©2006-2012 Dynojet Research, Inc. All Rights Reserved. Installation Guide For In Ground Model 424x and 424xLC2 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 ................................................ v Specifications and Operating Requirements Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Dynamometer Specifications and Requirements . . . . . . .
TA B L E O F C O N T E N T S Chapter 3 4WD Dyno Installation Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Installing the Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Chapter 4 Eddy Current Brake Installation Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Before Installing the Eddy Current Brake: Verify Optimal Brake Cooling . . . 4-2 Before Installing the Eddy Current Brake: Verify Mounting Holes . . . . . . . . 4-3 Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Installing the Temperature Sensor . . . . . . . . . . . . . . . . . . . .
TA B L E O F C O N T E N T S Appendix B Power Requirements and Installation Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 Hard Wiring to the Building . . .
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 424x/424xLC2 Automotive Dynamometer (dyno). Dynojet’s software and dynamometers will give you the power to get the maximum performance out of the vehicles you evaluate.
CHAPTER 1 Introduction INTRODUCTION ................................... 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 specifications and requirements 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 Dynamometer Specifications and Requirements DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS ................................... The following specifications and requirements will help you set up your dyno area and verify you have the requirements necessary to operate your dyno safely.
SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements 93.83 cm (36.94 in.) frame and air brake assembly 73.66 cm (29.00 in.) 72.07 cm (28.375 in.) frame to floor AD129 58.42 cm (23.00 in.) frame only 218.44 cm (86.00 in.) frame only 106.93 cm (42.10 in.) eddy current brake 321.23 cm (126.47 in.
CHAPTER 1 Dynamometer Specifications and Requirements 130.18 cm (51.25 in.) frame and cradle assembly 218.44 cm (86.00 in.) dyno frame only 321.23 cm (123.47 in.) frame and brake 73.66 cm (29.00 in.) frame AD375 218.44 cm (86.00 in.) track 234.32 cm (92.25 in.
SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements 584.20 cm (230.00 in.) frame and covers full out 609.60 cm (240.00 in.) out with bridge extension* 469.90 cm (185.00 in.) frame and covers full in 495.30 cm (195.00 in.) in with bridge extension* 161.54 cm (63.60 in.) 492.76 cm (194.00 in.) eddy current brake covers 229.87 cm (90.50 in.) AD131 345.44 cm (136.00 in.
CHAPTER 1 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 • have a 3/8-inch inside diameter COMPUTER SPECIFICATIONS You will need to provide a computer system to run the WinPEP software.
SPECIFICATIONS AND OPERATING REQUIREMENTS Dynamometer Specifications and Requirements 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 2,495 kg (5,500 lb.) to lift the crated dyno and to lift the dyno off the crate and into position in your dyno room. You will also need a pair of straps capable of supporting the uncrated dyno. Dynojet recommends using single loop style straps.
CHAPTER 1 Model 424 Stationary and 4WD Dynamometer MODEL 424 STATIONARY AND 4WD DYNAMOMETER ...................................
SPECIFICATIONS AND OPERATING REQUIREMENTS Model 424 4WD Dynamometer With Pit Covers MODEL 424 4WD DYNAMOMETER WITH PIT COVERS ...................................
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 placing the dyno in the pit, take a moment to verify the dimensions of the pit are correct. Refer to the pit specifications (P/N 98219111) you received from your salesman for more detailed specifications. • pit depth: 72.07 cm (28.375 in.) • pit length: 88-130-inch wheel base 452.12 cm (178.00 in.) 98-140-inch wheel base 477.52 cm (188.00 in.
CHAPTER 2 STATIONARY DYNO INSTALLATION This chapter will walk you through unpacking and installing the stationary dyno. 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 2,114 kg (4,660 lb.) to move the crated dyno into position in your dyno room.
STATIONARY DYNO INSTALLATION Unpacking and Inspecting the Dyno part Version 7 description runner tie slide (2) P/N 21214705 part description washer, 3/8", splitlock, steel (4) P/N 36932100 drum guard, right, 4WD dyno P/N 21216101 anchor, redhead, 3/8" (6) P/N 37513200 drum guard, left, 4WD dyno P/N 21216102 installation tool, redhead anchor P/N 37518200 drum guard, rear (2) P/N 21216103 axle strap, 21" (4) P/N 30AS21 drum guard, left, stationary P/N 21219113 car tie-down, 2" x 10’ (4) P/N 500-C
CHAPTER 2 Unpacking and Inspecting the Dyno part description forward pit cover, middle P/N 21219117 part description riser foot assembly (4) P/N 61319600 forward pit cover, left P/N 21219118 dyno electronics P/N 76100003N runner mount, short (2) P/N 21514801 bolt kit, 424 bridge P/N 79110002 runner mount (2) P/N 21514802 bolt kit, 4WD above ground P/N 79110004 runner support (2) P/N 21514803 bolt kit, 3/8-16 x 5", black oxide P/N 79110006 forward pit cover spacer P/N 21519140 ground hook kit (
STATIONARY DYNO INSTALLATION Unpacking and Inspecting the Dyno part description chock (4) P/N 2A092 part nut, 1/4-20, nylock (4) P/N 36468100 description inductive primary pickup clip P/N DE100-110L bolt, 3/8-16 x 1", hex (6) P/N DM150-019-012 bolt, 1/4-20 x 1.
CHAPTER 2 Unpacking and Inspecting the Dyno part description nut, 1/2-13, nylock, hex (4) P/N 36708100 part bolt, 1/2-13 x 1.
