©2006-2012 Dynojet Research, Inc. All Rights Reserved.
#
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)
2
Automotive Dynamometers.
Stationary Dynamometer Number: ______________________________________________
Eddy Current Brake
(Retarder) Number:____________________________________________________________
4WD Dynamometer Number: ___________________________________________________
Eddy Current Brake
(Retarder) Number:_________________________________________________________
T
ABLE OF
C
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
i
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
ii
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
Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
iii
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
iv
In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
W
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
v
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.
vi
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
S
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
O
PERATING
R
EQUIREMENTS
1
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
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Version 7 In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
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CHAPTER 1
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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.)
1-4
In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
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
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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
1-6
In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
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
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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
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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
1-10
In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
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
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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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In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
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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
S
TATIONARY
C HAPTER
D
YNO INSTALLATION
2
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
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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
2-3
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
2-4
In Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
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
2-6
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
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