Dynojet 248x Installation Guide

©1993-2005 Dynojet Research, Inc. All Rights Reserved.

Installation Guide For Model 248 Four Post Lift Automotive Dynamometers.

This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual, as well as the software described in it, is
furnished under license and may only be used or copied in accordance with the terms of
such license. This manual is furnished for informational use only, is subject to change
without notice, and should not be construed as a commitment by Dynojet. Dynojet
assumes no responsibility or liability for any error or inaccuracies that may appear in this
manual. Except as permitted by such license, no part of this manual may be reproduced,
stored in a retrieval system, or transmitted, in any form or by any means, electronic,
mechanical, recording, or otherwise, without the prior written permission of Dynojet.

The Dynojet logo is a trademark of Dynojet Research, Inc.

Any trademarks, trade names, service marks, or service names owned or registered by any
other company and used in this guide are the property of their respective companies.

Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA.

Printed in USA.

Part Number: 98219101 Version 5 (12/2005)

Contents

Chapter 1 .......................................................1-1

Initial Setup and Requirements

Introduction................................................................................. 1-1

Four Post Lift/Dyno Placement ................................................. 1-2

DynoWare EX+ Placement ......................................................... 1-3

Requirements to Unload Truck.................................................. 1-4

Requirements to Install the Dynamometer .............................. 1-4

Other Requirements ................................................................... 1-5

Uncrating the Dyno .................................................................... 1-6

Chapter 2 .......................................................2-1

Hardware Installation

DynoWare EX+............................................................................ 2-1

Atmospheric Sensing Module .....................................................................2-1

RPM Module ............................................................................................... 2-2

Dynamometer Input/Output Module............................................................2-3

CPU Module ...............................................................................................2-4

Connecting the DynoWare EX+................................................. 2-5

Chapter 3 .......................................................3-1

Installing the Dynamometer

Install the Lift .............................................................................. 3-1

Install the Dynamometer............................................................ 3-1

Installing the Brakes .................................................................. 3-5

Wiring the Dyno Part 1 ............................................................... 3-7

Catwalk Installation .................................................................. 3-11

Wiring the Dyno Part 2 ............................................................. 3-14

Connect the Dyno..................................................................... 3-22

Document #98219101 i

Contents

Chapter 4 .......................................................4-1

Basic Dyno Operation

Loading the Vehicle.................................................................... 4-2

Connecting the RPM Pickup...................................................... 4-5

RPM Pickup Descriptions ...........................................................................4-6

Connecting the Secondary Inductive Pickup ..............................................4-7

Connecting the Primary Inductive Pickup ...................................................4-8

Pre-run Inspection...................................................................... 4-9

Before Starting the Engine..........................................................................4-9

Engine Warm Up.......................................................................................4-10

After Engine Warm Up ..............................................................................4-10

Making a Test Run .................................................................... 4-11

Appendix A ................................................... A-1

Dyno to Lift Location..................................................................A-1

Interface Assembly.....................................................................A-2

ii Document #98219101

Document #98219101 1 - 1

Chapter 1

Initial Setup
and Requirements

Thank you for purchasing the Dynojet
Dynamometer. This document will give you the
information you need to install the Dynojet
Dynamometer (four post model). If you have any
questions please call Dynojet at [phone].

Introduction

Before installing your Dynojet Dynamometer,
there are a few factors to consider. This
chapter, “Initial Setup and Requirements”, is
a brief overview of what you need to know to
install your dynamometer and an overview of
the installation steps. Comprehensive
instructions are included in the remaining
chapters. “Initial Setup and Requirements”
should help you to decide where you want to
place your dynamometer in your shop , where
to place the Dynojet electronics, what you
need to unload your dyno and what you will
have to provide for the dynamometer.

1 - 2 Document #98219101

Four Post Lift/Dyno Placement

Four Post Lift Placement

Before you install the F our Post Lift, you need
to think about the position of the lift relative to
the garage and the dynamometer.

