Dynojet 424xLC2 Installation Guide

RECORD

Installation Guide For Above Ground Model 424x and 424xLC Dynamometers.

This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, and the software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license. 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: 98200054 Version 1 (08/2014)

Automotive

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Model 424 Stationary and 4WD Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Model 424 4WD Dynamometer With Bridge and Deck . . . . . . . . . . . . . . . . . . . 1-12

DynoWare RT Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Main Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

Lift Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Chapter 2 Stationary Dyno Installation

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

Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Placing the Dyno in Front of the Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Installing the Interface Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Anchoring the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Installing the Air Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

TABLE OF CONTENTS

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

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

Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Identifying the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Routing the Cables—Without the Eddy Current Brakes . . . . . . . . . . . . . . . . . . . . 3-15

Routing the Cables—With One Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . 3-17

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

Hydraulic Movement Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23

Rotating the Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Wiring the Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Filling the Hydraulic Motor with Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Air Can Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32

4WD Dyno Movement Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Bridge Installation—Stationary Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34

Installing the Drum Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35

Installing the Runner Mounts and Runner Supports . . . . . . . . . . . . . . . . . . . . . . 3-36

Installing the Runner Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37

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 Cover and Runner Tie Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Logo Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51

Chapter 4 Eddy Current Brake Installation

Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Before Installing the Eddy Current Brake: Verify Optimal Brake Cooling . . . . . . 4-2

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

Before Installing the Eddy Current Brake: Verify Mounting Holes . . . . . . . . . . . . 4-3

Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Installing the Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Installing the Bearing, Splined Shaft, and Driveline Assembly . . . . . . . . . . . . . . 4-11

Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Installing the Front and Rear Brake Covers and Eddy Current Brake Driver . . . 4-16

Installing the Top and Logo Panel Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Load Cell Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

TABLE OF CONTENTS

Chapter 5 Side Deck Assembly Installation

Side Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Installing the Side Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Chapter 6 Basic Dyno Operation

Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

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

Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Connecting the Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Verifying the SAAR Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Maintaining the SAAR Brake Shoe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Dynos with 4WD Attachment—Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Appendix A Red Head Anchor Installation

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

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

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 B-5

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

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

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

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

Version 1 Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

iii

TABLE OF CONTENTS

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

Appendix C Stationary Dyno Upgrade

Deck Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2

Removing the Early Style Deck from an Early Model Dyno . . . . . . . . . . . . . . . . . . C-2

Removing the New Style Deck from a New Model Dyno . . . . . . . . . . . . . . . . . . . . C-6

Installing the Early Style Deck on the 4WD Dyno . . . . . . . . . . . . . . . . . . . . . . . . . C-11

Installing the New Style Deck on the 4WD Dyno . . . . . . . . . . . . . . . . . . . . . . . . . C-15

Lift Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16

Air Fittings Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17

Appendix D Bridge Extension Assembly

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

Appendix E Interface Roller Assembly Installation

Interface Roller Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2

Appendix F Torque Values

Standard Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2

Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-3

Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

Grade 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

Grade 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4

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

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

ARNINGS

Disclaimers

Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the c onte nt s 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.

Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

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

WARN ING S

Electrostatic Discharge Precautions

Electrostatic Discharge

Electrostatic Discharge (ESD), or static shock, can damage electronic components within the dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade the component, resulting in a premature component failure later. To avoid ESD damage, always practice good ESD control precautions when servicing the dynamometer. Dynojet designs its dynamometers to be very tolerant of static shocks 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 o bjects 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 di ffer ence of pote nt ial befo re the el ect r oni cs 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 positi ve 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.

WARN ING S

Other Potential Hazards

The AC power outlet shall be installed near the equipment and it shall be easily accessible to allow for disconnect before service.

The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing it could cause death.

Any dyno room design must incorporate sufficient exhaust extraction. Equipment is intended for indoor use only. The dynamometer is not designed to be installed or

operated in an outdoor environment. 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 1 Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

vii

CHAPTER 1

PECIFICATIONS AND

PERATING

EQUIREMENTS

Thank you for purchasing Dynojet’s Above Ground Model 424x/424xLC2 Automotive Dynamometer (dyno). Dynojet’s software and dynamometers will give you the power to get the maximum performance out of the vehicles you evaluate. Whether you are new to the benefits of a chassis dynamometer or an experienced performance leader, the repeatability and diagnostic tools of Power Core 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: 98200054 Version 1 Last Updated: 08-19-14

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 1-11

• Model 424 4WD Dynamometer with Bridge and Deck, page 1-12

• DynoWare RT Electronics, page 1-13

• Lift Specifications and Requirements, page 1-16

Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

1-1

CHAPTER 1

Introduction

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

1-2

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.

SIDE DECK ASSEMBLY INSTALLATION

This chapter describes the procedures for installing the side deck assembly.

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.

INTERFACE ROLLER ASSEMBLY INSTALLATION

This appendix describes the procedures for installing the interface roller assembly.

TORQUE VALUES

This appendix describes the standard and metric torque values.

SPECIFICATIONS AND OPERATING REQUIREMENTS

Introduction

CONVENTIONS USED IN THIS MANUAL

RECORD

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.

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 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-3

CHAPTER 1

Dynamometer Specifications and Requirements

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

1-4

DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS

description specifications

Length

Height

Width

Track Assembly

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.)

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, deck, bridge—full in 397.00 cm (156.30 in.) both frames, deck, bridge—full in

with extension kit both frames, deck, bridge—full out 487.68 cm (192.00 in.) both frames, deck, bridge—full out

with extension kit

Length 208.92 cm (82.25 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.)

72.07 cm (28.375 in.)

422.40 cm (166.30 in.)

513.08 cm (202.00 in.)

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

A598D

93.83 cm

(36.94 in.)

frame and

air brake

115.49 cm (45.47 in.)

frame, air brake, and

interface kit

321.23 cm (126.47 in.) frame and brake

65.58 cm (25.82 in.) brake only

80.01 cm (31.50 in.)

brake to floor

106.93 cm (42.10 in.) brake

218.44 cm (86.00 in.)

73.66 cm (29.00 in.)

72.02 cm (28.375 in.) frame to floor

58.42 cm (23.00 in.) frame only

Figure 1-1: Model 424 Stationary Dyno Dimensions

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-5

CHAPTER 1

Dynamometer Specifications and Requirements

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

1-6

A599D

218.44 cm (86.00 in.)

frame only

321.23 cm (126.47 in.) frame and brake

218.44 cm (86.00 in.) track

224.15 cm (88.25 in.) track

65.58 cm (25.82 in.) brake only

80.01 cm (31.50 in.)

brake to floor

73.66 cm

(29.00 in.)

frame

130.18 cm (51.25 in.)

frame and cradle assembly

193.45 cm (76.16 in.)

frame, cradle assembly,

and deck

228.60 cm (90.00 in.)

deck

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

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

Figure 1-3: Model 424 4WD Dyno with Bridge and Deck Dimensions

A 600D

508.00 cm (200.00 in.) deck full out to lift

416.56 cm (164.00 in.)

deck full in to lift

487.68 cm (192.00 in.)

frame and deck full out

397.00 cm (156.30 in.)

frame and deck full in

91.44 cm

(36.00 in.)

