©2006-2014 Dynojet Research, Inc. All Rights Reserved. Installation Guide For Above 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 5 Side Deck Assembly Installation Side Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Installing the Side Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Chapter 6 Basic Dyno Operation Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Connecting the RPM Pickup . . . .
TA B L E O F C O N T E N T S Appendix C Stationary Dyno Upgrade Deck Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2 Removing the Early Style Deck from an Early Model Dyno . . . . . . . . . . . . . . . . . . C-2 Removing the New Style Deck from a New Model Dyno . . . . . . . . . . . . . . . . . . . . C-6 Installing the Early Style Deck on the 4WD Dyno . . . . . . . . . . . . . . . . . . . . . . . . .
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 NIN GS 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 NIN 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. Equipment is intended for indoor use only.
C HAPTER 1 SPECIFICATIONS AND OPERATING REQUIREMENTS Thank you for purchasing Dynojet’s Above 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: S PECIFICATIONS AND O PERATING REQUIREMENTS This chapter describes the specifications and requirements for the dyno.
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S 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.
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S Dynamometer Specifications and Requirements 115.49 cm (45.47 in.) frame, air brake, and interface kit 93.83 cm (36.94 in.) frame and air brake 106.93 cm (42.10 in.) brake 73.66 cm (29.00 in.) 72.02 cm (28.375 in.) frame to floor AD598 58.42 cm (23.00 in.) frame only 218.44 cm (86.00 in.) 321.23 cm (126.47 in.) frame and brake 65.58 cm (25.82 in.) brake only 80.01 cm (31.50 in.
CHAPTER 1 Dynamometer Specifications and Requirements 193.45 cm (76.16 in.) frame, cradle assembly, and deck 130.18 cm (51.25 in.) frame and cradle assembly 73.66 cm (29.00 in.) frame 218.44 cm (86.00 in.) frame only 321.23 cm (126.47 in.) frame and brake AD599 218.44 cm (86.00 in.) track 228.60 cm (90.00 in.) deck 224.15 cm (88.25 in.) track 65.58 cm (25.82 in.) brake only 80.01 cm (31.50 in.
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S Dynamometer Specifications and Requirements 508.00 cm (200.00 in.) deck full out to lift 416.56 cm (164.00 in.) deck full in to lift extension kit dimensions* 533.40 cm (210.00 in.) deck full out to lift 441.96 cm (174.00 in.) deck full in to lift 513.08 cm (202.00 in.) frame and deck full out 422.40 cm (166.30 in.) frame and deck full in 487.68 cm (192.00 in.) frame and deck full out 397.00 cm (156.30 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 Power Core software.
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S Dynamometer Specifications and Requirements ELECTRICAL REQUIREMENTS description Power Requirements: 4WD electronics Power Requirements: dyno electronics Power Requirements: hydraulic motor Power Requirements: computer Power Requirements: optional eddy current brake specifications 100-240 VAC, 50/60 Hz 100-240 VAC, 50/60 Hz 110 VAC, 60 Hz, 20A/240 VAC, 60 Hz, 10A Per computer manufacturer specifications 240v 30amp single phase circui
CHAPTER 1 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.
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S Model 424 Stationary and 4WD Dynamometer MODEL 424 STATIONARY AND 4WD DYNAMOMETER Drum precision balanced and knurled Stationary Dyno Interface Guide Track Assembly Dyno Movement Hydraulic Motor Air Brake AD601 Eddy Current Brake with stiffener plate and eddy current brake driver 4WD Dyno Cradle Assembly Figure 1-4: Model 424 Stationary and 4WD Dynamometer Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Insta
CHAPTER 1 Model 424 4WD Dynamometer With Bridge and Deck MODEL 424 4WD DYNAMOMETER WITH BRIDGE AND DECK Stationary Dyno Bridge and Center Cover Stationary Dyno 4WD Dyno Bridge and Center Cover 4WD Dyno AD602 Runner Support Pillar Tie-Down Deck Figure 1-5: Model 424 4WD Dynamometer with Bridge and Deck Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide 1-12
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S DynoWare RT Electronics DYNOWARE RT ELECTRONICS The DynoWare RT electronics consists of a main module and a speed pickup. Optional modules include the Air Fuel Ratio (AFR) module and the Eddy Current Brake (ECB) driver. Use this section to identify the modules and connections. More detailed information for configuring the DynoWare RT electronics can be found in the Power Core Help.
CHAPTER 1 DynoWare RT Electronics MAIN MODULE CONNECTIONS A description of the main module symbols and connections follows. 1 1 A B 2 C Linx 1 2 1 2 2 Status Analog 1 2 3 ! 4 use this port RPM Inputs to Connect inductive and optical RPM inputs. use this port Auxiliary Temperature to Connect to an auxiliary input for an infrared temperature sensor. Communication I/O Connect to auxiliary Dynojet products such as the Power Commander, Wideband 2, Power Vision, etc.
S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S DynoWare RT Electronics NETWORK CONNECTIONS The Dynojet DynoWare RT dyno electronics connects to your computer directly or over a Local Area Network. If you have an existing network, connect the DynoWare RT main module to a router or a network switch on your network. If you don't have an existing network, you can create a network for the DynoWare RT by connecting the main module to a router.