• For AMCO lifts you may place the
dynamometer on either end of the lift but it
is recommended that you place the dyno
on the end of the lift with the hydraulics.

• For BENWIL lifts you place the dyno on the
opposite end of the hydraulic controls.

• Keep in mind the placement of your
computer, monitor and DynoWare EX+
hardware.

Document #98219101 1 - 3

DynoWare EX+ Placement

The DynoWare EX+ system is comprised of
four modules: the CPU module, the
Dynamometer Input/Output module, the
RPM module and the Atmospheric module.
The Dynamometer Input/Output module
connects to the dynamometer. (A 20 foot
(6.1 meter) long cable is provided.) The CPU
module connects to a personal computer.(A
12 foot (3.7 meter) long cable is provided.)
RPM Pickups and a Hand Held Pendant also
connect to the modules. These modules
need to be located where they will be visible
during a dyno run. It is recommended that
they be mounted on a shelf on the wall or on
a cart along side the PC. An optional
extended Hand Held Pendant cable is
available if needed.

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Requirements to Unload Truck

When your dyno arrives, you must provide
equipment to unload the dynamometer from
the truck, with skids or forks a minimum of 6
inchs wide by 6 feet long. It must be capable
of lifting and moving at least 8000 pounds
(3642 KG).

The dyno has 2 C-Channels that run
lengthwise along the bottom of the dyno.
Unload the dynamometer using these
channels.

Requirements to Install the Dynamometer

Installation of the dynamometer requires
equipment capable of lifting and moving at
least 8000 pounds (3642 KG).

Other Requirements

Shop Air

The dyno air brake requires a 3/8-inch air hose with a minimum
pressure of 60 psi.

You must provide 3/8-inch air line that will reach from the
dynamometer to the Air Pressure Regulator and another air hose
to connect the regulator to your shop air supply.

Computer Requirements

You will need to provide a computer system to run the WinPEP
software. WinPEP 7 includes complete documentation in online
Help. From the WinPEP 7 menu bar, choose Help WinPEP 7
Help or visit www.winpep.com (accessible with a valid user
name and password).

minimum system requirements recommended systems requirements

• Microsoft® Windows 2000/XP • Microsoft® Windows 2000/XP

• Pentium 800 MHz Processor • 2.4 GHz Processor or greater

• 256 MB of available RAM • 256 MB of available RAM or greater

• one COM port, two COM ports for
Tuning Link

• 800x600, 256 color monitor (SVGA) • 1280x1024 256 color monitor

• 1.2 gigabyte hard drive • 1.2 gigabyte hard drive

• 30 MB of available hard-disk space • 100 MB of available hard-disk space

• CD ROM and floppy disk drive • CD ROM and floppy disk drive

• printer, if hard copies are needed • printer (preferably HP DeskJet®)

• one COM port, two COM ports for
Tuning Link

(SVGA) or better

Document #98219101 1 - 5

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Uncrating the Dyno

Step 1

Use a crowbar or the like to remove the
plywood shipping shell from the
dynamometer.

• Remove catwalk pallet from the top of the
crate (if purchased).

• Remove the top of the crate.

• Remove the sides of the crate.

• Remove the bottom skids and discard.

Step 2

Remove the front and back dyno covers.

Step 3

Carefully remove the cardboard boxes and
brake weldments that are stored within the
dynamometer’s frame.

Document #98219101 1 - 7

Step 4

Verify the hardware contents as follows:

Brake Hardware:

• 2 brake weldments

(The following are attached to the dyno
frame)

• six 5/8" bolts

• six lock washers

• six flat washers

• six nuts

Mounting Hardware:

• 4- Foot Stands

• 4- 7/16” x 1” Bolts

• 4- 7/16” Flat Washers

• 4- 7/16” Lock Washers

• 4- 3/8” x 1” Bolts

• 4- 3/8” Flat Washers

• 4- 3/8” Lock Washers

• 4- Anchors

• 1- Set Tool

1 - 8 Document #98219101

Electronic Hardware:

Pictures and descriptions on page 3- 6 :

Lift Hooks:

• 6 Catwalk Hooks

Straps:

• 2 axle straps

• 2 Long axle straps (not shown)

• 4 ratchet straps

• 2 ratchet straps with sleeves

Chocks (4):

Document #98219101 2 - 1

Chapter 2

Hardware Installation

DynoWare EX+

The standard dynamometer electronics package is

comprised of 4 interconnected modules:

Atmospheric Sensing Module:

The atmospheric sensing module measures

absolute pressure, air temperature and relative

humidity. These measurements are used by

WinPEP to correct power and torque

measurements to standard atmospheric conditions

according to a DIN, SAE or other formula.

The green LED glows when the atmospheric

sensing module is receiving power.

The flashing amber LED indicates the module

processor is operating properly.

System Expansion Connector

Atmospheric Sensing Module

RPM Module

Dynamometer Input/Output
Module

CPU Module

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RPM Module:

The RPM module receives and processes signals

from up to 2 inductive pickups for measurement

of engine RPM. Each input has an automatic

gain circuit to compensate for a wide variance of

ignition systems.

The green LED glows when the RPM module is

receiving power.

The amber LED flashes when an RPM signal is

detected. A steady flash rate, proportional to

engine RPM, indicates a good RPM signal.

These connectors are the inputs for both primary

and secondary inductive pickup clips. Either

input may be used with a primary inductive

pickup or a secondary inductive pickup on a

single ended coil. Both inputs can be used for a

wasted spark ignition.

Document #98219101 2 - 3

Dynamometer Input/Output Module:

The dynamometer I/O module sends and receives

data from the dynamometer and the hand held

pendant. The module also contains a buzzer and

light which are activated when either the vehicle

or dynamometer speed limit is approached.

The green LED glows when the dynamometer

input/output module is receiving power.

The amber LED flashes proportionally to

dynamometer drum RPM.

This 25-pin receptacle connects to the shielded

cable from the dynamometer.

This 9-pin receptacle connects to the hand held

pendant which houses the button used to

Start/Stop acquiring data. The pendant may also

contain a brake switch.

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CPU Module:

The CPU module contains a 32-bit processor

which acquires data from the expansion modules

and communicates to the main computer running

the WinPEP software. The processor queries the

expansion modules to determine their identity

and capabilities.

The green LED glows when the CPU module is

receiving power.

The blue LED is lighted when data from the

modules is being acquired and saved.

One of these connectors is used to communicate

to the main computer. The 9-pin receptacle (left)

connects to the PC’s RS-232 serial

communications port. The 8-pin modular

connector (right) provides communications

according to the RS-422/485 specification.

Document #98219101 2 - 5

CPU Module: ..... Continued

This connector provides a synchronization signal

to a 3rd-party data acquisition system.

This connector provides 12 Volt DC power to a

3rd-party data acquisition system.

This connector accepts 12 Volt DC power from a

power supply or battery. The adjacent LED

glows bright green when power is properly

connected.

When this switch is on, power is supplied to all

connected modules.

Connecting the DynoWare EX+

Use the cables that came in the DynoWare

package to make the following connections:

• 9-pin shielded serial cable between the RS-232
connector of the CPU Module and a free COM
(serial communications) port on the PC. A 9­pin to 25-pin adapter may be required at the
PC.

• 25-pin shielded cable from the dynamometer to
the Dynamometer Input/Output Module.

• 9-pin connector from the hand held pendant to
the Dynamometer Input/Output Module.

• 3-pin plug from the power supply to the CPU
Module with its flat side facing down.

(Refer to the picture on the next page)

Note:

The DynoWare EX+ stack must be
mounted in your shop so as to be easily
seen while making dyno runs.

2 - 6 Document #98219101

Remote Switch

Breakout Board to
DynoWare Cable

Cord from Power Supply

Primary Inductive Pickup Cable
(not shown)

Computer Serial Port Cable