach additional tie-down straps from the rear of the vehicle as shown in Figure 3-2. • Attach two tie-down straps from secure anchor points to the front of the vehicle.
CHAPTER 3 Connecting the RPM Pickup CONNECTING THE RPM PICKUP ................................... Your Dynojet dynamometer includes a primary wire inductive pickup and two secondary wire inductive pickups. These small “clothespin like” inductive pickups are used to sense RPM. An RPM pickup is required if you want to view torque graphs. Generally you will use one secondary wire inductive pickup on a spark plug wire. Vehicles with wasted spark ignition systems may require two secondary inductive pickups.
BASIC DYNO OPERATION Connecting the RPM Pickup CONNECTING THE SECONDARY INDUCTIVE PICKUP The secondary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray electrical interference may result. You will need the following part: 1 2 • DE100-109S secondary inductive pickup (2) Clip the secondary inductive pickup around one spark plug wire.
CHAPTER 3 Connecting the RPM Pickup CONNECTING THE PRIMARY INDUCTIVE PICKUP The primary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray electrical interference may result. You will need the following part: 1 2 • DE100-110L primary inductive pickup Clip the primary inductive pickup around the primary side of the coil.
BASIC DYNO OPERATION Pre-Run Inspection PRE-RUN INSPECTION ................................... Perform a vehicle inspection before making a run. • Check the radiator coolant and oil levels. • Check the fuel source. • Rotate the drum(s) and check for rocks caught in the tire tread that could fly out. • Check the tire pressure and tire speed rating. Improperly inflated tires or exceeding the maximum speed rating can result in premature wear or severe tire damage.
CHAPTER 3 Pre-Run Inspection ENGINE WARM UP Warm the vehicle’s engine and drivetrain before beginning testing. Consistent engine temperatures will assure your runs are repeatable. AFTER ENGINE WARM UP Always leave the vehicle in park (automatic transmission) or in first gear (manual transmission), with the engine off, and make sure the emergency brake and the dyno brake are on when you get out of the vehicle.
BASIC DYNO OPERATION Making a Test Run MAKING A TEST RUN ................................... Dyno runs provide safe, reliable road testing right in the shop. The dyno allows you to measure, record, and diagnose performance problems quickly. The dyno combined with WinPEP 7 produces consistent, easily interpretable power graphs. Use the following instructions to ensure repeatable and accurate measurements. 1 2 3 4 5 Verify the vehicle is secured properly.
CHAPTER 3 Preventative Maintenance PREVENTATIVE MAINTENANCE ................................... This section covers maintenance items for all model 224 dynos with the Spring Applied Air Release (SAAR) brake. For more detailed maintenance instructions, refer to the Maintenance Guide for Automotive Dynamometers (P/N 98119101). THINGS TO CHECK • Check all air fittings for leaks monthly. Correct any leaks found. • Once per month verify the brake pressure gauge reads 100psi (690kPa).
BASIC DYNO OPERATION Preventative Maintenance VERIFYING THE SAAR BRAKE PRESSURE 1 2 Verify the SAAR brake pressure gauge reads 100psi (690kPa). Using the knob, adjust the regulator until the correct pressure is achieved.
CHAPTER 3 Preventative Maintenance MAINTAINING THE SAAR BRAKE SHOE CLEARANCE 1 2 3 Verify the area is clear and the dyno can be operated safely. Power up the dyno electronics. Using the pendant, turn the brake to the OFF position. This will release the SAAR brake by moving the brake shoe away from the drum. Keep hands and fingers clear when operating dyno. 4 Measure the gap between the brake shoe and the drum surface. This gap should be between .125 inch - .375 inch (3mm - 10mm).
BASIC DYNO OPERATION Preventative Maintenance 5 6 7 8 If the brake shoe clearance is out of specification, loosen the upper nut on the bottom of the air can rod. Adjust the lower nut until the brake shoes are .25 inch (6mm) away from the dyno drum. Tighten the upper nut on the air can rod down onto the brake actuating tube to sandwich the tube between the two nuts. Torque the lower nut to 110 foot-pounds. If you cannot adjust the brakes to specification, you will need new brake shoes. Contact Dynojet.
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.
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 Carbon Steel RM-38/RL-38 (9.5 mm) drill bit size 1/2-inch minimum hole depth 1 5/8-inch (41.2 mm) setting tool catalog number 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 TORQUE VALUES This appendix contains tables for standard and metric torque values. Use these values when specified values are not given in other sections of this manual.
APPENDIX B Standard Bolt Torque Values STANDARD BOLT TORQUE VALUES ................................... Always use the torque values specified in other sections of this manual. When specific values are not available, use the torque values listed below. Use the following guidelines when tightening torque: • These values are based on use of clean, dry threads. • The following tables include values for plain finish and plated fasteners. • Reduce torque by 10% when engine oil is used as a lubricant.
TO R Q U E V A L U E S Standard Bolt Torque Values GRADE 8 size in-threads/in 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-12 Version 4 in•lb 143 164 295 326 523 593 837 935 1277 1439 1843 2055 2543 2880 4509 5036 7277 8017 10908 11934 torque, plain ft•lb N•m 12 16 14 19 25 33 27 37 44 59 49 67 70 95 78 106 106 144 120 163 154 208 171 232 212 287 240 325 376 509 420 569 606 822 668 906 909 1232 995 1348 in•lb 10
APPENDIX B Metric Bolt Torque Values METRIC BOLT TORQUE VALUES ................................... Always use the torque values specified in other sections of this manual. When specific values are not available, use the torque values listed below. Use the following guidelines when tightening torque: • These values are based on use of clean, dry threads. • The following tables include values for plain finish and plated fasteners. • Reduce torque by 10% when engine oil is used as a lubricant.
INDEX 25-pin cable 2-7 A air brake 2-7 anchor the dyno 2-6 B battery hazards iv bearing grease 3-10 brake pressure gauge 3-10, 3-11 regulator 3-10, 3-11 shoe clearance 3-12 brake solenoid cable, wiring 2-9 breakout board jumper settings 2-9 wiring 2-9 C compressed air requirements 1-7 computer specifications 1-7 conventions 1-3 crate removing the dyno 2-4 unpacking dyno 2-2 verifying parts 2-2 D dimensions 1-6 disclaimers iii document part number 1-1 dyno electronics 1-10, 2-7 dyno requirements 1-5
INDEX M making a test run 3-9 metric torque values grade 10.9 B-4 grade 8.