CHAPTER 1 Lift Specifications and Requirements LIFT SPECIFICATIONS AND REQUIREMENTS Dynojet recommends installing the four-post lift before installing your dynamometer. However, if space constraints make it difficult to install the lift first, the dynamometer can be installed before the lift. Dynojet acts as a liaison for Rotary Lifts, to ensure that you receive the proper four-post lift. Dynojet recommends purchasing Rotary Lift’s SM14L four-post lift.
C HAPTER 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.
S T AT I O N A R Y D Y N O I N S T A L L AT I O N Unpacking and Inspecting the Dyno part Version 1 description runner tie slide (2) P/N 21214705 part description riser foot assembly (4) P/N 61319600 side deck P/N 21216101 DynoWare RT main module P/N 66100016 side deck, left P/N 21216102 remote atmos assembly P/N 66400011 side deck, center P/N 21216103 pendant assembly P/N 76100007 runner mount, short (2) P/N 21514801 primary inductive pickup (2) P/N 76950201 runner mount (2) P/N 2
CHAPTER 2 Unpacking and Inspecting the Dyno part description axle strap, 21" (4) P/N 30AS21 part description bolt kit, 3/8-16 x 5", Black oxide P/N 79110006 power cord, 125V, 10A P/N 318110301 model 224-2 dyno P/N 81200000 bolt, 3/8-16 x 1.
S T AT I O N A R Y D Y N O I N S T A L L AT I O N Unpacking and Inspecting the Dyno part Version 1 description lower mounting bracket, logo panel (2) P/N 21200009 part description nut, 7/16-14, hex, grade-5 (4) P/N 36491100 center panel, deck P/N 21214300 screw, 1/4-20 x 5/8", panhead, torx (36) P/N 36561045 outer panel, deck (2) P/N 21214301 bolt, 3/8-16 x 1.
CHAPTER 2 Unpacking and Inspecting the Dyno part description deck tube P/N 21619103 part brace, deck (4) P/N 21714200 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide 2-6 description washer, 3/8", flat (8) P/N DM150-011-002 bolt, 3/8-16 x 3/4", hex (8) P/N DM150-019-008
S T AT I O N A R Y D Y N O I N S T A L L AT I O N Dyno Installation DYNO INSTALLATION This section will walk you through removing the dyno from the crate and installing the dyno in front of your lift. 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.) to lift the dyno off the crate and into position in your dyno room.
CHAPTER 2 Dyno Installation 8 With the dyno on the forklift, secure the four feet to the bottom of the dyno using the four 3/8 x 1.5-inch flange bolts removed earlier. Note: If the feet are already installed, skip this step.
S T AT I O N A R Y D Y N O I N S T A L L AT I O N Dyno Installation PLACING 1 2 3 4 5 THE DYNO IN FRONT OF THE LIFT Verify the interface bracket faces the lift as shown in Figure 2-3. Verify the lift is in the down position. Using the forklift, bring the dyno in front of the lift. The dyno should be about 10.16 cm (4.00 in.) from the lift cross member. Center the dyno drum with the lift runways. Gently lower the dyno into position. lift runway lift runway interface bracket 10.16 cm (4.00 in.
CHAPTER 2 Dyno Installation INSTALLING THE INTERFACE GUIDE The interface guide secures the dyno to the four-post lift. It is a good idea to install your interface guide before anchoring your dyno to the ground. If you have the interface roller assembly, refer to Appendix E. You will need the following parts: • • 1 2 21600000 21600001 Interface Bar Interface Bracket secured to the dyno using P/N 36582471 Bolt, 3/8-16 x 1.
S T AT I O N A R Y D Y N O I N S T A L L AT I O N Dyno Installation 3 Align the interface guide pin on the lift cross member with the interface bracket on the dyno. The interface bracket is already installed on the dyno. Note: The distance between the dyno and the lift may need to be adjusted. 4 Lower the lift until the interface guide pin just starts to enter the interface bracket on the dyno.
CHAPTER 2 Dyno Installation 5 6 7 8 9 Verify the interface guide clears the interface bracket by 1/8-inch to 1/4-inch as shown in Figure 2-6. Slide the interface guide up until the bottom bolt touches the cross member. Lower the top bolt down in the slots until it touches the cross member. Tighten the hardware securing the interface guide to the lift cross member. Note: The lower and upper interface guide mounting bolts should touch the lift cross member.
S T AT I O N A R Y D Y N O I N S T A L L AT I O N 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 2 Dyno Installation INSTALLING THE AIR FITTINGS Before the stationary dyno can be used with the 4WD dyno, the existing air fittings on the stationary dyno must be upgraded. You will need the following parts: 1 2 3 4 5 6 • 3400X4 Fitting, Street Tee • 141900001 Fitting, Barbed Hose • 34122231 Bushing, 1/4"F x 3/8"M, Brass • 34161320 Elbow-90, 3/8"H x 1/4"P Remove the existing air inlet fitting from the brake solenoid assembly. Install the street tee.
S T AT I O N A R Y D Y N O I N S T A L L AT I O N Eddy Current Brake Installation EDDY CURRENT BRAKE INSTALLATION Refer to Chapter 4 for eddy current brake installation instructions and install your eddy current brake at this time.
C HAPTER 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.
4 W D D Y N O I N S T A L L AT I O N Unpacking and Inspecting the Dyno part Version 1 description spacer, 424 hydraulic movement (2) P/N 26100000 part description rail tie assembly (2) P/N 61314300 spacer, rail clamp (8) P/N 26152020 rail clamp (4) P/N 61314700 rail clip (10) P/N 31619500 calibration arm assembly P/N 61319001 clevis pin, 3/4 x 4.