229.62 cm (90.40 in.) deck

extension kit dimensions*

533.40 cm (210.00 in.) deck full out to lift

441.96 cm (174.00 in.)

deck full in to lift

513.08 cm (202.00 in.)

frame and deck full out

422.40 cm (166.30 in.)

frame and deck full in

*requires extension parts,

inquire with Dynojet sales

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-7

CHAPTER 1

Dynamometer Specifications and Requirements

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

1-8

COMPRESSED AIR

The following requirements are needed for the air brake:

• Clean and dry air, between 100-140 psi

• shut off valve

• 1/4-inch NPT pipe thread connector (to attach air to the dyno), if air hose does not have a 3/8-inch inside diameter

• have a 3/8-inch inside diameter

COMPUTER SPECIFICATIONS

You will need to provide a computer system to run the Power Core software.

description minimum specifications recommended specifications

Operating System Windows XP (service pack 3) or

higher

Processor Dual Core Processor, 2GHz or

faster Memory 2GB System Ram 4GB System Ram or more Hard Drive 100GB or larger

(54MB required for program) Monitor/Graphics Card 1280x1024 (SXGA) resolution or

higher Network Adapter 1 free 10/100 Mbps

RJ45 Ethernet Port External Media CD Rom Drive CD Rom Drive Printer Printer, if prints or needed Color printer, if prints are needed

Windows 7 or later

Intel Core i5 2.8GHz or faster

500GB or larger (54 MB required for program)

1600x900 resolution or higher

1 free 100Mbps RJ45 or Wireless

DRILL AND DRILL BIT REQUIREMENTS

You will need to provide a drill and drill bit capabl e of dril ling 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)

SPECIFICATIONS AND OPERATING REQUIREMENTS

Dynamometer Specifications and Requirements

ELECTRICAL REQUIREMENTS

description specifications

Power Requirements: 4WD electronics 100-240 VAC, 50/60 Hz Power Requirements: dyno electronics 100-240 VAC, 50/60 Hz Power Requirements: hydraulic motor 110 VAC, 60 Hz, 20A/240 VAC, 60 Hz, 10A Power Requirements: computer Per computer manufacturer specifications Power Requirements: optional eddy

current brake

The hydraulic pump/motor power source and eddy current braking power source require user supplied grounded electrical outlets with over current and short circuit protection. These must be accessible to the operator to be used as a disconnect.

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

ENVIRONMENTAL REQUIREMENTS

description specifications

Temperature

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

Humidity 0 to 95% non condensing

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-9

CHAPTER 1

Dynamometer Specifications and Requirements

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

1-10

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 dy no off the c r ate 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 downl oading new information and updates.

TIE-DOWN STRAPS

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

SPECIFICATIONS AND OPERATING REQUIREMENTS

Model 424 Stationary and 4WD Dynamometer

MODEL 424 STATIONARY AND 4WD DYNAMOMETER

A601D

Drum

precision balanced

and knurled

Air Brake

Track Assembly

Dyno Movement

Hydraulic Motor

Cradle Assembly

4WD Dyno

Stationary Dyno

Eddy Current Brake

with stiffener plate and

eddy current brake driver

Interface Guide

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

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-11

CHAPTER 1

Model 424 4WD Dynamometer With Bridge and Deck

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

1-12

MODEL 424 4WD DYNAMOMETER WITH BRIDGE AND DECK

A602D

Deck

Stationary Dyno Bridge

and Center Cover

4WD Dyno

Stationary Dyno

4WD Dyno Bridge

and Center Cover

Tie-Down

Runner Support

Pillar

Figure 1-5: Model 424 4WD Dynamometer with Bridge and Deck

SPECIFICATIONS AND OPERATING REQUIREMENTS

DynoWare RT Electronics

DYNOWARE RT ELECTRONICS

AD510

air fuel ratio

module

eddy current

brake driver

main module

speed pickup

The DynoWare RT electronics consists of a main module and a speed pickup. Optional modules include the Air Fuel Ratio (AFR) module and the Eddy Current Brake (ECB) driver. Use this section to identify the modules and connections. More detailed information for configuring the DynoWare RT electronics can be found in the Power Core Help.

Figure 1-6: DynoWare RT Electronics

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-13

CHAPTER 1

DynoWare RT Electronics

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

1-14

MAIN MODULE CONNECTIONS

Linx

Dynojet Research, Inc.

2191 Mendenhall Drive

N. Las Vegas, NV 89081

100-240 VAC

50-60 Hz

1.0 A

1234

Analog

Status

A description of the main module symbols and connections follows.

use this port to use this port to

RPM Inputs Connect inductive and optical

RPM inputs.

Auxiliary Temperature

Connect to an auxiliary input for an infrared temperature sensor.

Communication I/O Connect to auxiliary Dynojet

Communication I/O Connect to auxiliary dyno

Communication I/O Connect to internal dyno

Drum Connect to the drum 1 and

products such as the Power Commander, Wideband 2, Power Vision, etc.

electronics such as the pendant, atmospheric module, AFR module, etc.

electronics and controllers such as the ECB controller.

drum 2 speed inputs and digital brake outputs.

Auxiliary Switch Connect to the brake air

pressure switch on 248 and older 224 dynos.

Emergency Stop Connects the dyno electronics

to the emergency stop input on the 200i/250i dynos.

Network Connection

Connects the dyno electronics to your computer or computer network.

Refer to Instructions

Do not press this button unless instructed to do so by a Dynojet Technician. This button may need to be pressed to update the device.

SPECIFICATIONS AND OPERATING REQUIREMENTS

DynoWare RT Electronics

NETWORK CONNECTIONS

wireless network

internet and router

direct connection

point to point

The Dynojet DynoWare RT dyno electronics connects to your computer directly or over a Local Area Network. If you have an existing network, connect t he DynoWare RT main module to a router or a network switch on your network. If you don't have an existing network, you can create a network for the DynoWare RT by connecting the main module to a router.

There are some advantages to connecting the DynoWare RT to a network, particularly a wireless network. With DynoWare RT on a network, you don't have to have one dedicated computer for the dyno. Any computer on the network can connect and operate the dyno. A wireless connection allows you to control the dyno from inside the vehicle without a cable running to the DynoWare RT main module.

Note: Only one computer at a time can connect.

