Dynojet 424x Installation Guide

RECORD

Installation Guide For In Ground Model 424x and 424xLC

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. 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: 98219112 Version 07 (03/2012)

Automotive Dynamometers.

Stationary Dynamometer Number: ______________________________________________

Eddy Current Brake (Retarder) Number:____________________________________________________________

4WD Dynamometer Number: ___________________________________________________

Eddy Current Brake (Retarder) Number:_________________________________________________________

ABLE OF

ONTENTS

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Chapter 1 Specifications and Operating Requirements

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . .1-4

Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Model 424 Stationary and 4WD Dynamometer . . . . . . . . . . . . . . . . . . . 1-10

Model 424 4WD Dynamometer With Pit Covers . . . . . . . . . . . . . . . . . . .1-11

Dyno Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Pit Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Chapter 2 Stationary Dyno Installation

Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

Placing the Dyno in the Pit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Anchoring the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

TABLE OF CONTENTS

Chapter 3 4WD Dyno Installation

Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Installing the Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Placing the Dyno on the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Identifying the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Routing the Cables—Without the Eddy Current Brakes . . . . . . . . . . . . . . 3-13

Wiring the Breakout Board—Without the Eddy Current Brakes . . . . . . . . .3-15

Routing the Cables—With One Eddy Current Brake . . . . . . . . . . . . . . . . .3-16

Wiring the Breakout Board—With One Eddy Current Brake . . . . . . . . . . .3-18

Routing the Cables—With Two Eddy Current Brakes . . . . . . . . . . . . . . . .3-20

Wiring the Advanced Breakout Board—With Two Eddy Current Brakes . . 3-23

Hydraulic Movement Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25

Filling the Hydraulic Motor with Hydraulic Fluid . . . . . . . . . . . . . . . . . . . .3-29

Wiring the Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30

Air Can Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-31

4WD Dyno Movement Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

Bridge Installation—Stationary Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Installing the Drum Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34

Installing the Runner Mounts and Runner Supports . . . . . . . . . . . . . . . . .3-35

Installing the Runner Assemblies and Runner Extension . . . . . . . . . . . . . .3-36

Installing the Bridge Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-39

Bridge Installation—4WD Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40

Installing the Drum Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-41

Installing the Runner Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-42

Installing the Runner Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-43

Installing the Bridge Cover and Runner Tie Straps . . . . . . . . . . . . . . . . . . 3-44

Forward Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-45

Ground Hook Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Installing the Bearing, Spline Shaft, and Driveline Assembly . . . . . . . . . . . .4-7

Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Installing the Theta Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Torque Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Installing the Torque Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Connecting the Load Cell Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Load Cell Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Chapter 5 Basic Dyno Operation

TAB LE OF CONT ENTS

Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

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

RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . .5-6

Connecting the Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Verifying the SAAR Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

Maintaining the SAAR Brake Shoe Clearance . . . . . . . . . . . . . . . . . . . . . . 5-13

Dynos with 4WD Attachment—Things to Check . . . . . . . . . . . . . . . . . . . 5-15

Appendix A Red Head Anchor Installation

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

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TABLE OF CONTENTS

Appendix B Power Requirements and Installation

Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power

Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Power Requirements and Installation—Excluding North America and Japan

Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Appendix C Stationary Dyno Upgrade

Lift Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2

Air Fittings Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-3

Appendix D Bridge Extension Assembly

Bridge Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Appendix E Torque Values

Standard Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3

Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Grade 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Grade 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

ARNINGS

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.

Dynojet is not responsible for false operation due to unexpected dynamometer operation such as may be caused by static, software bugs, hardware failure, etc.

Dynojet is not responsible for damage resulting from improper installation of the dynamometer or from improper service rendered to the dynamometer. Dynojet is not responsible for damage incurred due to alteration of the dynamometer or components, use of unapproved parts, or abuse to the dynamometer.

Do not connect or disconnect cables or components on the dynamometer with the power on. Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when

using and servicing the dynamometer.

Equipment Power Requirements

The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect voltage will void the dynamometer warranty. Installation may require a licensed electrician.

Potentially Lethal Voltages

Components attached to and within the dynamometer operate with potentially lethal voltages. To provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power source before servicing electrical components or wiring. Disconnect all power cords before servicing electrical components for the greatest assurance of safety.

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

WARN IN 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. Dynojet designs its dyn amo me ter s t o be ver y t ole ran t o f st ati c sh oc ks by the users, but the electronics are vulnerable when the electronics are exposed. ESD occurs as a result of a difference of potential between two objects when the two objects touch. Damage occurs as a result of the energy released when the discharge (touch) occurs. The difference of potential can accumulate by as simple an action as a user moving across carpet or a seat. If that person’s energy is discharged directly to the electronics, the electronics can be damaged.