STATIONARY DYNO INSTALLATION Unpacking and Inspecting the Dyno part description part description The following parts are included in each Ground Hook Kit P/N 79190001: Version 7 ground hook/D-ring P/N 10111 anchor, redhead, 3/8" (2) P/N 37513200 D-ring bracket, surface mount P/N 10112 washer, 5/16", flat (2) P/N DM150-002-007 washer, 3/8", splitlock, steel (2) P/N 36932100 bolt, 3/8-16 x 1", hex (2) P/N DM150-019-012 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide 2-7
CHAPTER 2 Unpacking and Inspecting the Dyno 4 5 6 7 8 9 Remove the crate braces that support the top portion of the crate. Remove the four lag bolts and washers securing the dyno to the crate base. Remove the five screws securing the front and rear drum guards and set aside. Remove the front and rear drum guards and set aside. Remove the two screws securing the left and right drum guards and set aside. Remove the left and right drum guards and set aside.
STATIONARY DYNO INSTALLATION Dyno Installation DYNO INSTALLATION ................................... This section will walk you through removing the dyno from the crate and installing the dyno in your pit. Refer to Chapter 4 for instructions on installing the eddy current brake. Note: Refer to Appendix C for instructions on upgrading an existing dyno. REMOVING THE DYNO FROM THE CRATE You will need to provide equipment capable of lifting a minimum of 2,114 kg (4,660 lb.
CHAPTER 2 Dyno Installation 6 With the dyno on the forklift, secure the four feet to the bottom of the dyno using one 3/8-16 x 1.5-inch bolt, lock washer, and washer each. Note: If the feet are already installed, skip this step.
STATIONARY DYNO INSTALLATION Dyno Installation PLACING THE DYNO IN THE PIT 1 Using the forklift, gently lower the dyno into the pit. Note: Make sure the dyno air brake is facing towards the center of the pit. 2 3 Gently lower the dyno into position. Verify the side of the dyno is 8.26 cm (3.25 in) from the pit wall. When installing the Linx option, verify the side of the dyno is 118.75 cm (46.75 in) from the pit wall.
CHAPTER 2 Dyno Installation ANCHORING THE DYNO Dynojet recommends you secure your dyno to the floor in your dyno room using concrete anchors. Use the following instructions to secure the dyno to the floor.
CHAPTER 3 4WD DYNO INSTALLATION This chapter will walk you through unpacking and installing the 4WD dyno. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 3 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 2,495 kg (5,500 lb.) to move the crated dyno into position in your dyno room.
4WD DYNO INSTALLATION Unpacking and Inspecting the Dyno part Version 7 description rail tie (3) P/N 21716400 part description rail tie assembly (2) P/N 61314300 spacer, 424 hydraulic movement (2) P/N 26100000 rail clamp (4) P/N 61314700 spacer, rail clamp (8) P/N 26152020 calibration arm assembly P/N 61319001 rail clip (10) P/N 31619500 runner assembly (30) P/N 61319500 clevis pin, 3/4 x 4.
CHAPTER 3 Unpacking and Inspecting the Dyno 6 7 8 9 Remove the crate braces that support the top portion of the crate. Remove the four lag bolts and washers securing the dyno to the crate base using a 9/16-inch socket, open or box end wrench. Remove the drum guards if installed. If the drum guards are not installed, skip to step #9. 8a Remove the five screws securing the rear drum guard and set aside. 8b Remove the rear drum guard and set aside.
4WD DYNO INSTALLATION Track Assembly TRACK ASSEMBLY ................................... The stationary dyno must be installed before proceeding with the 4WD dyno installation. Refer to chapter 2 for stationary dyno installation instructions. Before installing the track assembly, layout the entire track assembly using the following instructions and Figure 3-2 for position and alignment.
CHAPTER 3 Track Assembly stationary dyno 128.27 cm (50.50 in.) without extension 153.67 cm (60.50 in.) with extension (requires extension parts, inquire with Dynojet sales) center line for stationary dyno and track assembly 184.15 cm (72.5 in.) track layout first rail tie assembly 49.37 cm (19.438 in.) first rail tie mark and drill holes 103.82 cm (40.875 in.) second rail tie 158.28 cm (62.313 in.
4WD DYNO INSTALLATION Track Assembly INSTALLING THE TRACK ASSEMBLY Once all the holes are marked and drilled, install the track assembly. You will need the following parts: 1 2 3 • 21514282 Rail (2) • 21716400 Rail Tie (3) • 31619500 Rail Clip (10) • 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (10) • 61314300 Rail Tie Assembly (2) • 61314700 Rail Clamp (4) Layout the first and last rail tie assemblies and the rail ties.
CHAPTER 3 Track Assembly 4 5 6 Loosely install the ten rail tie clips using one 3/8-16 x 1.5-inch flange-head bolt per clip. There are five rail tie clips on each side of the track assembly. Verify the track assembly is square and make any necessary adjustments. Tighten all ten bolts. Note: For clarity, the pit and stationary dyno are not shown.
4WD DYNO INSTALLATION Dyno Installation DYNO INSTALLATION ................................... With the track assembly installed and secured to the floor, you are ready to install the 4WD dyno. This section will walk you through removing the dyno from the crate and securing the dyno to the track. REMOVING THE DYNO FROM THE CRATE You will need to provide equipment capable of lifting a minimum of 2,495 kg (5,500 lb.) to lift the dyno off the crate and into position in your dyno room.