When the DynoWare RT main module is on a network connected to the internet, automatic updates for both the box and software are possible.

connection method auto updates

Wireless Network Internet

Wireless Network Router

Direct Connection Point to Point

Yes Yes Yes

multi-computer connection wireless connection

Yes Yes

Figure 1-7: DynoWare RT Network Connections

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

1-15

CHAPTER 1

Lift Specifications and Requirements

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

1-16

LIFT SPECIFICATIONS AND REQUIREMENTS

Dynojet recommends installing the four-post lift before installing your dynamometer. However, if space constraints make it difficult to install the lift first, the dynamometer can be installed before the lift.

Dynojet acts as a liaison for Rotary Lifts, to ensure that you receive the proper four-post lift. Dynojet recommends purchasing Rotary Lift’s SM14L four-post lift. The information given and the images shown in this manual is currently based on Rotary Lift’s SM14L four-post lift. This information is subject to change, contact Rotary Lift for technical assistance and installation instructions, 1-800-532-6973.

description specifications

voltage single phase 208V-230V

CHAPTER 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 2-7

• Eddy Current Brake Installation, page 2-15

TATIONARY

YNO INSTALLATION

Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

2-1

CHAPTER 2

Unpacking and Inspecting the Dyno

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

2-2

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, remove the top and

sides of the crate.

3 Inspect the exterior of the dyno for any indications of damage. Report any damage

immediately.

4 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

network cable P/N 42900000

runner clamp, short (2) P/N 21214702

runner clamp plate (2) P/N 21214703

runner slide (2) P/N 21214704

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

runner support pillar assembly (4) P/N 61314500

STATIONARY DYNO INSTALLATION

Unpacking and Inspecting the Dyno

part description part description

runner tie slide (2) P/N 21214705

riser foot assembly (4) P/N 61319600

side deck P/N 21216101

side deck, left P/N 21216102

side deck, center P/N 21216103

runner mount, short (2) P/N 21514801

runner mount (2) P/N 21514802

DynoWare RT main module P/N 66100016

remote atmos assembly P/N 66400011

pendant assembly P/N 76100007

primary inductive  pickup (2) P/N 76950201

secondary inductive  pickup (2) P/N 76950203

runner support (2) P/N 21514803

chock (4) P/N 2A092

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

bolt kit, 424 bridge P/N 79110002

bolt kit, 4WD above ground P/N 79110004

2-3

CHAPTER 2

Unpacking and Inspecting the Dyno

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

2-4

part description part description

axle strap, 21" (4) P/N 30AS21

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

power cord, 125V, 10A P/N 318110301

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

washer, 3/8", flat (4) P/N 36923100

anchor, redhead, 3/8" (4) P/N 37513200

installation tool, redhead anchor P/N 37518200

model 224-2 dyno P/N 81200000

washer, #8 ext star (4) P/N 91114A009

banner, dynojet (2) P/N D706

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

The following parts are included in the Above Ground Kit P/N 78112001:

ground hook/D-ring (6)  P/N 10111

mounting bracket, logo panel (4) P/N 21200004

axle strap, (2) P/N 30AS72

cap plug, 1.75" x 1/2",  black (2) P/N 35521420

STATIONARY DYNO INSTALLATION

Unpacking and Inspecting the Dyno

part description part description

lower mounting bracket, logo panel (2) P/N 21200009

nut, 7/16-14, hex,  grade-5 (4) P/N 36491100

center panel, deck P/N 21214300

outer panel, deck (2) P/N 21214301

right drum guard P/N 21216101

left drum guard P/N 21216102

lateral drum guard (2) P/N 21216103

screw, 1/4-20 x 5/8", panhead, torx (36) P/N 36561045

bolt, 3/8-16 x 1.25", button head flange allen, (12) P/N 36582034

bolt, 7/16-14 x 1", hex (4) P/N 36591670

washer, 7/16", flat (4) P/N 36933100

logo panel assembly (2) P/N 61100001

support angel, deck (2) P/N 21610807

brace mount, deck (2) P/N 21614102

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

interface guide assembly P/N 71300000

bolt kit, 224-2 above ground P/N 79110003

2-5

CHAPTER 2

Unpacking and Inspecting the Dyno

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

2-6

part description part description

deck tube P/N 21619103

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

brace, deck (4) P/N 21714200

bolt, 3/8-16 x 3/4", hex (8) P/N DM150-019-008

STATIONARY DYNO INSTALLATION

Dyno Installation

DYNO INSTALLATION

RECORD

A539D

place strap through

opening in dyno frame

dyno number

remove feet

set aside bolts

This section will walk you through removing the dyno from the crate and installing the dyno in front of your lift. Refer to Appendix C for instructions on upgrading an existing dyno.

REMOVING THE DYNO FROM THE CRATE

You will need to provide equipment capable of lifting a minimum of 2,114 kg  (4,660 lb.) to lift the dyno off the crate and into position in your dyno room. 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.

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

1 Remove the crate braces that support the top portion of the crate. 2 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. 3 Remove and set aside the four flange bolts securing the crate feet to the dyno. 4 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. 5 Push the forklift forks together. 6 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. 7 Using the forklift, carefully lift the dyno off the crate and move it into position in

your dyno room.

Figure 2-1: Loop Strap Placement

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

2-7

CHAPTER 2

Dyno Installation

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

2-8

8 With the dyno on the forklift, secure the four feet to the bottom of the dyno using

AD540

feet

the four 3/8 x 1.5-inch flange bolts removed earlier.

Note: If the feet are already installed, skip this step.

Figure 2-2: Install the Feet

STATIONARY DYNO INSTALLATION

Dyno Installation

PLACING THE DYNO IN FRONT OF THE LIFT

lift runway

cross member

interface bracket

10.16 cm

(4.00 in.)

1 Verify the interface bracket faces the lift as shown in Figure 2-3. 2 Verify the lift is in the down position. 3 Using the forklift, bring the dyno in front of the lift. The dyno should be about

10.16 cm (4.00 in.) from the lift cross member. 4 Center the dyno drum with the lift runways. 5 Gently lower the dyno into position.

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

Figure 2-3: Dyno with Lift

2-9

CHAPTER 2

Dyno Installation

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

2-10

INSTALLING THE INTERFACE GUIDE

A512D

lift cross member

interface guide

interface guide with the pin facing

the dyno and near the bottom of

the lift cross member

The interface guide secures the dyno to the four-post lift. It is a good idea to install your interface guide before anchoring your dyno to the ground. If you have the interface roller assembly, refer to Appendix E.

You will need the following parts:

• 21600000 Interface Bar

• 21600001 Interface Bracket

secured to the dyno using P/N 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (2)

• 36488100 Nut, 3/8-16, Nylock (2)

• 36500000 Bolt, 3/8-16 x 4.5", Hex, Full Thread (2)

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

• 61100000 Interface Guide 1 Raise the lift until the bottom of the lift is approximately 86.36 cm (34.00 in.)

above the floor.

2 Loosely attach the interface guide to the lift cross member using two 

3/8-16 x 4.5-inch bolts, four 3/8-inch flat washers, and two 3/8-inch nylock nuts. Note: Verify the interface guide with the pin is facing the dyno and is near the

bottom of the lift cross member.