Precautions

To protect against ESD damage, you must eliminate the difference of potential before the electronics are handled. Touch the chassis of the dynamometer before touching any of the electronics. By touching the chassis, you discharge any static shocks to the chassis instead of to the electronics.

If you are holding a circuit board or dynamometer component in your hand when you approach the machine, touch the chassis of the dynamometer with your hand before installing the circuit board or component.

When handing a circuit board or component to someone, touch that person with your hand first, then hand them the component.

Always carry circuit boards in anti-static bags when the boards are exposed (removed from the dynamometer).

Battery Fire and Explosion Hazards

There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Discard used batteries according to the manufacturer’s instructions.

Automotive Batteries

In operation, batteries generate and release flammable hydrogen gas. They must always be assumed to contain this gas which, if ignited by burning cigarette, naked flame or spark, may cause battery explosion with dispersion of casing fragments and corrosive liquid electrolyte. Carefully follow manufacturer's instructions for installation and service. Keep away all sources of gas ignition and do not allow metallic articles to simultaneously contact the negative and positive terminals of a battery.

Do not allow the positive and negative terminals to short-circuit. The dynamometer chassis is tied to the negative side of the battery. Do not short between the positive battery terminal or the starter connections to the chassis. In addition, make sure metal tools such as screw drivers, wrenches, and torque wrenches do not come in contact with the negative and positive terminals of the battery. Short circuiting the terminals of the battery can cause burn injuries, damage to the dynamometer, or trigger explosions.

Charging

Batteries being charged will generate and release flammable hydrogen gas. Charging space should be ventilated. Keep battery vent caps in position. Prohibit smoking and avoid creation of flames and sparks nearby.

Wear protective clothing, eye and face protection, when charging or handling batteries.

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

WAR NIN GS

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. Always wear proper ear and eye protection when operating the dynamometer. Never operate the dynamometer with the covers removed. Never stand behind the dynamometer when in operation. Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems

before proceeding. Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken. Verify brake operation before beginning any dynamometer testing. Verify the vehicle is properly secured to the dynamometer. Never operate the blowers without the guards installed. Exercise care with any dynamometer testing; portions of the dynamometer and vehicle may become

hot. As with any equipment using electricity and having moving parts, there are potential hazards. To use

this dynamometer safely, the operator should become familiar with the instructions for operation of the dynamometer and always exercise care when using it.

Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically recommended in published user-repair instructions that you understand and have the skills to carry out.

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

vii

C HAPTER

PECIFICATIONS AND

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. Whether you are new to the benefits of a chassis dynamometer or an experienced performance leader, the repeatability and diagnostic tools of WinPEP 7 software and a Dynojet dynamometer will give you the professional results you are looking for.

This document provides instructions for installing the stationary dyno, the four wheel drive (4WD) dyno, and the eddy current brakes. This document will walk you through operating requirements, hardware installation, electronics set up, and basic dyno operation. To ensure safety and accuracy in the procedures, perform the procedures as they are described.

Document Part Number: 98219112

PERATING

EQUIREMENTS

Versio n 7

Last Updated: 03-01-2012

This chapter is divided into the following categories:

•Introduction, page 1-2

• Dynamometer Specifications and Requirements, page 1-4

• Model 424 Stationary and 4WD Dynamometer, page 1-10

• Model 424 4WD Dynamometer with Pit Covers, page 1-11

• Dyno Electronics, page 1-12

• Pit Specifications, page 1-13

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-1

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.

STATIONARY DYNO INSTALLATION

This chapter describes the procedures for installing the stationary dyno.

4WD DYNO INSTALLATION

This chapter describes the procedures for installing the 4WD dyno.

EDDY CURRENT BRAKE INSTALLATION

This chapter describes the procedures for installing the eddy current brake, torque module, and load cell. This chapter also includes the procedures for load cell calibration.

BASIC DYNO OPERATION

This chapter describes basic dyno operating procedures and maintenance.

RED HEAD INSTALLATION

This appendix describes the procedures for installing the Red Head anchors.

POWER REQUIREMENTS

This appendix describes the power requirements and installation instructions for the eddy current brake.

STATIONARY DYNO UPGRADE

This appendix describes the procedures for upgrading an existing stationary dyno to be used with the 4WD dyno.

BRIDGE EXTENSION ASSEMBLY

This appendix describes the procedures for installing the bridge extension assembly.

TORQUE VALUES

This appendix describes the standard and metric torque values.

1-2

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

SPECIFICATIONS AND OPERATING REQUIREMENTS

RECORD

CONVENTIONS USED IN THIS MANUAL

The conventions used in this manual are designed to protect both the user and the equipment.

example of convention 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.

The Warning icon indicates potential harm to the person performing a procedure and/or the dynamometer equipment.

The Record # icon reminds you to record your dynamometer and/or eddy current brake (retarder) number on the inside cover of this manual.