CHAPTER 3 Dyno Installation PLACING THE DYNO ON THE TRACK You will need to keep the cable track routed underneath the dyno and towards the stationary dyno. You will need the following parts: 1 2 3 4 • 26152020 Spacer, Rail Clamp (8) • 36800973 Bolt, Shoulder, 3/8-16, 1/2"D x 1"L (8) Remove the cotter pin and pin from all four cradle assemblies as shown in Figure 3-6. Verify the rail clamps are positioned as shown in Figure 3-6. Verify the dyno movement motor is facing away from the stationary dyno.
4WD DYNO INSTALLATION Dyno Installation 5 6 7 8 Secure the rail clamps to the cradle assembly on the dyno using two 3/8-inch shoulder bolts and two spacers each. Replace the pins and cotter pins removed earlier from the four cradle assemblies as shown in Figure 3-6. Move the rail clamps up and down and verify they move freely. Roll the dyno back and forth and verify the rail clamps are not binding and the track assembly is square. Note: For clarity, the pit and stationary dyno are not shown.
CHAPTER 3 Cable Routing CABLE ROUTING ................................... Use the following instructions to identify and route the cables for dynos with and without eddy current brakes.
4WD DYNO INSTALLATION Cable Routing ROUTING THE CABLES—WITHOUT THE EDDY CURRENT BRAKES Use these instructions for routing cables without the eddy current brake. Refer to page 3-16 for more information on routing cables with one eddy current brake and page 3-20 for more information on routing cables with two eddy current brakes. Refer to Figure 3-8 for cable locations. Refer to page 3-15 for more information on wiring the Breakout board.
CHAPTER 3 Cable Routing power supply for dyno electronics DRY AIR IN 100-140 PSI breakout board dyno electronics B I stationary dyno A dyno movement pendant C D E H F G power supply first cable track second cable track 4WD dyno AD390 Figure 3-8: Routing the Cables—Without the Eddy Current Brakes 3-14 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
4WD DYNO INSTALLATION Cable Routing WIRING THE BREAKOUT BOARD—WITHOUT THE EDDY CURRENT BRAKES 1 Attach the pickup card cable (B, C) to the Breakout board. This cable may already be connected. The pickup card cable (B) from the stationary dyno has four wires which connect to the wiring block labeled DRUM 1. The pickup card cable (C) from the 4WD dyno has four wires which connect to the wiring block labeled DRUM 2.
CHAPTER 3 Cable Routing ROUTING THE CABLES—WITH ONE EDDY CURRENT BRAKE Use these instructions for routing cables with only one eddy current brake. The single eddy current brake is installed on the stationary dyno. Refer to Chapter 4 for eddy current brake, torque module, and load cell installation instructions. Refer to page 3-20 for more information on routing cables with two eddy current brakes. Refer to Figure 3-10 for cable locations.
4WD DYNO INSTALLATION Cable Routing 11 Route the theta signal cable (L) from the stationary dyno theta controller to the Breakout board. Refer to page 3-15 for more information on wiring the Breakout board. 12 Route the temperature sensor cable (N) from the stationary dyno eddy current brake to the Breakout board. Refer to page 3-15 for more information on wiring the Breakout board. 13 Route the theta power cable (P) from the stationary dyno, through the pit conduit, and to your 240V power source.
CHAPTER 3 Cable Routing WIRING THE BREAKOUT BOARD—WITH ONE EDDY CURRENT BRAKE 1 Attach the pickup card cable (B, C) to the Breakout board. This cable may already be connected. The pickup card cable (B) from the stationary dyno has four wires which connect to the wiring block labeled DRUM 1. The pickup card cable (C) from the 4WD dyno has four wires which connect to the wiring block labeled DRUM 2.
4WD DYNO INSTALLATION Cable Routing theta signal pickup card stationary brake signal pickup card 4WD jumpers J1 and J2 temperature sensor four wheel drive with one eddy current brake jumper settings Figure 3-11: Wiring the Breakout Board—With One Eddy Current Brake Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide 3-19
CHAPTER 3 Cable Routing ROUTING THE CABLES—WITH TWO EDDY CURRENT BRAKES Use these instructions for routing cables with two eddy current brakes. Refer to Chapter 4 for eddy current brake, torque module, and load cell installation instructions. Refer to Figure 3-13 for cable locations. Refer to page 3-23 for more information on wiring the Advanced Breakout board.
4WD DYNO INSTALLATION Cable Routing 10 Route the brake signal cable (D) from the first cable track to the Advanced Breakout board. Refer to page 3-23 for more information on wiring the Advanced Breakout board. 11 Route the air hose (E) from the second cable track to the T fitting on the stationary dyno brake solenoid. 12 Route the long air hose (F) from the second cable track to the barbed fitting on the air brake can on the stationary dyno.
CHAPTER 3 Cable Routing 20 Route the power cable (G) from the first cable track, through the pit conduit, and connect to the power supply. Plug the power supply into your power source. 21 Connect the power supply to the dyno electronics. Plug the power supply into your power source.
4WD DYNO INSTALLATION Cable Routing WIRING THE ADVANCED BREAKOUT BOARD—WITH TWO EDDY CURRENT BRAKES Refer to Figure 3-14 for Advanced Breakout board locations. 1 Attach the pickup card cable (B, C) to the Advanced Breakout board. The pickup card cable (B) from the stationary dyno has four wires which connect to the wiring block labeled DRUM 1. The pickup card cable (C) from the 4WD dyno has four wires which connect to the wiring block labeled DRUM 2.