CHAPTER 3 Unpacking and Inspecting the Dyno 5 6 7 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. Before removing the dyno from the crate, you will need to install the track assembly in your dyno room. Refer to the instructions page 3-5 for more information on installing the track assembly.
4 W D D Y N O I N S T A L L AT I O N 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 3-1 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.
4 W D D Y N O I N S T A L L AT I O N 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-hex 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 stationary dyno is not shown.
4 W D D Y N O I N S T A L L AT I O N 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 3-5. Verify the rail clamps are positioned as shown in Figure 3-5.
4 W D D Y N O I N S T A L L AT I O N 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 3-5. 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 stationary dyno is not shown.
CHAPTER 3 Eddy Current Brake Installation EDDY CURRENT BRAKE INSTALLATION Refer to Chapter 4 for eddy current brake installation instructions and install your eddy current brake at this time.
4 W D D Y N O I N S T A L L AT I O N Cable Routing CABLE ROUTING Use the following instructions to identify and route the cables for dynos with and without eddy current brakes.
CHAPTER 3 Cable Routing cable K - 76950568 CAN control cable brief routing description connects the eddy current brake driver to the DynoWare RT C L - 76950569 IR temp sensor cable connects the temp sensor to the eddy current brake driver M - 76950574 load cell cable connects the load cell to the eddy current brake driver N - 76952008 4WD power supply with cable connects the 4WD board to the 4WD power cable (B) O - 76953004 dyno movement pendant cable connects to the 4WD board P - air hose conne
4 W D D Y N O I N S T A L L AT I O N Cable Routing ROUTING THE CABLES—WITHOUT THE EDDY CURRENT BRAKES Use the following instructions along with Figure 3-8 on page 3-16 for routing cables without eddy current brakes. You will need the following parts: 1 2 • DM150-009-003 Washer, 1/4", Flat (4) • DM150-011-005 Bolt, 1/4" x 1/2", Hex (4) Secure the first and second cable tracks to the front rail tie assembly using two 1/4-20 x 1-inch hex-head screws and two washers each.
CHAPTER 3 Cable Routing router hand held pendant F RPM pickup C H DynoWare RT remote atmos J pickup card AD607 J D A brake solenoid P J P DRY AIR IN 100-140 PSI O R Q dyno movement pendant G second cable track N first cable track B pickup card 4WD board J Figure 3-8: Routing the Cables—Without the Eddy Current Brakes Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide 3-16
4 W D D Y N O I N S T A L L AT I O N Cable Routing ROUTING THE CABLES—WITH ONE EDDY CURRENT BRAKE Use the following instructions along with Figure 3-9 on page 3-19 for routing cables with one eddy current brake. Refer to Chapter 4 for eddy current brake installation instructions.
CHAPTER 3 Cable Routing 11 Connect the IR temperature sensor cable (L) to the eddy current brake driver. 12 Connect the load cell cable (M) to the eddy current brake driver. 13 Connect the controller cable (E) from the eddy current brake to the eddy current brake driver. 14 Connect the CAN pendant cable (F) to the DynoWare RT module. 15 Connect the primary/secondary pickup cable (H) to the DynoWare RT module. 16 Connect the remote atmos cable (D) to the DynoWare RT module.
4 W D D Y N O I N S T A L L AT I O N Cable Routing router hand held pendant F RPM pickup C H DynoWare RT remote atmos K L J pickup card AD609 J D A brake solenoid P J P DRY AIR IN 100-140 PSI I M E O eddy current brake driver R Q dyno movement pendant G second cable track N first cable track B pickup card 4WD board J Figure 3-9: Routing the Cables—With One Eddy Current Brake Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide 3-19
CHAPTER 3 Cable Routing ROUTING THE CABLES—WITH TWO EDDY CURRENT BRAKES Use the following instructions along with Figure 3-11 on page 3-22 for routing cables with two eddy current brakes. Refer to Chapter 4 for eddy current brake installation instructions. You will need the following parts: 1 2 • DM150-009-003 Washer, 1/4", Flat (4) • DM150-011-005 Bolt, 1/4" x 1/2", Hex (4) Pull both the first and second cable tracks out from under the dyno. Using a screwdriver, open the crossbar on each link.
4 W D D Y N O I N S T A L L AT I O N Cable Routing 10 Route the air hose (P) from the T fitting on the air brake can on the stationary dyno to your clean dry air supply. Refer to “Installing the Air Fittings” on page 214 for more information. The air brake comes installed with a hose barb for a 3/8-inch inside diameter air hose. If your hose does not have an inside diameter of 3/8-inch then you will need an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply to the dyno.
CHAPTER 3 Cable Routing router hand held pendant F RPM pickup C H DynoWare RT remote atmos K L J pickup card AD608 J K D A brake solenoid P J P DRY AIR IN 100-140 PSI I M E O eddy current brake driver R Q dyno movement pendant G I second cable track first cable track N B pickup card L 4WD board M E K eddy current brake driver I J Figure 3-11: Routing Cables—With Two Eddy Current Brakes Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide 3-22
4 W D D Y N O I N S T A L L AT I O N Hydraulic Movement Installation HYDRAULIC MOVEMENT INSTALLATION Use the following instructions to install the hydraulic movement. You will need the following parts: 1 • 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.