Introduction

Bold Highlights items you can select on in the software



interface, including buttons and menus.

The arrow indicates a menu choice. For example, “select

File Open” means “select the File menu,

then select the

Open choice on the File menu.”

TECHNICAL SUPPORT

For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.

Visit us on the World Wide Web at www.dynojet.com and www.winpep.com where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product lines.

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-3

CHAPTER 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dynamometer Specifications and Requirements

DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS

description specifications

Length

Height

Width

Track Assembl y

Weight

Drum

Frame structural steel channel and angle

Maximum Speed 322 KPH (200 MPH)

Maximum Axle Weight 1361 kg (3000 lb.) Remote Switches remote software control

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.

CHASSIS SPECIFICATIONS

of frame 218.44 cm (86.00 in.) of frame with eddy current brake 321.23 cm (126.47 in.)

including eddy current brake and covers

to top of frame 58.42 cm (23.00 in.) to top of frame with feet/track

assembly

of frame 73.66 cm (29.00 in.)

including cradle assembly 130.18 cm (51.25 in.) including air brake 93.83 cm (36.94 in.)

both frames, bridge, covers—full out 584.20 cm (230.00 in.)

both frames, bridge, covers—full out with extension kit

both frames, bridge, covers—full in 469.90 cm (185.00 in.) both frames, bridge, covers—full in

with extension kit

Length 234.32 cm (92.25 in.)

Width 218.44 cm (86.00 in.)

stationary crated dyno 2,114 kg (4,660 lb.)

4WD crated dyno 2,495 kg (5,500 lb.)

diameter 60.96 cm (24.00 in.)

width 205.74 cm (81.00 in.)

345.44 cm (136.00 in.)

72.07 cm (28.375 in.)

609.60 cm (240.00 in.)

495.30 cm (195.00 in.)

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SPECIFICATIONS AND OPERATING REQUIREMENTS

AD129

73.66 cm (29.00 in.)

72.07 cm (28.375 in.) frame to floor

218.44 cm (86.00 in.) frame only

321.23 cm (126.47 in.)

frame and eddy current brake

106.93 cm (42.10 in.) eddy current brake

93.83 cm (36.94 in.)

frame and air brake assembly

58.42 cm (23.00 in.) frame only

Dynamometer Specifications and Requirements

Figure 1-1: Model 424 Stationary Dyno Dimensions

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-5

CHAPTER 1

AD375

218.44 cm (86.00 in.) dyno frame only

321.23 cm (123.47 in.) frame and brake

130.18 cm (51.25 in.)

frame and cradle assembly

73.66 cm

(29.00 in.)

frame

218.44 cm (86.00 in.) track

234.32 cm (92.25 in.) track

Dynamometer Specifications and Requirements

Figure 1-2: Model 424 4WD with Track Assembly Dimensions

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SPECIFICATIONS AND OPERATING REQUIREMENTS

AD131

161.54 cm (63.60 in.)

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*

345.44 cm (136.00 in.)

229.87 cm (90.50 in.)

492.76 cm (194.00 in.)

eddy current brake covers

*requires extension parts, inquire with Dynojet sales

Dynamometer Specifications and Requirements

Figure 1-3: Model 424 4WD with Bridge and Pit Covers Dimensions

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-7

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. A complete list of system requirements can be found in your WinPEP 7 User Guide. This manual is included with your dyno and is also available on your WinPEP 7 CD.

DRILL AND DRILL BIT REQUIREMENTS

You will need to provide a drill and drill bit capable of drilling holes in concrete. Refer to Appendix A for more information on installing Red Head Anchors.

• drill bit size: 1/2-inch

• minimum hole depth: 1 5/8-inch (41.2 mm)

description specifications

Power Requirements: 4WD electronics 110v 60Hz or 240v 50Hz

Power Requirements: dyno electronics 110v 60Hz or 240v 50Hz Power Requirements: hydraulic motor 110v 60Hz or 240v 50Hz or 60Hz

Power Requirements: computer 110v 60Hz or 240v 50Hz

Power Requirements: optional eddy current brake

description specifications

Te mp e r at u r e

Humidity 0 to 95% non condensing

ELECTRICAL REQUIREMENTS

240v 30amp single phase circuit for each eddy current brake Refer to Appendix B for more information.

ENVIRONMENTAL REQUIREMENTS

operating min./max 10°C/50°C (50°F/122°F) storage min./max 0°C/70°C (32°F/158°F)

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In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

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. Use an approved strap lifting attachment for the forklift to prevent strap slippage. To use lift straps with bare forks is not OSHA compliant.

HYDRAULIC MOTOR

You will need to provide up to five quarts of AW-68 hydraulic fluid for the hydraulic motor.

PHONE AND INTERNET ACCESS

Dynojet recommends you have a phone close to the dyno to call for assistance in an emergency. You may also wish to contact Dynojet to troubleshoot your dyno.