Figure 2-4: Interface Guide and Lift Cross Member

STATIONARY DYNO INSTALLATION

Dyno Installation

3 Align the interface guide pin on the lift cross member with the interface bracket on

A 513D

interface bracket

on dyno

(dyno not shown

for clarity)

mounting bolt

lift cross member

the dyno. The interface bracket is already installed on the dyno. Note: The distance between the dyno and the lift may need to be adjusted.

4 Lower the lift until the interface guide pin just starts to enter the interface bracket

on the dyno.

Figure 2-5: Align the Interface Bracket and the Interface Guide

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

2-11

CHAPTER 2

Dyno Installation

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

2-12

5 Verify the interface guide clears the interface bracket by 1/8-inch to 1/4-inch as

interface guide on

cross member

interface bracket

on dyno

0.125" to .250"

shown in Figure 2-6.

6 Slide the interface guide up until the bottom bolt touches the cross member.

Lower the top bolt down in the slots until it touches the cross member.

7 Tighten the hardware securing the interface guide to the lift cross member.

Note: The lower and upper interface guide mounting bolts should touch the lift cross member.

8 Raise and lower the lift several times to make sure that the interface guide is

working smoothly. Adjust the interface guide if needed.

9Verify the lift can be lowered down to floor level.

Figure 2-6: Verify Distance Between Interface Guide and Interface Bracket

STATIONARY DYNO INSTALLATION

Dyno Installation

ANCHORING THE DYNO

A514D

secure dyno

to floor

secure dyno to

floor

lift

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 2-7: Secure the Dyno to the Floor

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

2-13

CHAPTER 2

Dyno Installation

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

2-14

INSTALLING THE AIR FITTINGS

A560D

existing air inlet fitting

brake solenoid

assembly

street tee

barbed hose fitting

bushing and elbow fitting

Before the stationary dyno can be used with the 4WD dyno, the existing air fittings on the stationary dyno must be upgraded.

You will need the following parts:

• 3400X4 Fitting, Street Tee

• 141900001 Fitting, Barbed Hose

• 34122231 Bushing, 1/4"F x 3/8"M, Brass

• 34161320 Elbow-90, 3/8"H x 1/4"P 1 Remove the existing air inlet fitting from the brake solenoid assembly. 2 Install the street tee. 3 Replace the air inlet fitting removed earlier. 4 Install a barbed hose fitting into the street tee. 5 Remove the existing plug from the air can. 6Install one 3/8-1/4-inch bushing and elbow fitting.

Figure 2-8: Upgrade the Air Fittings

STATIONARY DYNO INSTALLATION

Eddy Current Brake Installation

EDDY CURRENT BRAKE INSTALLATION

AD603

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

Figure 2-9: Eddy Current Brake

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

2-15

CHAPTER 3

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

• Eddy Current Brake Installation, page 3-12

• Cable Routing, page 3-13

•Hydraulic Movement Installation, page 3-23

• Air Can Sleeve, page 3-32

• 4WD Movement Test, page 3-33

• Bridge Installation—Stationary Dyno, page 3-34

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

• Deck Installation, page 3-45

YNO INSTALLATION

• Logo Panel Installation, page 3-51

Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

3-1

CHAPTER 3

Unpacking and Inspecting the Dyno

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

3-2

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: At this point, you will want to inspect the exterior of the dyno for any

indications of damage. Report any damage immediately.

3 Remove the following parts from the crate and set aside.

Note: Some of these parts may have been shipped in the stationary dyno crate (crate 1).

4 Verify the contents of the hardware boxes and set aside.

Note: The hardware required for the 4WD dyno installation may be packed in the stationary dyno crate (crate 1).

part description part description

bridge cover, stationary dyno P/N 21219511

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

bridge cover, 4WD dyno P/N 21219512

rail (2) P/N 21514282

rail tie (3) P/N 21716400

installation tool, redhead anchor P/N 37518200

cylinder mount, dyno P/N 61300016

cylinder mount, floor P/N 61300061

4WD DYNO INSTALLATION

Unpacking and Inspecting the Dyno

part description part description

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

rail tie assembly (2) P/N 61314300

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

weight (4) P/N 35430899

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 (4) P/N DM150-011-002

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

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

Version 1 Above 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 (6) P/N DM150-019-012

3-3

CHAPTER 3

Unpacking and Inspecting the Dyno

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

3-4

5 Remove the crate braces that support the top portion of the crate. 6 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.

7 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.

4WD DYNO INSTALLATION

Track Assembly

TRACK ASSEMBLY

The stationary dyno must be installed before proceeding with the 4WD dyno installation. Refer to chapter 2 for stationary dyno installation instructions.

Before installing the track assembly, layout the entire track assembly using the following instructions and Figure 3-1 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 3-1.

• 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 ten Red Head anchors. Refer to Appendix A for installation

instructions.

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-5

CHAPTER 3

Track Assembly

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

3-6

A604

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

Figure 3-1: Mark and Drill Holes for the Track Assembly

4WD DYNO INSTALLATION

Track Assembly

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 stationary dyno is not shown.

Figure 3-2: Install the Track Assembly

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-7

CHAPTER 3

Track Assembly

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

3-8

4 Loosely install the ten rail tie clips using one 3/8-16 x 1.5-inch flange-hex bolt per

AD103

bolt

rail tie clip

rail

anchor in floor

rail tie

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. 6Tighten all ten bolts.

Note: For clarity, the stationary dyno is not shown.

Figure 3-3: Install the Rail Tie Clips

4WD DYNO INSTALLATION

Dyno Installation

DYNO INSTALLATION

RECORD

AD351

dyno number

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.

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

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.

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

Figure 3-4: Loop Strap Placement

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-9

CHAPTER 3

Dyno Installation

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

3-10

PLACING THE DYNO ON THE TRACK

A605D

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

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 3-5. 2 Verify the rail clamps are positioned as shown in Figure 3-5. 3 Verify the hydraulic movement motor is facing away from the stationary dyno. 4 Using the forklift, gently lower the dyno onto the rails.

Figure 3-5: Lower the Dyno onto the Rails

4WD DYNO INSTALLATION

Dyno Installation

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

AD353

spacer

bolt

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

as shown in Figure 3-5. 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 stationary dyno is not shown.