4 W D D Y N O I N S T A L L AT I O N 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 5 6 7 8 9 Using the floor cylinder mount as a template, mark each hole needed to secure the mount to the floor. Remove the clevis pin, spacers, and floor cylinder mount. Move the hydraulic ram out of the way. Drill the holes marked in step #4. Install the Red Head anchors. Refer to Appendix A for installation instructions. Secure the floor cylinder mount to the floor using four 3/8-16 x 1-inch hex bolts and four 3/8-inch flat washers. Note: Four 3/8-16 x 1.
4 W D D Y N O I N S T A L L AT I O N Hydraulic Movement Installation ROTATING THE HYDRAULIC MOTOR Before rotating the hydraulic motor, verify the motor is wired for your needs. The motor is wired for 110v but can be changed to 220v. Refer to “Wiring the Hydraulic Motor” on page 3-29. 1 Remove the four bolts and washers securing the motor.
CHAPTER 3 Hydraulic Movement Installation 2 3 Rotate the motor as shown in Figure 3-17. Secure the motor using the bolts and washers removed earlier.
4 W D D Y N O I N S T A L L AT I O N 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. Refer to the Hydraulic Movement Wiring Diagram in Figure 3-19 on page 3-30.
BLK YEL WHT power supply BLK RED movement switch BLK WHT rail brake pressure switch BLK YEL drum brake from B.O.B.
4 W D D Y N O I N S T A L L AT I O N Hydraulic Movement Installation FILLING THE 1 2 3 HYDRAULIC MOTOR WITH HYDRAULIC FLUID Remove the cap on the hydraulic motor. Add four quarts of AW-68 hydraulic fluid. Replace the cap.
CHAPTER 3 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.
4 W D D Y N O I N S T A L L AT I O N 4WD Dyno Movement Test 4WD DYNO MOVEMENT TEST Verify the movement of the 4WD dyno before installing the bridge. 1 2 3 4 5 6 Verify the hydraulic motor is filled with hydraulic fluid. Refer to “Filling the Hydraulic Motor with Hydraulic Fluid” on page 3-31 for more information. Turn the dyno electronics on. Verify the dyno has 100-140 psi of compressed air. Press the red button on the dyno pendant. The button should light up indicating the brakes are activated.
CHAPTER 3 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.
4 W D D Y N O I N S T A L L AT I O N Bridge Installation—Stationary Dyno INSTALLING 1 2 3 THE DRUM GUARDS Secure the left and right drum guards using one 3/8-16 x 1.25-inch button-head flange bolt each. Secure the drum guard (closest to the interface assembly) using five 3/8-16 x 1.25inch button-head flange bolts. Loosely attach the drum guard (closest to the air brake) using the center 3/8-16 x 1.25-inch button-head flange bolt only.
CHAPTER 3 Bridge Installation—Stationary Dyno INSTALLING THE RUNNER MOUNTS AND RUNNER SUPPORTS Refer to Appendix D for bridge extension kit installation instructions. 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.
4 W D D Y N O I N S T A L L AT I O N Bridge Installation—Stationary Dyno INSTALLING 1 2 3 4 THE RUNNER ASSEMBLIES 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.
CHAPTER 3 Bridge Installation—Stationary Dyno 5 6 Square up the runner assemblies. 5a Place a square along the edge of the stationary dyno and along one of the runner assemblies. Move the runner assemblies until they are square with they dyno. 5b Tighten the bolts securing the runner assemblies to the runner mounts. 5c 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.
4 W D D Y N O I N S T A L L AT I O N Bridge Installation—Stationary Dyno INSTALLING 1 2 3 4 THE BRIDGE COVER Remove the center bolt from the rear 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 using two 3/8-16 x 1/2-inch buttonhead 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.
4 W D D Y N O I N S T A L L AT I O N Bridge Installation—4WD Dyno INSTALLING 1 2 3 THE DRUM GUARDS Secure the left and right drum guards using one 3/8-16 x 1.25-inch button-head flange bolt each. Loosely attach the drum guard (closest to the bridge assembly) using the center 3/8-16 x 1.25-inch button-head flange bolt only. Loosely attach the drum guard (closest to the air brake) using the center 3/8-16 x 1.25-inch button-head flange bolt only.
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 bolts.
4 W D D Y N O I N S T A L L AT I O N Bridge Installation—4WD Dyno INSTALLING 1 2 THE RUNNER ASSEMBLIES 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 1 2 3 THE COVER AND RUNNER TIE STRAPS Secure the cover to the runner mounts using the two reserved 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.
4 W D D Y N O I N S T A L L AT I O N Deck Installation DECK INSTALLATION Use the following instructions to install the deck. Note: Refer to Appendix C for instructions on upgrading an existing deck.
CHAPTER 3 Deck Installation 1 2 3 Verify the drum guards are installed. Refer to page 3-41 for installation instructions. Verify the front and rear eddy current brake covers are installed. Refer to page 416 for installation instructions. Install the deck brace mounting bracket using two 3/8-16 x 1.5-inch flange hex bolts. Note: If you do not have an eddy current brake, you will need to install one deck mounting bracket on each side of the dyno.