Internet access on your computer is desirable for contacting Dynojet and downloading new information and updates.

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

TIE-DOWN STRAPS

Dynojet recommends using tie-down straps for securing the car on the dyno. The dyno comes with an automotive tie-down package.

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

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CHAPTER 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AD376

Drum

precision balanced

and knurled

Track Assembly

Dyno Movement Hydraulic Motor

Cradle Assembly

4WD Dyno

Stationary Dyno

Eddy Current Brake

with theta controller

Spring Applied Air

Brake

Breakout Board

Spring Applied Air

Brake

Model 424 Stationary and 4WD Dynamometer

MODEL 424 STATIONARY AND 4WD DYNAMOMETER

Figure 1-4: Model 424 Stationary and 4WD Dynamometer

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SPECIFICATIONS AND OPERATING REQUIREMENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AD133

Forward Pit Covers

Stationary Dyno Bridge

and Center Cover

4WD Dyno

Stationary Dyno

4WD Dyno Bridge

and Center Cover

Eddy Current Brake

Pit Covers

Model 424 4WD Dynamometer With Pit Covers

MODEL 424 4WD DYNAMOMETER WITH PIT COVERS

Figure 1-5: Model 424 4WD Dynamometer with Pit Covers

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

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CHAPTER 1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-pin RS-232 socket

CPU module

atmospheric

sensing module

RPM module

input/output module

9-pin hand

held pendant

3-pin power plug

system expansion

connector

inductive pickup

socket

25-pin socket

power

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.

Figure 1-6: Dyno Electronics

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PIT SPECIFICATIONS

AD139

452.12 cm (178.00 in.)

88-130-inch wheel base

477.52 cm (188.00 in.)

98-140-inch wheel base**

72.07 cm

(28.375 in.)

233.68 cm (92.00 in.)

with no eddy current brake

340.36 cm (134.00 in.)

with eddy current brake

451.49 cm (177.75 in.)

eddy current brake with Linx*

*Linx option can not be used with the extended wheel base **requires extension parts, inquire with Dynojet sales

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.)

Note: Extended wheel base requires extension parts, inquire with Dynojet sales. Linx option can not be used with the extended wheel base.

• pit width: with no eddy current brake 233.68 cm (92.00 in.) with optional eddy current brake 340.36 cm (134.00 in.) with optional eddy current brake and Linx option 451.49 cm (177.75 in.)

Note: Linx option can not be used with the extended wheel base.

SPECIFICATIONS AND OPERATING REQUIREMENTS

Pit Specifications

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

Figure 1-7: Pit Specifications

1-13

TATIONARY

C HAPTER

YNO 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.

This chapter is divided into the following categories:

• Unpacking and Inspecting the Dyno, page 2-2

• Dyno Installation, page 2-9

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

2-1

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. Refer to “Dynamometer Specifications and Requirements” on page 1-4 for more information.

1 Move the crated dyno to a clear area near your dyno room. 2 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the

top and sides of the crate. Note: Inspect the exterior of the dyno for any indications of damage. Report any

damage immediately.

3 Remove the boxes and loose parts from the crate, verify their condition and

contents and set them aside. Note: Some of these parts may have been shipped in the 4WD dyno crate

(crate 2).