Figure 3-6: Secure the Dyno to the Rail Clamps

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-11

CHAPTER 3

Eddy Current Brake Installation

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

3-12

EDDY CURRENT BRAKE INSTALLATION

AD606

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

Figure 3-7: Eddy Current Brake

4WD DYNO INSTALLATION

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 - 318110301 power cable connects the DynoWare RT to a power outlet B - 318110301 power cable connects the 4WD board power supply with cable (N)

to a power outlet

C - 42900000 network cable connects the DynoWare RT to your local network

D - 66400011 remote atmos cable assembly connects to the DynoWare RT

E - 66952003 controller cable connects the eddy current brake to the eddy current

brake driver

F - 76100007 CAN pendant cable assembly connects to the DynoWare RT

G - 76950135 hydraulic pump power cable connects to a power outlet

H - 76950201 primary RPM pick up cable

- 76950203 secondary pick up cable

I - 76950311 power cable connects the eddy current brake driver to a power

J - 76950547 speed pick up/brake cable connects the brake solenoid and speed pick up to the

connects to the DynoWare RT

outlet

DynoWare RT

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-13

CHAPTER 3

Cable Routing

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

3-14

cable brief routing description

K - 76950568 CAN control cable connects the eddy current brake driver to the

DynoWare RT

L - 76950569 IR temp sensor cable connects the temp sensor to the eddy current brake

driver

M - 76950574 load cell cable connects the load cell to the eddy current brake

N - 76952008 4WD power supply with cable connects the 4WD board to the 4WD power cable (B)

O - 76953004 dyno movement pendant cable connects to the 4WD board

P - air hose connects the air can on the stationary dyno to your

Q - rail brake air hose connects the air can on the 4WD dyno to the T fitting

R - drum brake air hose connects the drum brake air can on the 4WD dyno to

driver

clean dry shop air (customer supplied)

on the stationary dyno air can

the drum brake air can on the stationary

4WD DYNO INSTALLATION

Cable Routing

ROUTING THE CABLES—WITHOUT THE EDDY CURRENT BRAKES

Use the following instructions along with Figure 3-8 on page 3-16 for routing cables without eddy current brakes.

You will need the following parts:

• 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-inch hex-head screws and two washers each. 2 Route the pickup/brake cable (J) from the speed pickup card and the brake

solenoid leads on the stationary dyno to DRUM 1 on the back of the DynoWare RT

module.

Route the pickup/brake cable (J) from the second cable track to DRUM 2 on the

back of the DynoWare RT module. 3 Route the air hose (P) from the T fitting on the air brake can on the stationary

dyno to your clean dry air supply. Refer to “Installing the Air Fittings” on page 2-

14 for more information.

The air brake comes installed with a hose barb for a 3/8-inch inside diameter air

hose. If your hose does not have an inside diameter of 3/8-inch then you will need

an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply to the

dyno. Once the pressure is connected, the air brake is ready to use. 4 Route the drum brake air hose (R) from the cable track to the air brake can on the

stationary dyno. 5 Route the rail brake air hose (Q) from the second cable track to the T fitting on the

air brake can on the stationary dyno.

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. 6 Route the hydraulic pump power cable (G) from the first cable track and connect

to a 110VAC or 220VAC outlet. The pump motor is wired for 110VAC, refer to

Figure 3-19 on page 3-30 for more information on wiring the hydraulic pump

motor. 7 Route the 4WD board power cable (N) from the first cable track and connect to

the power supply. Plug the power supply cable (B) into your power source. 8 Route the dyno movement pendant cable (O) from the second cable track and

connect to the pendant. 9 Connect the CAN pendant cable (F) to the DynoWare RT module. 10 Connect the primary/secondary pickup cable (H) to the DynoWare RT module. 11 Connect the remote atmos cable (D) to the DynoWare RT module. 12 Connect the ethernet cable (C) to your DynoWare RT module and connect to your

network. Refer to “Network Connections” on page 1-15 for more information. 13 Connect the power cable (A) to the DynoWare RT module. Plug the power ca ble

into your power source.

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-15

CHAPTER 3

Cable Routing

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

3-16

4WD board

RJQ

brake

solenoid

pickup

card

RPM pickup

remote

atmos

pickup

card

hand held

pendant

router

DynoWare RT

DRY IR IN A

100-140 PSI

A 607D

dyno movement

pendant

first cable track

second cable track

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

4WD DYNO INSTALLATION

Cable Routing

ROUTING THE CABLES—WITH ONE EDDY CURRENT BRAKE

Use the following instructions along with Figure 3-9 on page 3-19 for routing cables with one eddy current brake. Refer to Chapter 4 for eddy current brake installation instructions.

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-inch hex-head screws and two washers each. 2 Route the pickup/brake cable (J) from the speed pickup card and the brake

solenoid leads on the stationary dyno to DRUM 1 on the back of the DynoWare RT

module.

Route the pickup/brake cable (J) from the second cable track to DRUM 2 on the

back of the DynoWare RT module. 3 Route the CAN control cable (K) from the eddy current brake driver on the

stationary dyno to the back of the DynoWare RT module. 4 Route the air hose (P) from the T fitting on the air brake can on the stationary

dyno to your clean dry air supply. Refer to “Installing the Air Fittings” on page 2-

14 for more information.

The air brake comes installed with a hose barb for a 3/8-inch inside diameter air

hose. If your hose does not have an inside diameter of 3/8-inch then you will need

an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply to the

dyno. Once the pressure is connected, the air brake is ready to use. 5 Route the drum brake air hose (R) from the cable track to the air brake can on the

stationary dyno. 6 Route the rail brake air hose (Q) from the second cable track to the T fitting on the

air brake can on the stationary dyno.

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. 7 Route the hydraulic pump power cable (G) from the first cable track and connect

to a 110VAC or 220VAC outlet. The pump motor is wired for 110VAC, refer to

Figure 3-19 on page 3-30 for more information on wiring the hydraulic pump

motor. 8 Route the 4WD board power cable (N) from the first cable track and connect to

the power supply. Plug the power supply cable (B) into your power source. 9 Route the eddy current brake driver power cable (I) from the eddy current brake

driver on the stationary dyno to your power source. Plug the power cable into your

power source. Refer to Appendix B for power requirements. 10 Route the dyno movement pendant cable (O) from the second cable track and

connect to the pendant.

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-17

CHAPTER 3

Cable Routing

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

3-18

11 Connect the IR temperature sensor cable (L) to the eddy current brake driver. 12 Connect the load cell cable (M) to the eddy current brake driver. 13 Connect the controller cable (E) from the eddy current brake to the eddy current

brake driver. 14 Connect the CAN pendant cable (F) to the DynoWare RT module. 15 Connect the primary/secondary pickup cable (H) to the DynoWare RT module. 16 Connect the remote atmos cable (D) to the DynoWare RT module. 17 Connect the ethernet cable (C) to your DynoWare RT module and connect to your

network. Refer to “Network Connections” on page 1-15 for more information. 18 Connect the power cable (A) to the DynoWare RT module. Plug the power cable

into your power source.