CHAPTER 3 Cable Routing theta signal cable stationary dyno R19 R16 R23 R12 R15 R18 R21 C33 U11 J2 C32 U9 U5 R40 R41 C20 C13 U13 L5 L4 C3 R32 X1 U3 C34 C19 C8 C2 R8 R7 J1 C31 R44 C25 TB5 C11 R6 C36 R47 C9 U8 U12 C7 R31 C35 R30 R25 U15 R26 R28 R27 R29 C14 GRN WHT BLK RED SH GRN WHT BLK RED SH TEMP FROM DRUM 1 TEMP FROM DRUM 2 R9 C15 R4 C4 R5 R3 U4 R1 R2 C1 L1 TB1 C16 C12 R46 R45 C5 C28 R10 C23 C30 U14 U6 C29 R14 R22 R13 D6 Q1 C17 MC9S12UF32PUL -SEE MANU
4WD DYNO INSTALLATION Hydraulic Movement Installation HYDRAULIC MOVEMENT INSTALLATION ................................... Use the following instructions to install the hydraulic movement. You will need the following parts: 1 • 21200064 Cylinder Mount, Floor • 26100000 Spacer,424 Hydraulic Movement (2) • 32900000 Clevis Pin, 3/4 x 4.5" (2) • 32904080 Hairpin Cotter, 7/16 x 3/4" (2) • 36582471 Bolt, 3/8-16 x 1.
CHAPTER 3 Hydraulic Movement Installation 2 Secure the hydraulic ram to the dyno cylinder mount using one clevis pin and hairpin cotter.
4WD DYNO INSTALLATION Hydraulic Movement Installation 3 Temporarily hold the floor cylinder mount to the hydraulic ram using two spacers and one clevis pin.
CHAPTER 3 Hydraulic Movement Installation 4 Using the floor cylinder mount as a template, mark each hole needed to secure the mount to the floor. 5 Remove the clevis pin, spacers, and floor cylinder mount. 6 Move the hydraulic ram out of the way. 7 Drill the holes marked in step #4. 8 Install the Red Head anchors. Refer to Appendix A for installation instructions. 9 Secure the floor cylinder mount to the floor using two 3/8-16 x 1-inch hex bolts and two 3/8-inch flat washers.
4WD DYNO INSTALLATION Hydraulic Movement Installation FILLING THE HYDRAULIC MOTOR WITH HYDRAULIC FLUID 1 2 3 Remove the cap on the hydraulic motor. Add four quarts of AW-68 hydraulic fluid. Replace the cap.
CHAPTER 3 Hydraulic Movement Installation WIRING THE HYDRAULIC MOTOR Verify the motor is wired for your needs. The motor is wired for 110v but can be changed to 220v. 1 2 Remove the wiring box cover. Follow the instructions on the cover to wire the motor for 220v.
4WD DYNO INSTALLATION Air Can Sleeve AIR CAN SLEEVE ................................... When you receive your dyno, the nut holding the air can sleeve will be tight. You will need to loosen the nut on all four air cans. Using a wrench, loosen the nut as far as you can. The sleeve will drop down as shown in Figure 3-21.
CHAPTER 3 4WD Dyno Movement Test 4WD DYNO MOVEMENT TEST ................................... Verify the movement of the 4WD dyno before installing the grates. 1 The Breakout board jumper settings are preset, however, verify jumpers are set appropriately as shown in Figure 3-9, Figure 3-11, or Figure 3-14. Note: The Breakout board is located on the stationary dyno. 2 Verify the hydraulic motor is filled with hydraulic fluid.
4WD DYNO INSTALLATION Bridge Installation—Stationary Dyno BRIDGE INSTALLATION—STATIONARY DYNO ................................... Use the following instructions to install the drum guards, runner mounts and supports, runner assemblies, and the bridge cover.
CHAPTER 3 Bridge Installation—Stationary Dyno INSTALLING THE DRUM GUARDS 1 Secure the longer left and right drum guards using one 3/8-16 x 1.25-inch buttonhead bolt each. Note: These drum guards are longer (88.90 cm, 35.00 in.) than the left and right drum guards for the 4WD dyno and must be mounted on the stationary dyno. 2 Secure the wider front drum guard using five 3/8-16 x 1.25-inch button-head bolts. Note: This front drum guard is wider (27.94 cm, 11.00 in.
4WD DYNO INSTALLATION Bridge Installation—Stationary Dyno INSTALLING THE RUNNER MOUNTS AND RUNNER SUPPORTS Refer to Appendix D for instructions on installing the bridge extension assembly. 1 Place the runner mount (z-shaped) with eight round holes on top of the drum guard. Note: The standard runner mount is smaller than the extended runner mount used with the bridge extension kit. Be sure to use the correct runner mount for your installation.
CHAPTER 3 Bridge Installation—Stationary Dyno INSTALLING THE RUNNER ASSEMBLIES AND RUNNER EXTENSION 1 2 3 4 Place the plastic runner slide on top of the runner support. Slide each runner assembly into the runner mount. Verify the plastic end faces away from the stationary dyno. Loosely secure each runner assembly to the runner mount using one 3/8 x 5-inch bolt, flat washer, lock washer, and nut. These bolts will be tightened later.
4WD DYNO INSTALLATION Bridge Installation—Stationary Dyno 5 Install the runner extension. There is a left and right version of the runner extension; the left version is shown in Figure 3-25. Note: Do not install the runner extension on the side of the dyno where the eddy current brake will be installed. 5a Secure the support leg to the runner extension using two 1/4 x 1.5-inch bolts, two flat washers, and two 1/4-20 nuts. 5b Remove the two 1/4-20 torx screws from the runner assembly.
CHAPTER 3 Bridge Installation—Stationary Dyno 6 7 Square up the runner assemblies. 6a Place a square ruler along the edge of the stationary dyno and along one of the runner assemblies. Move the runner assemblies until they are square with the dyno. 6b Tighten the bolts securing the runner assemblies to the runner mounts. 6c Tighten the bolts securing the runner mounts to the dyno. Dynojet recommends you anchor the support pillars to the dyno room floor, however this step is optional.