part description part description

runner tie strap (2) P/N 21214701

runner clamp, short (2) P/N 21214702

runner clamp plate (2) P/N 21214703

runner slide (2) P/N 21214704

bolt, 3/8-16 x 1/2", buttonhead, flange (14) P/N 36580434

bolt, 3/8-16 x 1.5", flange, hex (4) P/N 36582471

bolt, 3/8-16 x 3", flange, hex (5) P/N 36584871

washer, 3/8", flat (8) P/N 36923100

2-2

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

STATIONARY DYNO INSTALLATION

Unpacking and Inspecting the Dyno

part description part description

runner tie slide (2) P/N 21214705

washer, 3/8", splitlock, steel (4) P/N 36932100

drum guard, right, 4WD dyno P/N 21216101

drum guard, left, 4WD dyno P/N 21216102

drum guard, rear (2) P/N 21216103

drum guard, left, stationary P/N 21219113

drum guard, front, stationary P/N 21219114

anchor, redhead, 3/8" (6) P/N 37513200

installation tool, redhead anchor P/N 37518200

axle strap, 21" (4) P/N 30AS21

car tie-down, 2" x 10’ (4) P/N 500-C10

car tie-down, hi-perf, 2" x 10’ (2) P/N 500-C10W/S

drum guard, right, stationary P/N 21219115

forward pit cover, right P/N 21219116

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

runner extension support leg (2) P/N 61119810

runner support pillar assembly (4) P/N 61314500

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CHAPTER 2

Unpacking and Inspecting the Dyno

part description part description

forward pit cover, middle P/N 21219117

riser foot assembly (4) P/N 61319600

forward pit cover, left P/N 21219118

runner mount, short (2) P/N 21514801

runner mount (2) P/N 21514802

runner support (2) P/N 21514803

forward pit cover spacer P/N 21519140

dyno electronics P/N 76100003N

bolt kit, 424 bridge P/N 79110002

bolt kit, 4WD above ground P/N 79110004

bolt kit, 3/8-16 x 5", black oxide P/N 79110006

ground hook kit (10) P/N 79190001

runner extension, left P/N 21519811

runner extension, right P/N 21519812

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see list of parts below

banner, dynojet (2) P/N D706

inductive secondary pickup (2) P/N DE100-109S

STATIONARY DYNO INSTALLATION

Unpacking and Inspecting the Dyno

part description part description

chock (4) P/N 2A092

inductive primary pickup clip P/N DE100-110L

nut, 1/4-20, nylock (4) P/N 36468100

bolt, 1/4-20 x 1.5", hex (4) P/N 36562470

The following parts are included in the Retarder Upgrade P/N 77010005:

theta controller mounting bracket (2) P/N 21616205

splined shaft P/N 22117130

bearing, flange P/N 32355056

bolt, 3/8-16 x 1", hex (6) P/N DM150-019-012

washer, 1/2", flat (4) P/N 36943102

driveline assembly P/N 62240130

torque module P/N 66104001

nut, 3/8-16, nylock (4) P/N 36488100

screw, 8-32 x 3/8", pan-head, sems, phil (8) P/N 36540647

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

theta controller (2) P/N 66411004

load cell assembly P/N 76950505

2-5

CHAPTER 2

Unpacking and Inspecting the Dyno

part description part description

nut, 1/2-13, nylock, hex (4) P/N 36708100

temperature sensor P/N 76955001

bolt, 1/2-13 x 1.5", flange, hex (6) P/N 36801080

washer, 3/8", flat (12) P/N 36923100

The following parts are included in the Retarder Cover Kit P/N 78119004:

calibration cover (2) P/N 21217513

foot, retarder cover (6) P/N 21919101

bolt, 3/8-16 x 1", hex (12) P/N DM150-019-012

support leg P/N 61319507

pit cover, retarder (2) P/N 61329400

screw, 1/4-20 x 5/8", panhead, torx (12) P/N 36561045

bolt, 3/8-16 x 1.5", hex (8) P/N 36582477

anchor, redhead, 3/8" (8) P/N 37513200

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In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

washer, 3/8", flat (8) P/N DM150-011-002

bolt, 3/8-16 x 1", hex (8) P/N DM150-019-012

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:

ground hook/D-ring P/N 10111

anchor, redhead, 3/8" (2) P/N 37513200

D-ring bracket, surface mount P/N 10112

washer, 3/8", splitlock, steel (2) P/N 36932100

washer, 5/16", flat (2) P/N DM150-002-007

bolt, 3/8-16 x 1", hex (2) P/N DM150-019-012

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

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CHAPTER 2

RECORD

AD134

front/rear drum guard

dyno number

left/right drum guard

Unpacking and Inspecting the Dyno

4 Remove the crate braces that support the top portion of the crate. 5 Remove the four lag bolts and washers securing the dyno to the crate base. 6 Remove the five screws securing the front and rear drum guards and set aside. 7 Remove the front and rear drum guards and set aside. 8 Remove the two screws securing the left and right drum guards and set aside. 9 Remove the left and right drum guards and set aside.

Be sure you record the dynamometer number on the inside cover of this manual.

2-8

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

Figure 2-1: Remove the Drum Guards

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DYNO INSTALLATION

place strap through

opening in dyno frame

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

STATIONARY DYNO INSTALLATION

Dyno Installation

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. You will also need a pair of straps capable of supporting the same weight. Dynojet recommends using two 2-inch x 6-foot single loop style straps. Refer to “Forklift Requirements” on page 1-7.

1 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.

2 Route the loop strap through the opening in the dyno frame and through itself.

Pull the strap tight. Do this on each side of the dyno frame. 3 Push the forklift forks together. 4 Place each loop strap over both forks.

Note: The straps must be the same length and meet in the middle. Verify each

loop strap is over both forks to prevent the forks from being pulled apart.

5 Using the forklift, carefully lift the dyno off the crate and move it into position in

your dyno room.

Figure 2-2: Loop Strap Placement

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

2-9

CHAPTER 2

AD377

feet

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.

Figure 2-3: Install the Feet

2-10

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

PLACING THE DYNO IN THE PIT

AD427

eddy current

brake to be

installed here

8.26 cm

(3.25 in.)

10.16 cm

(4.00 in.)

vehicles loaded

from this end

rear of dyno

side of dyno

118.75 cm (46.75 in.)