4WD DYNO INSTALLATION

Cable Routing

4WD board

brake

solenoid

pickup

card

RPM pickup

remote

atmos

eddy current

brake driver

pickup

card

hand held

pendant

router

DynoWare RT

DRY IR IN A

100-140 PSI

A609

dyno movement

pendant

first cable track

second cable track

Figure 3-9: Routing the Cables—With One Eddy Current Brake

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-19

CHAPTER 3

Cable Routing

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

3-20

ROUTING THE CABLES—WITH TWO EDDY CURRENT BRAKES

AD079

cable track

link

crossbar

use screwdriver

to open

Use the following instructions along with Figure 3-11 on page 3-22 for routing cables with two eddy current brakes. Refer to Chapter 4 for eddy current brake installation instructions.

You will need the following parts:

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

• DM150-011-005 Bolt, 1/4" x 1/2", Hex (4) 1 Pull both the first and second cable tracks out from under the dyno. 2 Using a screwdriver, open the crossbar on each link.

Figure 3-10: Open the Crossbar

3 Place the eddy current brake driver power cable (I) in the first cable track.

Note: Keep the power cables in a separate cable track from the signal cables.

4 Place the pickup/brake cable (J), the CAN control cable (K), and the air hose (Q)

in the second cable track. 5 Close the cable door on each link. 6 Place the cable tracks back under the dyno. 7 Secure the first and second cable tracks to the front rail tie assembly using two 

1/4-20 x 1-inch hex-head screws and two washers each. 8 Route the pickup/brake cable (J) from the speed pickup card and the brake

solenoid leads on the stationary dyno to DRUM 1 on the back of the DynoWare RT

module.

Route the pickup/brake cable (J) from the second cable track to DRUM 2 on the

back of the DynoWare RT module. 9 Route the CAN control cable (K) from the eddy current brake driver on the

stationary dyno to the back of the DynoWare RT module.

Route the CAN control cable (K) from the second cable track to the back of the

DynoWare RT module.

4WD DYNO INSTALLATION

Cable Routing

10 Route the air hose (P) from the T fitting on the air brake can on the stationary

dyno to your clean dry air supply. Refer to “Installing the Air Fittings” on page 2-

14 for more information.

The air brake comes installed with a hose barb for a 3/8-inch inside diameter air

hose. If your hose does not have an inside diameter of 3/8-inch then you will need

an air hose nipple (1/4-inch NPT) to connect your clean, dry shop air supply to the

dyno. Once the pressure is connected, the air brake is ready to use. 11 Route the drum brake air hose (R) from the cable track to the air brake can on the

stationary dyno. 12 Route the rail brake air hose (Q) from the second cable track to the T fitting on the

air brake can on the stationary dyno.

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. 13 Route the hydraulic pump power cable (G) from the first cable track and connect

to a 110VAC or 220VAC outlet. The pump motor is wired for 110VAC, refer to

Figure 3-19 on page 3-30 for more information on wiring the hydraulic pump

motor. 14 Route the 4WD board power cable (N) from the first cable track and connect to

the power supply. Plug the power supply cable (B) into your power source. 15 Route the eddy current brake driver power cable (I) from the eddy current brake

driver on the stationary dyno to your power source. Plug the power cable into your

power source. Refer to Appendix B for power requirements.

Route the eddy current brake driver power cable (I) from the first cable track to

your power source. Plug the power cable into your power source. Refer to

Appendix B for power requirements. 16 Route the dyno movement pendant cable (O) from the second cable track and

connect to the pendant. 17 Connect the IR temperature sensor cables (L) to the eddy current brake drivers. 18 Connect the load cell cables (M) to the eddy current brake drivers. 19 Connect the controller cables (E) from the eddy current brake to the eddy current

brake drivers. 20 Connect the CAN pendant cable (F) to the DynoWare RT module. 21 Connect the primary/secondary pickup cable (H) to the DynoWare RT module. 22 Connect the remote atmos cable (D) to the DynoWare RT module. 23 Connect the ethernet cable (C) to your DynoWare RT module and connect to your

network. Refer to “Network Connections” on page 1-15 for more information. 24 Connect the power cable (A) to the DynoWare RT module. Plug the power cable

into your power source.

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-21

CHAPTER 3

Cable Routing

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

3-22

4WD board

brake

solenoid

pickup

card

RPM pickup

remote

atmos

eddy current

brake driver

eddy current

brake driver

pickup

card

hand held

pendant

router

DynoWare RT

DRY IR IN A

100-140 PSI

A608

dyno movement

pendant

first cable track

second cable track

Figure 3-11: Routing Cables—With Two Eddy Current Brakes

4WD DYNO INSTALLATION

Hydraulic Movement Installation

HYDRAULIC MOVEMENT INSTALLATION

AD346

dyno cylinder mount

Use the following instructions to install the hydraulic movement. You will need the following parts:

• 26100000 Spacer, 424 Hydraulic Movement (2)

• 32900000 Clevis Pin, 3/4 x 4.5" (2)

• 32904080 Hairpin Cotter, 7/16 x 3/4" (2)

• 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (2)

• 37513200 Anchor, Redhead, 3/8" (2)

• 61300016 Cylinder Mount, Dyno

• 61300061 Cylinder Mount, Floor

• DM150-011-002 Washer, 3/8", Flat (4)

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

1 Secure the dyno cylinder mount to the dyno using two 3/8-16 x 1.5-inch bolts.

Figure 3-12: Secure the Dyno Cylinder Mount to the Dyno

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-23

CHAPTER 3

Hydraulic Movement Installation

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

3-24

2 Secure the hydraulic ram to the dyno cylinder mount using one clevis pin and

AD343

clevis pin

hairpin cotter

dyno cylinder mount

hydraulic ram

hairpin cotter.

Figure 3-13: Secure the Hydraulic Ram to the Dyno Cylinder Mount

4WD DYNO INSTALLATION

Hydraulic Movement Installation

3 Temporarily hold the floor cylinder mount to the hydraulic ram using two spacers

AD485

clevis pin

spacers

floor cylinder

mount

hydraulic ram

and one clevis pin.

Figure 3-14: Hold the Floor Cylinder Mount to the Ram

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-25

CHAPTER 3

Hydraulic Movement Installation

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

3-26

4 Using the floor cylinder mount as a template, mark each hole needed to secure the

AD472

secure the hydraulic ram to

the floor cylinder mount

use the floor cylinder mount to mark holes

install the anchors and secure the

floor cylinder mount to the floor

mount to the floor. 5 Remove the clevis pin, spacers, and floor cylinder mount. 6 Move the hydraulic ram out of the way. 7 Drill the holes marked in step #4. 8 Install the Red Head anchors. Refer to Appendix A for installation instructions. 9 Secure the floor cylinder mount to the floor using four 3/8-16 x 1-inch hex bolts

and four 3/8-inch flat washers.

Note: Four 3/8-16 x 1.25-inch hex bolts were included if you find the anchors are

too deep for the 3/8-16 x 1-inch hex bolts. 10 Secure the hydraulic ram to the floor cylinder mount using the clevis pin and two

spacers removed in step #5 and one hairpin cotter.