4 W D D Y N O I N S T A L L AT I O N Deck Installation 4 5 6 7 Loosely install the inner deck braces to the dyno using two 3/8-16 x 1.5-inch flange hex bolts each. Loosely install one outer deck brace to the eddy current brake using two 3/8-16 x 1.5-inch flange hex bolts, washers, and nuts. Loosely install one outer deck brace to the mounting bracket using two 3/8-16 x 1.5-inch flange hex bolts, washers, and nuts.
CHAPTER 3 Deck Installation 8 Install the outside panels. 8a Secure the panel to the dyno frame using the 3/8-16 x 1.5-inch button-head flange bolt removed in step #7 and two additional 3/8-16 x 1.5-inch buttonhead flange bolts. 8b Secure the three tie downs to the panel and to the deck braces using two 3/816 x 1.5-inch flange hex bolts, two 3/8-inch washers, and two 3/8-inch nylock nuts each. 8c 8d Verify the panel is sandwiched between the tie-downs and the brace.
4 W D D Y N O I N S T A L L AT I O N Deck Installation 9 Remove the center bolt from the drum guard. 10 Secure the supports to the outer panels using three 1/4-20 x 5/8-inch screws and crush nuts each. 11 Secure the center panel to each support using three 1/4-20 x 5/8-inch screws and crush nuts each. 12 Secure center panel to dyno with the center bolt removed earlier.
CHAPTER 3 Deck Installation 13 Install the tube to the outer panels and deck supports using four 3/8-16 x 3-inch flange hex bolts, four 3/8-inch flat washers, and four 3/8-inch nylock nuts. 14 Install a plastic plug in each end of the tube.
4 W D D Y N O I N S T A L L AT I O N Logo Panel Installation LOGO PANEL INSTALLATION If you did not install the eddy current brakes, you will install four logo panels, two on the stationary dyno and two on the 4WD dyno using the instructions in this section. If you installed the eddy current brakes, use the following instructions to install one logo panel on each dyno. Refer to “Installing the Top and Logo Panel Covers” on page 4-18 to install the logo panel covers on the eddy current brake.
CHAPTER 3 Logo Panel Installation 2 Secure each mounting bracket to the dyno using two 3/8-16 x 3/4-inch hex bolts and two 3/8-inch flat washers. Use two mounting brackets per logo panel.
4 W D D Y N O I N S T A L L AT I O N Logo Panel Installation 3 Secure each logo panel to the mounting brackets using five 1/4-20 x 5/8-inch panhead torx screws.
C HAPTER 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. You will need to provide equipment capable of lifting the eddy current brake off the crate and into position in your dyno room.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N 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. AD566 60.96 cm (24.00 in.) 36.83 cm (14.50 in.) 6.67 cm (2.625 in.) 24.13 cm (9.50 in.) 1.59 cm (0.625 in.) 1.
CHAPTER 4 Eddy Current Brake Installation UNPACKING 1 2 part THE EDDY CURRENT BRAKE Remove the top and sides of the crate. Remove any hardware and parts boxes from the crate and verify the box contents.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation part description bolt, 1/2-13 x 1.
CHAPTER 4 Eddy Current Brake Installation 3 Remove the uprights and cross members from the crate.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation 4 5 6 Remove the four screws securing the small top cover to the brake. Set the screws and the cover aside. Remove the eight screws securing the large top cover to the brake. Set the screws and the cover aside. Remove the six screws securing the logo panel side cover to the brake. Set the screws and the cover aside.
CHAPTER 4 Eddy Current Brake Installation 7 Remove the five screws and nuts securing the front and rear covers. Set the screws, nuts, and covers aside. RECORD # Be sure you record the dynamometer and/or eddy current brake number on the inside cover of this manual.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation 8 9 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. 10 Using a forklift, lift the eddy current brake from the crate and place the brake near the dyno.
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: • 76950569 Temperature Sensor Assembly temperature sensor Figure 4-7: 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.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation INSTALLING THE BEARING, SPLINED 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 • 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.
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.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N 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.
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.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation INSTALLING THE LOAD CELL You will need the following part: 1 2 3 • 76950574 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.
CHAPTER 4 Eddy Current Brake Installation INSTALLING THE FRONT AND REAR BRAKE COVERS AND EDDY CURRENT BRAKE DRIVER You will need the following part: 1 • 21200068 Bracket, Eddy Current Brake Driver (2) • 36500029 Screw, 4-40 x 1/4", Ph-Phil (4) • 36540647 Screw, 8-32 x 3/8", Ph-Sems, Phil (4) • 66400012 Eddy Current Brake Driver • 134490301 Nut, 8-32, with Lock Washer (4) • A10Z2-304A Bumper, 3/8 x 1/2" (4) Install the front and rear covers removed earlier to the frame using five 1/4-20 x 3/4-inc
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation 2 3 Secure the mounting brackets to the eddy current brake driver using two 4-40 x 1/4-inch screws each. Secure the four bumpers to the mounting brackets using four 8-32 x 3/8-inch screws. install mounting brackets install bumpers Figure 4-16: Install the Mounting Brackets and Bumpers 4 Install the eddy current brake driver to the cover using four 8-32 nuts.