4WD DYNO INSTALLATION Bridge Installation—Stationary Dyno INSTALLING THE BRIDGE COVER 1 2 3 4 Remove the center bolt from the front drum guard. Place the cover on the drum guard while supporting the other end of the cover. Replace the center bolt. Secure the cover to each runner support pillar two 3/8-16 x 1/2-inch button-head flange bolts. Installing the cover will square up the other set of runner assemblies. 5 Tighten all bolts.
CHAPTER 3 Bridge Installation—4WD Dyno BRIDGE INSTALLATION—4WD DYNO ................................... This section will walk you through installing the drum guards, runner mounts, runner assemblies, cover, and runner tie straps.
4WD DYNO INSTALLATION Bridge Installation—4WD Dyno INSTALLING THE DRUM GUARDS 1 Secure the shorter left and right drum guards using one 3/8 x 1.25-inch buttonhead bolt each. Note: These drum guards are shorter than the left and right drum guards for the stationary dyno and must be mounted on the 4WD dyno. 2 Secure the rear drum guard using the center 3/8 x 1.25-inch button-head bolt.
CHAPTER 3 Bridge Installation—4WD Dyno INSTALLING THE RUNNER MOUNTS The runner mounts and runner clamps are shorter for the moveable dyno. 1 2 3 Place the runner mount (z-shaped) with seven round holes on top of the drum guard. Place the runner clamp plate with seven round holes on top of the runner mount. Loosely secure each runner mount and runner clamp to the dyno using three 3/8 x 1.5-inch flange hex allen bolts.
4WD DYNO INSTALLATION Bridge Installation—4WD Dyno INSTALLING THE RUNNER ASSEMBLIES 1 2 Slide each runner assembly into the runner mount.Verify the plastic end faces away from the 4WD dyno. Loosely secure the six outside runner assemblies to the runner mount using one 3/8 x 5-inch bolt, flat washer, lock washer, and nut each. Note: Leave the seventh inner bolt out. This bolt will be used to secure the center cover.
CHAPTER 3 Bridge Installation—4WD Dyno INSTALLING THE BRIDGE COVER AND RUNNER TIE STRAPS 1 2 3 Secure the cover to the runner mounts using the two reserved 3/8 x 1.5-inch flange hex allen bolts from earlier. Secure the cover to the runner assemblies using two 1/4 x 5/8-inch torx head bolts. Secure one runner tie strap and one plastic runner tie slide to each set of moveable runner assemblies using six 1/4 x 5/8-inch torx head bolts each.
4WD DYNO INSTALLATION Forward Pit Covers FORWARD PIT COVERS ................................... Before installing the 4WD dyno pit covers, be sure to install the Linx option at this time. Refer to the Linx Installation Guide P/N 98200021. Use the following instructions to install the 4WD dyno pit covers.
CHAPTER 3 Forward Pit Covers 3 4 5 Secure the left and right pit covers to the pit cover spacer and dyno frame using two 3/8-16 x 3-inch bolts each. Secure the left and right pit covers to the middle pit cover using five 3/8-16 x 1/2-inch bolts each. Secure the end of the middle pit cover to the end of the left and right pit covers using two 3/8-16 x 1/2-inch bolts each.
4WD DYNO INSTALLATION Ground Hook Installation GROUND HOOK INSTALLATION ................................... Using the pit drawing as a guide, place the ground hooks in a location that works best for your dyno application. Refer to the pit specifications (P/N 98219111) you received from your salesman for more detailed specifications.
CHAPTER 4 EDDY CURRENT BRAKE INSTALLATION The eddy current brake along with the torque module, when added to Dynojet's market leading inertia dynamometer, results in a complete vehicle performance test. This chapter provides instructions for installing the eddy current brake (retarder) to the stationary and 4WD dynos. This chapter also provides instructions for installing the torque module and load cell along with load cell calibration procedures.
CHAPTER 4 Eddy Current Brake Installation EDDY CURRENT BRAKE INSTALLATION ................................... This section will walk you through removing the eddy current brake from the crate, installing the eddy current brake to the dyno, and installing the theta controller. These instructions will show the stationary dyno, but the instructions are the same for both the stationary and 4WD dynos.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation BEFORE INSTALLING THE EDDY CURRENT BRAKE: VERIFY MOUNTING HOLES Dynos with the serial number 2240308 and lower will need to have mounting holes drilled into the dyno frame before installing the eddy current brake. Using a 5/8-inch or 1/2-inch drill, mark and drill the four holes as shown in Figure 4-2. AD138 36.83 cm (14.50 in.) 6.67 cm (2.625 in.) 60.96 cm (24.00 in.) 24.13 cm (9.50 in.) 1.59 cm (0.625 in.) 1.59 cm (0.625 in.
CHAPTER 4 Eddy Current Brake Installation UNPACKING THE EDDY CURRENT BRAKE 1 2 3 Remove the top and sides of the crate. Remove any hardware and parts boxes from the crate and verify the box contents using the parts list. Remove the uprights and cross members from the crate.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation 4 5 Remove the four lag bolts securing the brake to the crate. Place the nylon loop strap around the shaft on either side of the brake. Dynojet recommends using single loop style straps. 6 Using a forklift, lift the eddy current brake from the crate and place the brake near the dyno. RECORD # Be sure you record the dynamometer and/or eddy current brake number on the inside cover of this manual.