Figure 3-15: Secure the Floor Cylinder Mount to the Floor

4WD DYNO INSTALLATION

Hydraulic Movement Installation

ROTATING THE HYDRAULIC MOTOR

AD486

motor

wiring box cover

Before rotating the hydraulic motor, verify the motor is wired for your needs. The motor is wired for 110v but can be changed to 220v. Refer to “Wiring the Hydraulic Motor” on page 3-29.

1 Remove the four bolts and washers securing the motor.

Figure 3-16: Removing the Hydraulic Motor

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-27

CHAPTER 3

Hydraulic Movement Installation

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

3-28

2 Rotate the motor as shown in Figure 3-17.

AD487

motor

3 Secure the motor using the bolts and washers removed earlier.

Figure 3-17: Rotate and Secure the Hydraulic Motor

4WD DYNO INSTALLATION

Hydraulic Movement Installation

WIRING THE HYDRAULIC MOTOR

A558D

wiring box cover

Verify the motor is wired for your needs. The motor is wired for 110V but can be changed to 220V.

1 Remove the wiring box cover. 2 Follow the instructions on the cover to wire the motor for 220v. Refer to the

Hydraulic Movement Wiring Diagram in Figure 3-19 on page 3-30.

Figure 3-18: Wiring the Hydraulic Motor

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-29

CHAPTER 3

Hydraulic Movement Installation

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

3-30

drum brake

from B.O.B.

BRN

T2T4T8

BRN

BLUE

110V

T2T3T5

BLUE

220V

hydraulic

motor

P/N 76950131

ground

BLK

P/N 76950135

GRN

WHT

P/N 76950136

GRN

BLU

BRN

relay

LOAD

rail brake

solenoid

P/N 76950130

RED

BLK

GRN

WHT

P/N 76950132

RED

BLK

GRN

WHT

in solenoid, hydraulic rear, A port

out solenoid, hydraulic front, B port

hydraulic

solenoid

BLK

YEL

WHT

BLK

RED

BLK

WHT

BLK

YEL

power supply

movement switch

rail brake

pressure switch

4WD movement board

AD507

wiring

cover

Figure 3-19: Hydraulic Movement Wiring Diagram

4WD DYNO INSTALLATION

Hydraulic Movement Installation

FILLING THE HYDRAULIC MOTOR WITH HYDRAULIC FLUID

AD488

remove the cap on the

hydraulic motor

1 Remove the cap on the hydraulic motor. 2 Add four quarts of AW-68 hydraulic fluid. 3 Replace the cap.

Figure 3-20: Fill the Hydraulic Motor with Oil

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-31

CHAPTER 3

Air Can Sleeve

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

3-32

AIR CAN SLEEVE

AD489

loosen nut

sleeve

shipped placement of

nut and sleeve

correct placement of

nut and sleeve

sleeve

nut

When you receive your dyno, the nut holding the air can sleeve will be tight. You will need to loosen the nut on all four air cans.

Using a wrench, loosen the nut as far as you can. The sleeve will drop down as shown in Figure 3-21.

Figure 3-21: Air Can Sleeve

4WD DYNO INSTALLATION

4WD Dyno Movement Test

4WD DYNO MOVEMENT TEST

Verify the movement of the 4WD dyno before installing the bridge. 1 Verify the hydraulic motor is filled with hydraulic fluid. Refer to “Filling the

Hydraulic Motor with Hydraulic Fluid” on page 3-31 for more information. 2 Turn the dyno electronics on. 3 Verify the dyno has 100-140 psi of compressed air. 4 Press the red button on the dyno pendant. The button should light up indicating

the brakes are activated. The red button will control the brakes on both dynos. 5 Verify the brakes are working properly by pressing the red button a few times to

cycle the brakes. 6 With the brakes on, press and hold the "in" button on the dyno movement

pendant. You should hear air venting, and the rail clamps releasing.

Note: The dyno brakes MUST be on or the 4WD dyno will not move.

Note: If the Linx is installed, the brake must be released.

7 Keep holding the "in" button down until you see the dyno begin to move. 8 Repeat this procedure holding the "out" button. 9 Remove the cap on the hydraulic motor and check the level of the oil. Add

additional oil if needed. Refer to “Filling the Hydraulic Motor with Hydraulic

Fluid” on page 3-31 for more information.

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-33

CHAPTER 3

Bridge Installation—Stationary Dyno

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

3-34

BRIDGE INSTALLATION—STATIONARY DYNO

Use the following instructions to install the drum guards, runner mounts and supports, runner assemblies, and the bridge cover.

You will need the following parts:

• 21214703 Runner Clamp Plate (2)

• 21214704 Runner Slide (2)

• 21216101 Drum Guard, Right

• 21216102 Drum Guard, Left

• 21216103 Drum Guard (2)

• 21219511 Stationary Cover

• 21514802 Runner Mount (z-shaped) (2)

• 36562070 Bolt, 1/4-20 x 1.25", Hex (16)

• 36580434 Bolt, 3/8-16 x 1/2", Button-Head, Flange, Allen (4)

• 36582034 Bolt, 3/8-16 x 1.25", Button-Head, Flange, Allen (8)

• 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (6)

• 36588071 Bolt, 3/8-16 x 5", Black Oxide (16)

• 36701100 Nut, 1/2-13, Hex (8)

• 36800000 Bolt, 1/2-13 3", Hex (8)

• 36912100 Washer, 1/4", Splitlock, Steel (16)

• 36923100 Washer, 3/8", Hardened, Flat, Steel (24)

• 36932100 Washer, 3/8", Splitlock, Steel (24)

• 36942100 Washer, 1/2", Splitlock, Steel (8)

• 37513200 Anchor, Redhead, 3/8" (4)

• 37518200 Redhead Anchor Installation Tool

• 61314500 Runner Support Assembly (4)

• 61319500 Runner Assembly (30)

• DM150-011-004 Nut, 3/8-16, Hex (16)

• DM150-011-006 Bolt, 3/8-16 x 1.25", Hex (8)

4WD DYNO INSTALLATION

Bridge Installation—Stationary Dyno

INSTALLING THE DRUM GUARDS

AD610

drum guard

closest to interface guide

drum guard

closest to air brake

left drum guard

right drum guard

1 Secure the left and right drum guards using one 3/8-16 x 1.25-inch button-head

flange bolt each. 2 Secure the drum guard (closest to the interface assembly) using five 3/8-16 x 1.25-

inch button-head flange bolts. 3 Loosely attach the drum guard (closest to the air brake) using the center 

3/8-16 x 1.25-inch button-head flange bolt only.

Figure 3-22: Install the Drum Guards

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-35

CHAPTER 3

Bridge Installation—Stationary Dyno

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

3-36

INSTALLING THE RUNNER MOUNTS AND RUNNER SUPPORTS

A611D

runner mount

assembly

runner clamp

runner mount

runner

support

runner support

pillar

runner support

assembly

drum guard

119.38cm

(47.00 in.)

inner holes on

runner support

outer holes on

runner support

Refer to Appendix D for bridge extension kit installation instructions.