Linx option

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 Gently lower the dyno into position. 3 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. For more information on installing the Linx option,

refer to the Linx Installation Guide P/N 98200021. 4 Verify the rear of the dyno is 10.16 cm (4.00 in) from the pit wall.

STATIONARY DYNO INSTALLATION

Dyno Installation

Figure 2-4: Placing the Dyno in the Pit

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

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CHAPTER 2

AD137

secure dyno to floor

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.

You will need the following parts:

• 36923100 Washer, 3/8", Hardened, Flat, Steel (4)

• 37513200 Anchor, Redhead, 3/8" (4)

• 37518200 Redhead Anchor Installation Tool

• DM150-019-012 Bolt, 3/8-16 x 1", Hex (4)

1 Using the mounting feet as a template, mark and drill each hole needed to secure

the four dyno feet to the floor. 2 Install four Red Head anchors. Refer to Appendix A for installation instructions. 3 Secure each mounting foot to the floor using one 3/8-16 x 1-inch hex-head bolt

and one 3/8-inch flat washer.

Figure 2-5: Secure the Dyno to the Floor

INSTALLING THE EDDY CURRENT BRAKE

Refer to Chapter 4 for eddy current brake installation instructions and install your eddy current brake at this time.

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C HAPTER

4WD D

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.

This chapter is divided into the following categories:

• Unpacking and Inspecting the Dyno, page 3-2

• Track Assembly, page 3-5

• Dyno Installation, page 3-9

• Cable Routing, page 3-12

• Hydraulic Movement Installation, page 3-25

• Air Can Sleeve, page 3-31

• 4WD Dyno Movement Test, page 3-32

• Bridge Installation—Stationary Dyno, page 3-33

• Bridge Installation—4WD Dyno, page 3-40

YNO INSTALLATION

• Forward Pit Covers, page 3-45

• Ground Hook Installation, page 3-47

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Unpacking and Inspecting the Dyno

UNPACKING AND INSPECTING THE DYNO

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. Refer to “Dynamometer Specifications and Requirements” on page 1-4 for more information.

1 Move the crated dyno (crate 2) to a clear area near your dyno room. 2 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the

top and sides of the crate.

Note: Inspect the exterior of the dyno for any indications of damage. Report any

damage immediately.

3 Remove the bridge pieces, pit covers, and track assembly from the top portion of

the crate and set aside. 4 Remove the following parts and hardware boxes from the crate and set aside. 5 Verify the contents of the hardware boxes and set aside.

Note: Some of these parts may have been shipped in the stationary dyno crate

(crate 1).

part description part description

cylinder mount, floor P/N 21200064

bridge cover, stationary dyno P/N 21219511

bridge cover, 4WD dyno P/N 21219512

rail (2) P/N 21514282

bolt, shoulder, 3/8-16, 1/2"D x 1"L (8) P/N 36800973

anchor, redhead, 3/8" (12) P/N 37513200

installation tool, redhead anchor P/N 37518200

cylinder mount, dyno P/N 61300016

3-2

In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

4WD DYNO INSTALLATION

Unpacking and Inspecting the Dyno

part description part description

rail tie (3) P/N 21716400

rail tie assembly (2) P/N 61314300

spacer, 424 hydraulic movement (2) P/N 26100000

spacer, rail clamp (8) P/N 26152020

rail clip (10) P/N 31619500

clevis pin, 3/4 x 4.5" (2) P/N 32900000

hairpin cotter, 7/16 x 3/4" (2) P/N 32904080

rail clamp (4) P/N 61314700

calibration arm assembly P/N 61319001

runner assembly (30) P/N 61319500

washer, 1/4", flat (4) P/N DM150-009-003

washer, 3/8", flat (2) P/N DM150-011-002

weight (4) P/N 35430899

bolt, 3/8-16 x 1.5", flange, hex (12) P/N 36582471

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

bolt, 1/4 x 1/2", hex (4) P/N DM150-011-005

bolt, 3/8-16 x 1", hex (4) P/N DM150-019-012

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CHAPTER 3

RECORD

AD394

rear drum guard

dyno number

left/right drum guard

Unpacking and Inspecting the Dyno

6 Remove the crate braces that support the top portion of the crate. 7 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. 8 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.

8c Remove the two screws securing the left and right drum guards and set

aside.

8d Remove the left and right drum guards and set aside. 9 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.

Be sure you record the dynamometer number on the inside cover of this manual.

Figure 3-1: Remove the Drum Guards

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In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.

You will need the following parts:

• 37513200 Anchor, Redhead, 3/8" (10)

• 37518200 Redhead Anchor Installation Tool

1 Line up the center line of the track assembly with the center line of the stationary

dyno. 2 Measure the following distances and set the track assembly as listed below and

shown in Figure 3-2.