CHAPTER 4 Eddy Current Brake Installation INSTALLING THE TEMPERATURE SENSOR Use the following instructions to secure the temperature sensor to the eddy current brake in the location shown. You will need the following part: • 76955001 Temperature Sensor Assembly temperature sensor Figure 4-5: Temperature Sensor Location 1 2 3 Remove the nut from the sensor. Slide the sensor through the cross brace. Secure the sensor to the brace using the nut removed earlier.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation INSTALLING THE BEARING, SPLINE SHAFT, AND DRIVELINE ASSEMBLY The eddy current brake can be installed on either side of your dyno, the installation instructions are the same. You will need the following parts: 1 • 22117130 Splined Shaft Assembly • 32355056 Bearing • 36801080 Bolt, 1/2-13 x 1.5", Flange-Hex (2) • 62240130 Driveline Assembly Install the bearing using two 1/2-13 x 1.5-inch flange-hex bolts. Leave the bolts loose.
CHAPTER 4 Eddy Current Brake Installation 2 Insert the splined shaft through the bearing and into the spline hub of drum. Note: Make sure the short splined end faces out. 3 4 5 6 Push the splined shaft in until the shoulder is flush with the bearing. Torque the bearing mounting bolts to 57 foot-pounds. Torque the two set screws on the bearing to 25 foot-pounds. Remove the four bolts securing the u-joint to the keyed driveline yoke.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation INSTALLING THE EDDY CURRENT BRAKE You will need the following parts: 1 2 3 4 • 36708100 Nut, 1/2-13, Nylock-Hex (4) • 36801080 Bolt, 1/2-13 x 1.5", Flange-Hex (4) • 36923100 Washer, 3/8", Hardened, Flat (8) • 36943102 Washer, 1/2", Hardened, Flat (4) • 37620844 Woodruff Key, 1/2 x 2.75" • DM150-019-012 Bolt, 3/8-16 x 1", Hex (8) Place the key in the eddy current brake shaft keyway. Place the keyed yoke onto the eddy current brake shaft.
CHAPTER 4 Eddy Current Brake Installation 5 6 7 8 Secure the side of the brake frame to the dyno using eight 3/8-16 x 1-inch hex bolts and eight 3/8-inch hardened flat washers. Not all of the bolts and washers are visible from this view. Secure the stiffener plate to the dyno using four 1/2-13 x 1.5-inch flange-hex bolts, four 1/2-inch flat washers, and four 1/2-13 nylock nuts. Not all of the bolts and washers are visible from this view.
EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation INSTALLING THE LOAD CELL You will need the following part: 1 2 3 • 76950505 Load Cell Assembly Verify the main dyno power is disconnected. Remove the two bolts and nuts securing the existing bar on the eddy current brake and remove the bar. Set the bolts and nuts aside. Verify the eyelets on the load cell are spaced the same as the bar removed earlier. Adjust the load cell spacing by loosening the lock nut and turning the eyelet.
CHAPTER 4 Eddy Current Brake Installation INSTALLING THE THETA CONTROLLER Use the following instructions to install the theta controller to both the stationary and 4WD dynos.
EDDY CURRENT BRAKE INSTALLATION Pit Covers PIT COVERS ................................... Before installing the eddy current brake pit covers, verify all cables have been routed and you have completed the 4WD dyno installation. Refer to “Cable Routing” on page 3-12 for more information. You will need the following parts: 1 2 3 • 21217513 Calibration Cover (2) • 21919101 Foot (6) • 36561045 Screw, 1/4-20 x 5/8", Pan-Head, Torx (12) • 36582477 Bolt, 3/8-16 x 1.
CHAPTER 4 Pit Covers 4 5 6 7 Using the support leg as a template, mark and drill the two holes needed to secure the leg to the floor. Install two Red Head anchors. Refer to Appendix A for installation instructions. Secure the leg to the floor using two 3/8-16 x 1.5-inch hex bolt and two 3/8-inch flat washers. Place the pit cover and leg into the pit. Place the leg near the 4WD bridge. Verify the edge of the pit cover sits on the floor. Verify the side of the pit cover is 26.04 cm (10.25 in.
EDDY CURRENT BRAKE INSTALLATION Pit Covers 13 Once you have calibrated the load cell, install the pit calibration covers using six 1/4-20 x 5/8-inch torx screws each. Note: Do not install these covers until you have finished calibrating the load cell. Refer to page 4-20 for calibration instructions.
CHAPTER 4 Torque Module Installation TORQUE MODULE INSTALLATION ................................... This section describes how to install the Torque Module(s), connect the load cell cable, and install the side and top brake covers. INSTALLING THE TORQUE MODULE You will need the following part: 1 2 3 • 66104001 Torque Module Verify the main dyno power is disconnected. Turn off the main power switch on the CPU Module and unplug the power cord. Remove the dust cover from the existing top module.
EDDY CURRENT BRAKE INSTALLATION Torque Module Installation 4 5 Loosen the top right screw on the back of the existing top module. Plug the Torque Module (or modules) into the existing top module. Place the dust cover, removed in step 3, on the Torque Module.
CHAPTER 4 Torque Module Installation 6 7 Secure the grounding strap on the back of the Torque Module to the existing top module. Secure the Torque Module to the dyno electronics with the plastic tie straps (one on each side). Note: Do not attach the load cell cable at this time.
EDDY CURRENT BRAKE INSTALLATION Torque Module Installation CONNECTING THE LOAD CELL CABLE The load cell cable was routed from the dyno to the dyno electronics on page 3-13 and page 3-20. 1 Attach the 9-pin connector on the load cell cable to the front of the Torque Module and tighten down the screws. Note: When there are two Torque Modules, connect the load cell cable from the 4WD dyno to the top Torque Module. 2 3 Attach the power cord to the CPU Module and turn the power switch on.