CHAPTER 4 Eddy Current Brake Installation INSTALLING THE TOP AND LOGO PANEL COVERS Note: Before installing the top and logo panel side covers, verify all cables have been routed and you have completed the 4WD dyno installation. Refer to “Cable Routing” on page 3-13 for more information. Repeat these steps for both eddy current brakes. 1 2 3 Install the small top cover using four 1/4-20 x 5/8-inch torx flange screws removed earlier.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Load Cell Calibration LOAD CELL CALIBRATION Before proceeding, make sure all cables have been routed and the covers have been installed. This section provides instructions for calibrating the load cell. Follow the directions on the screen exactly. Failure to perform the directions accurately will result in improper torque values.
CHAPTER 4 Load Cell Calibration Once the load cell is zeroed, the Calibration Mass window will appear. 7 Enter the calibration arm value in the Mass box. Refer to Figure 4-21. 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 4-20: Calibration Mass Window Enter the calibration number stamped near the bolt pattern at the end of the calibration arm in the Mass box.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Load Cell Calibration 8 Place the weights towards the rear of the vehicle. Note: Calibration arm placement determines positive direction for torque. Place the weights towards the rear of the vehicle. Refer to step 8 and Figure 4-23 on page 4-22 for calibration arm installation instructions.
CHAPTER 4 Load Cell Calibration 9 Install the calibration arm and weights using the bolts at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm. Refer to Figure 4-24 on page 4-23. 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.
E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Load Cell Calibration If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in Figure 4-24. 10 With the calibration arm and weights secured, click Next in the Load Cell Calibration dialog to continue.
CHAPTER 4 Load Cell Calibration 11 Once sending the torque cell calibration is complete, click Next to continue. Figure 4-25: Calibration Is Complete Window 12 Remove the calibration arm and weights and click Finish.
C HAPTER 5 SIDE DECK ASSEMBLY INSTALLATION This chapter will walk you through installing the optional side deck assembly. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
CHAPTER 5 Side Deck Installation SIDE DECK INSTALLATION This section describes how to install the side deck assembly. The side deck assembly is an optional accessory; if you did not order this accessory skip this chapter. You will need the following parts: • • • • • • • • • • • • • 36562470 36584870 36912100 36923100 36932100 61319501 61319502 61319503 61319504 61319505 DM150-009-003 DM150-009-005 DM150-011-004 Bolt, 1/4-20 x 1.
S I D E D E C K A S S E M B LY I N S T A L L AT I O N Side Deck Installation INSTALLING 1 2 3 THE SIDE DECK ASSEMBLY Lay the platform assembly on it’s side. Secure the two front step leg assemblies to the platform using two 3/8-16 x 3-inch hex bolts, four 3/8-inch flat washers, two 3/8-inch lock washers, and two 3/8inch nuts each. Secure the two back leg assemblies to the platform using two 3/8-16 x 3-inch hex bolts, four 3/8-inch flat washers, two 3/8-inch lock washers, and two 3/8-inch nuts each.
CHAPTER 5 Side Deck Installation 4 5 Turn the side deck assembly over and stand upright. Secure the step assemblies to the front legs using four 1/4-20 x 1.5-inch hex bolts, eight 1/4-inch flat washers, four 1/4-inch lock washers, and four 1/4-inch nuts each.
S I D E D E C K A S S E M B LY I N S T A L L AT I O N Side Deck Installation 6 Place the side deck assembly next to your dyno in a position that makes access to the vehicle convenient.
C HAPTER 6 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 Power Core Help.
CHAPTER 6 Loading the Vehicle LOADING THE VEHICLE Use the following steps to load a vehicle on the dyno. Refer to your lift instructions for lift operation.
B A S I C D Y N O O P E R AT I O N Loading the Vehicle 1 2 Verify your computer is running. Set the dyno brake on by pressing the red button on the hand-held pendant. For four or all-wheel drive vehicles, measure the wheel base on the vehicle and adjust the 4WD dyno to that dimension before driving the vehicle on the dyno. Do not make any adjustments with the vehicle on the dyno. 3 4 5 Drive the vehicle onto the lift and raise the lift to the same height as the dyno.
CHAPTER 6 Loading the Vehicle 9 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 6-2. 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.
B A S I C D Y N O O P E R AT I O N Loading the Vehicle 10 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). 11 Release the brake on the vehicle and the dyno.
CHAPTER 6 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. The primary wire inductive pickup senses RPM pulses from the coil.
B A S I C D Y N O O P E R AT I O N 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. 1 2 Clip the secondary inductive pickup around one spark plug wire.
CHAPTER 6 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. 1 2 Clip the primary inductive pickup around the primary side of the coil. Route the primary wire cable to the RPM port on the main module making sure the cable is clear of devices that produce electronic noise (spark plug wires, coil wire, coil etc.).
B A S I C D Y N O O P E R AT I O N 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 6 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.
B A S I C D Y N O O P E R AT I O N 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 the Power Core software produces consistent, easily interpretable power graphs. Use the following instructions to ensure repeatable and accurate measurements. 1 2 3 4 5 6 7 Verify the vehicle is secured properly.
CHAPTER 6 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. • Once per month verify the brake pressure gauge reads 100psi (690kPa).
B A S I C D Y N O O P E R AT I O N Preventative Maintenance VERIFYING 1 2 THE SAAR BRAKE PRESSURE Verify the SAAR brake pressure gauge reads 100psi (690kPa). Using the knob, adjust the regulator until the correct pressure is achieved.
CHAPTER 6 Preventative Maintenance MAINTAINING 1 2 3 THE SAAR BRAKE SHOE CLEARANCE 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).