• The track assembly should be 128.27 cm (50.50 in.) from the stationary dyno without the extension kit and 153.67 cm (60.50 in.) with the extension kit.

• The distance between the inside of the rails should be 184.15 cm (72.50-inches +/- 0.06 in.).

• The distance from the first rail tie assembly to the first rail tie is 49.37 cm (19.438 in.).

• The distance from the first rail tie assembly to the second rail tie is 103.82 cm (40.875 in.).

• The distance from the first rail tie assembly to the third rail tie is 158.28 cm (62.313 in.).

3 Verify the track assembly is square. Measure from corner to corner and verify

these measurements are equal. 4 Mark and drill all ten holes, five on each side of the track assembly. 5 Set the track assembly aside. 6 Install the Red Head anchors. Refer to Appendix A for installation instructions.

4WD DYNO INSTALLATION

Track Assembly

Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-5

CHAPTER 3

AD108

128.27 cm (50.50 in.)

without extension

153.67 cm (60.50 in.)

with extension

(requires extension

parts, inquire with

Dynojet sales)

49.37 cm

(19.438 in.)

103.82 cm

(40.875 in.)

158.28 cm

(62.313 in.)

184.15 cm (72.5 in.)

center line for

stationary dyno and

track assembly

stationary dyno

track layout

mark and

drill holes

first rail tie assembly

first rail tie

second rail tie

third rail tie

last rail tie assembly

Track Assembly

Figure 3-2: Mark and Drill Holes for the Track Assembly

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INSTALLING THE TRACK ASSEMBLY

AD045

rail clamps

rail

first rail tie

assembly

last rail tie

assembly

rail tie

holes for cable track assembly

Once all the holes are marked and drilled, install the track assembly.

You will need the following parts:

• 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)

1 Layout the first and last rail tie assemblies and the rail ties. Use the holes you

marked and drilled for placement of the rail tie assemblies and rail ties. Note: The first rail tie has four holes for securing the cable track assembly. Verify

this rail tie assembly is closest to the stationary dyno.

2 Place the rail clamps over the rails. 3 Place the rails into the rail tie assemblies.

Note: For clarity, the pit and stationary dyno are not shown.

4WD DYNO INSTALLATION

Track Assembly

Figure 3-3: Install the Track Assembly

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CHAPTER 3

AD103

bolt

rail tie clip

rail

anchor in floor

rail tie

Track Assembly

4 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. 5 Verify the track assembly is square and make any necessary adjustments. 6 Tighten all ten bolts.

Note: For clarity, the pit and stationary dyno are not shown.

Figure 3-4: Install the Rail Tie Clips

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DYNO INSTALLATION

AD351

place strap through

opening in dyno frame

hydraulic ram

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. You will also need a pair of straps capable of supporting the same weight. Dynojet recommends using two 2-inch x 6-foot single loop style straps.

1 Route the loop strap through the opening in the dyno frame and through itself.

Pull the strap tight. Do this on each side of the dyno frame. 2 Push the forklift forks together. 3 Place each loop strap over both forks.

Note: The straps must be the same length and meet in the middle. Verify each

loop strap is over both forks to prevent the forks from being pulled apart.

4 Using the forklift, carefully lift the dyno off the crate and move it into position in

your dyno room.

4WD DYNO INSTALLATION

Dyno Installation

Use caution when handling the hydraulic ram and the hoses connecting the ram to the hydraulic motor.

Figure 3-5: Loop Strap Placement

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CHAPTER 3

AD378

rail clamp

hydraulic movement

motor facing away

from stationary dyno

cable track under dyno and

towards stationary dyno

rail clamp

cradle

assembly

pin and cotter pin

stationary dyno

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:

• 26152020 Spacer, Rail Clamp (8)

• 36800973 Bolt, Shoulder, 3/8-16, 1/2"D x 1"L (8)

1 Remove the cotter pin and pin from all four cradle assemblies as shown in

Figure 3-6. 2 Verify the rail clamps are positioned as shown in Figure 3-6. 3 Verify the dyno movement motor is facing away from the stationary dyno. 4 Using the forklift, gently lower the dyno into the pit and onto the rails.

Figure 3-6: Lower the Dyno onto the Rails

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4WD DYNO INSTALLATION

AD353

spacer

bolt

Dyno Installation

5 Secure the rail clamps to the cradle assembly on the dyno using two 3/8-inch

shoulder bolts and two spacers each. 6 Replace the pins and cotter pins removed earlier from the four cradle assemblies

as shown in Figure 3-6. 7 Move the rail clamps up and down and verify they move freely. 8 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.

Figure 3-7: Secure Dyno to Rail Clamps

INSTALLING THE EDDY CURRENT BRAKE

Refer to Chapter 4 for eddy current brake installation instructions and install your eddy current brake at this time.