CHAPTER 4 Load Cell Calibration LOAD CELL CALIBRATION ................................... This section provides instructions for calibrating the load cell(s). The load cell must be calibrated prior to use. Follow the directions on the screen exactly. Failure to perform the directions accurately will result in improper torque values. Note: Repeat these steps for each eddy current brake.
EDDY CURRENT BRAKE INSTALLATION Load Cell Calibration Once the Zero Calibration is complete, the Calibration Mass window will appear. 5 Enter the Torque Module calibration value. Refer to Figure 4-23. Note: You must perform this step the first time you calibrate the load cell. Or If you are only performing a Zero Calibration, click Finish. Figure 4-22: Calibration Mass Window Enter the calibration number stamped near the bolt pattern at the end of the calibration arm.
CHAPTER 4 Load Cell Calibration 6 Click Next to continue. The Span Calibration window will appear. 7 Select a torque cell from the drop down list. Figure 4-24: Span Calibration Window 8 Install the calibration arm and weights Note: Calibration arm placement determines positive direction for torque. Place the weights towards the rear of the vehicle. Refer to step 9 and Figure 4-26 on page 4-23 for calibration arm installation instructions.
EDDY CURRENT BRAKE INSTALLATION Load Cell Calibration 9 Install the calibration arm and weights using the bolts at the end of the calibration arm. 9a Secure the calibration arm to the eddy current brake by tightening the bolt using the handle. 9b Gently place the weights on the calibration arm. Note: Verify the calibration arm is not contacting the cover. The calibration weights are very heavy. The weights must be set on the arm gently or you will damage the load cell.
CHAPTER 4 Load Cell Calibration While installing the calibration weights, you should notice the Torque Gauge on the DynoTrac Window moving from 0 to about 500 foot-pounds. Note: The Torque Gauge may or may not be in this range. • If the torque cell has been previously calibrated incorrectly or has not been calibrated for a while, the gauge may show values out of this range until calibration is complete. Note: Let the torque gauge needle stabilize before clicking Next.
CHAPTER 5 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 5 Loading the Vehicle LOADING THE VEHICLE ................................... Use the following steps to load a vehicle on the dyno. You will need the following parts: 1 2 • 2A092 Tire Chock (4) • 30AS21 Axle Strap (4) • 500-C10 Car Tie-Down (4) • 500-C10W/S Car Tie-Down, Hi-Performance (2) Verify your computer is running. Set the dyno brake on by pressing the red button on the hand-held pendant.
BASIC DYNO OPERATION Loading the Vehicle 8 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 5-2. • Attach two tie-down straps from secure anchor points to the front of the vehicle. Front Wheel Drive • Attach two tie-down straps from secure anchor points to the rear of the vehicle.
CHAPTER 5 Loading the Vehicle 9 Tighten the tie-down straps evenly making sure that the drive wheels remain centered on the drum. The tie-down straps should always be connected to the vehicle’s solid axle or the suspension control arms. Factory tie-down hooks connected to the vehicle’s frame may be used on the end opposite the drive wheels (for example: the front end of a rear driven vehicle). 10 Release the brake on the vehicle and the dyno.
BASIC DYNO OPERATION 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.
CHAPTER 5 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.
BASIC DYNO OPERATION 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.
CHAPTER 5 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.
BASIC DYNO OPERATION 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.
CHAPTER 5 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.
BASIC DYNO OPERATION Preventative Maintenance PREVENTATIVE MAINTENANCE ................................... This section covers maintenance items for all model 424 dynos with the Spring Applied Air Release (SAAR) brake and the 4WD attachment. 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.
CHAPTER 5 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.
BASIC DYNO OPERATION 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).
CHAPTER 5 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.
BASIC DYNO OPERATION Preventative Maintenance DYNOS WITH 4WD ATTACHMENT—THINGS TO CHECK • Check the hydraulic motor fluid once every six months, fill as necessary. • Remove the cap on the hydraulic motor. • Add additional AW-68 hydraulic fluid as needed. • Replace the cap. remove cap on hydraulic motor AD393 Figure 5-9: Fill the Hydraulic Motor with Oil • Inspect the hoses connecting the hydraulic motor to the ram. Replace as necessary (P/N 11100000).
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 POWER REQUIREMENTS AND INSTALLATION This appendix contains power requirements and installation instructions for the eddy current brake. 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.
APPENDIX B Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power POWER REQUIREMENTS AND INSTALLATION—NORTH AMERICA, JAPAN, AND LOCATIONS USING 60 HZ POWER ................................... The following power requirements and instructions are for North America, Japan, and locations using 60 Hz power. Refer to “Power Requirements and Installation— Excluding North America and Japan” on page B-5 for all other locations.
POWER REQUIREMENTS AND INSTALLATION Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the eddy current brake is connected to the outlet. If the voltage readings do not match the following table, DO NOT connect the brake. You must have a licensed electrician correct the power connection.
APPENDIX B Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power HARD WIRING TO THE BUILDING Use the following instructions to wire the brake directly to the building. The brake must connect to a two pole disconnect switch to allow the removal of all power to the brake for servicing. This box may contain fusing, circuit breakers, or the circuit protection may be upstream in the building power system.
POWER REQUIREMENTS AND INSTALLATION Power Requirements and Installation—Excluding North America and Japan POWER REQUIREMENTS AND INSTALLATION—EXCLUDING NORTH AMERICA AND JAPAN ................................... The eddy current brake (excluding North America and Japan) requires a dedicated wall receptacle which must be wired for operation and is included with the brake or may be shipped in advanced in a separate package.