B A S I C D Y N O O P E R AT I O N 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.
CHAPTER 6 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 AD502 Figure 6-9: Fill the Hydraulic Motor with Oil • Inspect the hoses connecting the hydraulic motor to the ram. Replace as necessary (P/N 11100000).
A PPENDIX 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. 1 Drill the hole in the concrete the same outside diameter as the anchor being used to any depth exceeding minimum embedment.
R E D H E A D A N C H O R I N S T A L L AT I O N 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.
A PPENDIX 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.
P O W E R R E Q U I R E M E N T S A N D I N S T A L L AT I O N 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.
P O W E R R E Q U I R E M E N T S A N D I N S T A L L AT I O N 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.
P O W E R R E Q U I R E M E N T S A N D I N S T A L L AT I O N 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.
A PPENDIX 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 Deck Relocation DECK RELOCATION Before installing the 4WD dyno with an existing 2WD 224 dyno, the deck must be removed from the stationary dyno to be installed on the 4WD dyno later. The following instructions will guide you through removing your existing deck and installing that deck on your 4WD dyno. REMOVING THE EARLY STYLE DECK FROM AN EARLY MODEL DYNO This section will guide you through removing the early style deck from an early model dyno.
S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 3 4 Remove the two side drum guard bolts and three front drum guard bolts securing the deck lip to the dyno and set aside. Remove the deck and set aside.
APPENDIX C Deck Relocation 5 6 7 8 Remove the two 3/8 x 1-inch bolts and two 3/8 x 1-inch nylock nuts securing the two outside deck braces to the mounting brackets and set aside. Remove the two outside deck braces and set aside. Remove the two 3/8 x 1-inch bolts and two 3/8-inch lock washers securing the two inside deck braces to the dyno and set aside. Remove the two inside deck braces and set aside.
S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 9 Remove the two 3/8-16 x 1-inch bolts and two washers securing each mounting bracket and set aside. 10 Remove the mounting bracket and set aside. Note: If you have an eddy current brake, there will be only one mounting bracket. 11 Continue with installing the lift kit on page C-16.
APPENDIX C Deck Relocation REMOVING THE NEW STYLE DECK FROM A NEW MODEL DYNO This section will guide you through removing the new style deck from a new model dyno. For instructions on installing this deck to your 4WD dyno, refer to page 3-45. 1 2 Remove the four 3/8-16 x 3-inch bolts, four flat washers, and four nylock nuts securing the tube to the outer panels and deck supports and set aside. Remove the tube and set aside.
S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 3 4 5 6 Remove the center bolt securing the center panel to the dyno and set aside. Remove the six 1/4-20 x 5/8-inch screws and six crush nuts securing the center panel and supports to the outer panels and set aside. Remove the six 1/4-20 x 5/8-inch screws and six crush nuts securing the center panel to each support and set aside. Remove the center panel and supports and set aside.
APPENDIX C Deck Relocation 7 Remove the outside panels. 7a Remove the 3/8-16 x 1-inch button-head flange bolt, washer, and nut securing the inside of the panel to the inner brace and set aside. 7b Remove the two 3/8-16 x 1-inch button-head flange bolts, two 3/8-inch washers, and two 3/8-inch nylock nuts securing each tie down to the panel and deck braces and set aside. 7c Remove the three 3/8-16 x 1-inch button-head flange bolts securing the panel to the dyno frame and set aside.
S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 8 9 Remove the two 3/8-16 x 1-inch bolts, washers, and nuts securing each outer deck brace to the mounting bracket and set aside. Remove the outer deck braces and set aside. Note: If you have and eddy current brake, the outer deck brace will secure right to the brake with no mounting bracket. 10 Remove the two 3/8-16 x 1-inch bolts securing each inner deck brace to the dyno. 11 Remove the inner deck braces and set aside.
APPENDIX C Deck Relocation 12 Remove the two 3/8-16 x 1-inch bolts and two washers securing each deck brace mounting bracket and set aside. 13 Remove the mounting bracket and set aside. Note: If you have an eddy current brake, there will be only one mounting bracket. 14 Continue with installing the lift kit on page C-16.
S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation INSTALLING THE EARLY STYLE DECK ON THE 4WD DYNO Before installing the deck, make sure to complete the 4WD dyno and bridge installation found in Chapter 3 along with the optional eddy current brake installation found in Chapter 4. The deck mounting holes must be modified before the early style deck can be mounted to the 4WD dyno. 1 2 3 4 For the two outer holes, mark each hole .5-inches up from the existing hole and .
APPENDIX C Deck Relocation 5 Install the deck mounting bracket using two 3/8-16 x 1-inch bolts and two washers. Note: If you do not have and eddy current brake, you will need to install an additional deck mounting bracket.
S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 6 7 8 Loosely attach one outside brace to the mounting bracket using two 3/8 x 1-inch bolts and two 3/8-inch nylock nuts. Loosely attach one outside brace to the eddy current brake using two 3/8 x 1-inch bolt and two 3/8-inch lock washers. Note: If you do not have an eddy current brake, secure the brace to the mounting bracket using two 3/8 x 1-inch bolts and two 3/8-inch nylock nuts.