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Cable Routing

CABLE ROUTING

Use the following instructions to identify and route the cables for dynos with and without eddy current brakes.

IDENTIFYING THE CABLES

cable brief routing description

A - 25-pin cable connects to the dyno electronics (P/N 42924250)

B - data acquisition (pickup card) cable, stationary C - data acquisition (pickup card) cable, 4WD dyno

four wires (red, white, black, shield) and ferrules, connects to the Breakout board (P/N 66954001, stationary; P/N 66953001, 4WD)

D - brake signal cable two wires and ferrules, connects to the Breakout

E - air hose, short (16 feet) connects to the barbed fitting on the air brake can on

F - air hose, long (18 feet) connects to the T fitting on the stationary dyno brake

G - 4WD power cable connects to the power supply (P/N 76952008)

H - hydraulic pump power cable connects to your 110VAC or 220VAC power outlet

I - dyno movement pendant cable connects to the dyno movement pendant

The following cables are used with the eddy current brake(s):

J - load cell cable, stationary dyno

K - load cell cable, 4WD dyno

L - theta signal cable, stationary dyno M - theta signal cable, 4WD dyno

board (P/N 76950213)

the stationary dyno

solenoid

(P/N 76953005, cable; P/N 76953004, pendant)

connects to the torque module on the dyno electronics (P/N 76950505)

five wires (black, white, red, green, shield) and ferrules, connects to the Advanced Breakout board (P/N 76950413)

N - temperature sensor cable, stationary

O - temperature sensor cable, 4WD dyno

P - theta power cable, stationary dyno

Q - theta power cable, 4WD dyno R - controller cable, stationary dyno

S - controller cable, 4WD dyno

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five wires (black, white, red, green, shield) and ferrules, connects to the Advanced Breakout board (P/N 76950420)

connects to your 240V power source (P/N 76950311)

connects to the theta controller (P/N 66952003)

4WD DYNO INSTALLATION

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.

You will need the following parts:

• DM150-009-003 Washer, 1/4", Flat (4)

• DM150-011-005 Bolt, 1/4" x 1/2", Hex (4)

1 Secure the first and second cable tracks to the front rail tie assembly using two

1/4-20 x 1/2-inch hex-head screws and two washers each. 2 Route the 25-pin cable (A) from the Breakout board, through the pit conduit, and

to the dyno electronics. Connect the 25-pin cable to the dyno electronics.

Refer to Figure 1-6 for information on where to connect the 25-pin cable.

3 Route the pickup card cable (B) from the stationary dyno to the Breakout board.

Refer to page 3-15 for more information on wiring the Breakout board.

4 Route the pickup card cable (C) from the first cable track to the Breakout board.

Refer to page 3-15 for more information on wiring the Breakout board.

5 Route the brake signal cable (D) from the first cable track to the Breakout board.

Refer to page 3-15 for more information on wiring the Breakout board.

6 Route the air hose (E) from the second cable track to the T fitting on the

stationary dyno brake solenoid. 7 Route the long air hose (F) from the second cable track to the barbed fitting on

the air brake can on the stationary dyno.

Note: Verify the stationary dyno has clean dry air regulated between 100-140 psi

supplied to the remaining barbed fitting on the brake solenoid assembly.

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. Once the pressure is connected, the air brake is ready to use.

8 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. 9 Connect the power supply to the dyno electronics. Plug the power supply into

your power source. 10 Route the hydraulic pump power cable (H) from the first cable track and connect

to a 110VAC or 220VAC outlet. Refer to page 3-30 for more information on wiring

the hydraulic pump motor. 11 Route the dyno movement pendant cable (I) from the first cable track, through

the pit conduit, and connect to the pendant.

Cable Routing

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DRY AIR IN

100-140 PSI

AD390

dyno electronics

stationary

dyno

4WD dyno

first cable

track

power supply

dyno movement

pendant

power supply for

dyno electronics

breakout

board

second

cable track

Cable Routing

Figure 3-8: Routing the Cables—Without the Eddy Current Brakes

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In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

4WD DYNO INSTALLATION

jumpers

J1 and J2

four wheel drive

with no eddy

current brake

jumper settings

pickup card

stationary

pickup card

4WD

brake signal

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.

• Red wire connects to R1 • Black wire connects to B1

• White wire connects to W1 • Ground (shield) wire connects to S1

2 Attach the brake signal cable (D) to the Breakout board. The brake signal cable

from the 4WD dyno has two wires which connect to the wiring block labeled

BRAKE.

Note: There will already be wires connected to BRAKE; add the brake signal wires

to this location.

3 Verify the jumpers are set as shown in Figure 3-9.

Cable Routing

Figure 3-9: Wiring the Breakout Board—Without the Eddy Current Brakes

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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.