APPENDIX B Power Requirements and Installation—Excluding North America and Japan INSTALLING THE WALL RECEPTACLE The wall receptacle is a single 240 volt 30A dedicated circuit with a ground. Note: The actual wall receptacle may be different from the image shown in Figure B-2; however, the installation instructions are the same. The cable carrying the power to this receptacle should be 4.0 mm2 (ten gauge) or larger. Check with local building codes for the correct size.
POWER REQUIREMENTS AND INSTALLATION Power Requirements and Installation—Excluding North America and Japan TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the eddy current brake is connected to the outlet. Using a voltmeter that is capable of measuring AC voltage, measure between the points listed below and verify that the correct voltages are present.
APPENDIX C STATIONARY DYNO UPGRADE This appendix contains instructions for upgrading an existing stationary dyno to be used with the 4WD dyno including relocating the deck, adding the lift kit, and adjusting the air fittings. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIX C Lift Kit Installation LIFT KIT INSTALLATION ................................... Once the rear deck has been removed, the lift kit must be installed. The lift kit will raise the stationary dyno to match the 4WD dyno. 1 2 3 4 5 6 7 Remove the four Red Head anchors securing the dyno to the floor and set aside. Using single loop straps and a forklift, raise the dyno off the floor. Remove the bolts and washers securing the existing feet and remove the feet.
STATIONARY DYNO UPGRADE Air Fittings Upgrade AIR FITTINGS UPGRADE ................................... Before the stationary dyno can be used with the 4WD dyno, the existing air fittings on the stationary dyno must be upgraded. 1 2 3 4 5 6 7 Remove the existing air inlet fitting from the brake solenoid assembly. Install the street tee. Replace the air inlet fitting removed earlier. Install a barbed hose fitting into the street tee. Remove the existing plug from the air can.
APPENDIX D BRIDGE EXTENSION ASSEMBLY This appendix contains instructions for installing the bridge extension assembly to the stationary dyno. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIX D Bridge Extension Installation BRIDGE EXTENSION INSTALLATION ................................... The optional bridge extension assembly (P/N 61119183) is used to extend the bridge range from an 88-130 inch wheel base to a 98-140 inch wheel base. Note: The Linx option can not be used with the extended wheel base. 1 Secure the extended runner mount (z-shaped bracket) to the drum guard using three 3/8 x 1.5-inch flange hex allen bolts.
BRIDGE EXTENSION ASSEMBLY Bridge Extension Installation When there is no eddy current brake, secure both outer brace mounts to the dyno using two 3/8 x 1.5-inch flange head bolts each.
APPENDIX D Bridge Extension Installation 5 Place the runner clamp on top of the extended runner mount. Note: The extended runner clamps used with the bridge extension are smaller and rectangular shaped compared to the standard runner clamps. Be sure to use the correct runner clamps. 6 With two brace mounts under the extended runner mount, secure the runner clamp and brace mounts using two 3/8 x 1.5-inch flange head bolts and two 3/8-inch nylock nuts each.
BRIDGE EXTENSION ASSEMBLY Bridge Extension Installation 7 Secure the two support arms to the brackets using two 1/2 x 1.5-inch bolts, two 1/2-inch lock washers, and two 1/2-inch nuts each.
APPENDIX D Bridge Extension Installation 8 9 Secure the center mount extension to the extended runner mounts using four 3/8 x 1/2-inch pan hex bolts. Continue with installing the runner supports, step 4 on page 3-35.
APPENDIX E 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 E 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 7 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 E 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 identifying 3-12 routing 3-13, 3-16, 3-20 4WD power cable identifying 3-12 routing 3-13, 3-17, 3-22 A advanced breakout board jumper settings 3-24 wiring 3-23 air brake 3-13, 3-16, 3-21 air can sleeve 3-31 air fittings C-3 air hose routing 3-12, 3-13, 3-16, 3-21 B battery hazards vi bearing 4-7 bearing grease 5-11 brake pressure gauge 5-11, 5-12 regulator 5-11, 5-12 shoe clearance 5-13 brake signal cable routing 3-12, 3-13, 3-16, 3-21 wiring 3-15, 3-18, 3-23 breakout board jumper set
INDEX D dimensions dyno 1-5, 1-6, 1-7 disclaimers v document part number 1-1 drill and drill bit 1-8 drum 1-4 drum guards installing, 4WD 3-41 installing, stationary 3-34 removing, 4WD 3-4 removing, stationary 2-8 dyno cylinder mount 3-25, 3-26 dyno electronics 1-12 dyno movement pendant cable identifying 3-12 routing 3-13, 3-16, 3-21 dyno requirements see also requirements E eddy current brake bearing 4-7 installing 4-9 keyed yoke 4-8, 4-9 mounting holes 4-3 optimal cooling 4-2 spline hub 4-8 splined s
INDEX R rail clamp 3-7 rail tie 3-7 rail tie assembly 3-7 rail tie clip 3-8 ram 3-26 red head anchor contact information A-1 installation A-2 setting tool A-3 warnings A-1 requirements chassis 1-4 compressed air 1-8 computer specifications 1-8 drill and drill bit 1-8 electrical 1-8 environmental 1-8 fire suppression 1-9 forklift 1-9 hydraulic motor 1-9 tie-down straps 1-9 routing cables 3-12–3-24 25-pin 3-12, 3-13, 3-16, 3-20 4WD power 3-12, 3-13, 3-17, 3-22 air hose 3-12, 3-13, 3-16, 3-21 brake signal 3-