APPENDIX C Deck Relocation 9 10 11 12 13 side drum guard bolt If not already removed, remove the three 3/8-16 x 1-inch button-head flange bolts from the front drum guard. If not already removed, remove the two 3/8-16 x 1.25-inch button-head flange bolts from the side drum guards. Gently place the deck on the deck braces making sure the deck lip is on top of the drum guards. Using the two 3/8-16 x 1.25-inch button-head flange bolts removed earlier, secure the deck lip to the dyno.
S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 14 Secure the deck to each deck brace using two 3/8 x 1-inch bolts and two 3/8-inch lock washers each. Make sure to use one 3/8-inch flat washer and one 3/8-inch nut on the inside of each outer deck brace. 15 Tighten all deck brace hardware.
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. You will need the following parts: 1 2 3 4 5 6 7 • 61319600 Riser Foot Assembly (4) • 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (4) Remove the four bolts securing the dyno to the floor and set aside. Using single loop straps and a forklift, raise the dyno off the floor.
S T AT I O N A R Y D Y N O U P G R A D E 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. You will need the following parts: 1 2 3 4 5 6 7 • 3400X4 Fitting, Street Tee • 141900001 Fitting, Barbed Hose • 34122231 Bushing, 1/4"F x 3/8"M, Brass • 34161320 Elbow-90, 3/8"H x 1/4"P Remove the existing air inlet fitting from the brake solenoid assembly. Install the street tee.
A PPENDIX 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. 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. Note: The extended runner mounts used with the bridge extension are longer than the standard runner mounts. Be sure to use the correct runner mounts.
B R I D G E E X T E N S I O N A S S E M B LY 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.
B R I D G E E X T E N S I O N A S S E M B LY Bridge Extension Installation 7 Secure the two support arms to the brackets using two 1/2 x 1.
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 3-36.
A PPENDIX E INTERFACE ROLLER ASSEMBLY INSTALLATION This appendix contains instructions for installing the interface roller assembly to the four-post lift. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
APPENDIX E Interface Roller Assembly Installation INTERFACE ROLLER ASSEMBLY INSTALLATION The roller assembly secures the dyno to the four-post lift. It is a good idea to install your interface roller assembly before anchoring your dyno to the ground. If you have the interface guide, refer to “Installing the Interface Guide” on page 2-10. Note: If you did not purchase the Above Ground Kit you will not have the interface roller assembly. 1 2 Raise the lift until the bottom of the lift is approximately 86.
I N T E R F A C E R O L L E R A S S E M B LY I N S T A L L AT I O N Interface Roller Assembly Installation 3 Align the rollers on the interface roller assembly with the interface tube on the dyno. Note: The distance between the dyno and the lift may need to be adjusted. 4 Using the 1/2-inch and the 1/4-inch thick shims as necessary, adjust the interface roller assembly to fit the lift cross member. Lower the lift until the interface roller assembly just starts to enter the interface tube.
A PPENDIX F 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 F 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 VA L U E S Standard Bolt Torque Values GRADE 8 size inthreads/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 1 torque, plain in•lb 143 164 295 326 523 593 837 935 1277 1439 1843 2055 2543 2880 4509 5036 7277 8017 10908 11934 ft•lb 12 14 25 27 44 49 70 78 106 120 154 171 212 240 376 420 606 668 909 995 torque, plated N•m 16 19 33 37 59 67 95 106 144 163 208 232 287 325 509 569 822 906 1232
APPENDIX F 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 4WD board power cable 3-13 4WD power cable routing 3-15, 3-17, 3-21 4WD power supply with cable 3-14 A above ground kit deck 3-45 interface guide 2-10 interface roller assembly E-2 logo panel 3-51 air brake 3-15, 3-17, 3-21 air can sleeve 3-32 air fittings 2-14, C-17 air hose drum brake 3-14 rail brake 3-14 stationary 3-14 atmos cable 3-13 B battery hazards vi bearing 4-11 bearing grease 6-12 brake pressure gauge 6-12, 6-13 regulator 6-12, 6-13 shoe clearance 6-14 brake cable 3-13 bridge cover 3-3
INDEX D deck center panel 3-49 inner brace 3-47 installing 3-45 mounting bracket 3-46 outer brace 3-47 outside panels 3-48 tube 3-50 deck relocation C-2 dimensions dyno, 4WD 1-6 dyno, bridge and deck 1-7 dyno, stationary 1-5 disclaimers v document part number 1-1 drill and drill bit 1-8 drum 1-4 drum brake air hose 3-14, 3-15, 3-17, 3-21 drum guards installing, 4WD 3-41 installing, stationary 3-35 dyno cylinder mount 3-23, 3-24 dyno electronics 1-13 dyno movement pendant cable 3-14 routing 3-15, 3-17, 3-2
INDEX logo panel 3-51 dyno 3-51 eddy current brake 4-18 loop straps 2-7, 3-9 M making a test run 6-11 metric torque values grade 10.9 F-4 grade 8.
INDEX speed pickup cable 3-13 spline hub 4-12 splined shaft 4-12 standard torque values grade 5 F-2 grade 8 F-3 stationary dyno upgrade air fittings C-17 deck relocation C-2 lift kit C-16 strap 1-10 T technical support 1-3 temperature sensor installing 4-10 temperature sensor cable routing 3-18, 3-21 testing voltages B-3, B-7 tie-down straps 6-4 torque values metric F-4 standard F-2 track assembly 3-5 installing 3-7 layout 3-6 length 1-4 rail clamp 3-7 rail tie 3-7 rail tie assembly 3-7 rail tie clip 3-8