1 Place the runner mount (z-shaped) with eight round holes on top of the drum

guard.

Note: The standard runner mount is smaller than the extended runner mount

used with the bridge extension kit. Be sure to use the correct runner mount for

your installation. 2 Place the runner clamp plate with eight round holes on top of the runner mount.

3 Loosely secure each runner mount and runner clamp to the dyno using three 

3/8 x 1.5-inch flange hex bolts. 4 Secure two runner support pillars to each runner support using two 

1/2 x 3-inch hex bolts, lock washers, and nuts per support pillar.

Note: Use the inner holes on the runner support closest to the outside of the

dynos. Use the outer holes on the runner support closest to the center of the

dynos. 5 Stand up the runner support assemblies and place approximately 119.38 cm 

(47.00 in.) from the stationary dyno.

Note: Do not secure the runner support to the floor at this time.

Figure 3-23: Install the Runner Mounts and Runner Supports

4WD DYNO INSTALLATION

Bridge Installation—Stationary Dyno

INSTALLING THE RUNNER ASSEMBLIES

A612

runner assembly

runner mount

runner

assembly

runner support

existing bolt on top

secure from underneath

(not visible from this view)

plastic end

runner slide

1 Place the plastic runner slide on top of the runner support. 2 Slide each runner assembly into the runner mount. Verify the plastic end faces

away from the stationary dyno. 3 Loosely secure each runner assembly to the runner mount using one 3/8 x 5-inch

bolt, flat washer, lock washer, and nut. These bolts will be tightened later. 4 Loosely secure each runner assembly to the runner support from underneath

using one 1/4 x 1.25-inch bolt and lock washer. These bolts will be tightened later.

Verify the existing bolt in each runner assembly is on top. There are sixteen

runner assemblies, eight with each runner mount.

Note: For clarity, only one runner assembly is shown.

Figure 3-24: Install the Runner Assemblies

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-37

CHAPTER 3

Bridge Installation—Stationary Dyno

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

3-38

5 Square up the runner assemblies.

AD613

edge of dyno

square ruler

runner assembly

support pillar

5a Place a square along the edge of the stationary dyno and along one of the

runner assemblies. Move the runner assemblies until they are square with

they dyno. 5b Tighten the bolts securing the runner assemblies to the runner mounts. 5c Tighten the bolts securing the runner mounts to the dyno.

6 Dynojet recommends you anchor the support pillars to the dyno room floor,

however this step is optional. 6a Using the support pillars as a template, mark and drill each hole needed to

secure the four pillars to the floor. 6b Install eight Red Head anchors. Refer to Appendix A for installation

instructions. 6c Secure each pillar to the floor using two 3/8-16 x 1.25-inch hex-head bolts,

two 3/8-inch lock washers, and two 3/8-inch flat washers.

Figure 3-25: Square up the Runner Assemblies

4WD DYNO INSTALLATION

Bridge Installation—Stationary Dyno

INSTALLING THE BRIDGE COVER

A614

center bolt

cover

support pillar

cover

1 Remove the center bolt from the rear drum guard. 2 Place the cover on the drum guard while supporting the other end of the cover. 3 Replace the center bolt. 4 Secure the cover to each runner support pillar using two 3/8-16 x 1/2-inch button-

head flange bolts. Installing the cover will square up the other set of runner assemblies.

5 Tighten all bolts.

Figure 3-26: Install the Center Cover

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-39

CHAPTER 3

Bridge Installation—4WD Dyno

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

3-40

BRIDGE INSTALLATION—4WD DYNO

This section will walk you through installing the drum guards, runner mounts, runner assemblies, cover, and runner tie straps.

You will need the following parts:

• 21214701 Runner Tie Strap (2)

• 21214702 Runner Clamp, Short (2)

• 21214705 Runner Tie Slide (2)

• 21216101 Drum Guard, Right

• 21216102 Drum Guard, Left

• 21216103 Drum Guard, Left/Right (2)

• 21219512 Moveable Cover

• 21514801 Runner Mount, Short (2)

• 36561045 Screw, 1/4-20 x 5/8", PH, Torx, Black (14)

• 36582034 Bolt, 3/8-16 x 1.25", Button-Head, Flange, Allen (4)

• 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (6)

• 36588071 Bolt, 3/8-16 x 5", Black Oxide (14)

• 36923100 Washer, 3/8", Hardened, Flat, Steel (14)

• 36932100 Washer, 3/8", Splitlock, Steel (14)

• 61319500 Runner Assembly (14)

• DM150-011-004 Nut, 3/8-16, Hex (14)

4WD DYNO INSTALLATION

Bridge Installation—4WD Dyno

INSTALLING THE DRUM GUARDS

A615D

drum guard

closest to bridge assembly

drum guard

closest to air brake

left drum guard

right drum guard

1 Secure the left and right drum guards using one 3/8-16 x 1.25-inch button-head

flange bolt each.

2 Loosely attach the drum guard (closest to the bridge assembly) using the center

3/8-16 x 1.25-inch button-head flange bolt only.

3 Loosely attach the drum guard (closest to the air brake) using the center 

3/8-16 x 1.25-inch button-head flange bolt only.

Figure 3-27: Install the Drum Guards

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-41

CHAPTER 3

Bridge Installation—4WD Dyno

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

3-42

INSTALLING THE RUNNER MOUNTS

A616D

runner clamp

runner mount

drum guard

The runner mounts and runner clamps are shorter for the moveable dyno. 1 Place the runner mount (z-shaped) with seven round holes on top of the drum

guard.

2 Place the runner clamp plate with seven round holes on top of the runner mount. 3 Loosely secure each runner mount and runner clamp to the dyno using three 

3/8 x 1.5-inch flange hex bolts.

Figure 3-28: Install the Runner Mounts

4WD DYNO INSTALLATION

Bridge Installation—4WD Dyno

INSTALLING THE RUNNER ASSEMBLIES

A617

runner mount

runner

assembly

leave inner bolt out

plastic end

1 Slide each runner assembly into the runner mount.Verify the plastic end faces

away from the 4WD dyno.

2 Loosely secure the six outside runner assemblies to the runner mount using one

3/8 x 5-inch bolt, flat washer, lock washer, and nut each. Note: Leave the seventh inner bolt out. This bolt will be used to secure the center

cover. Each runner assembly will lay on the runner supports between the stationary

dyno runner assemblies.

3 Verify the existing bolt in each runner assembly is on the bottom. There are

fourteen runner assemblies, seven on each runner mount.

Figure 3-29: Install the Runner Assemblies

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-43

CHAPTER 3

Bridge Installation—4WD Dyno

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

3-44

INSTALLING THE COVER AND RUNNER TIE STRAPS

A618

1/4 x 5/8-inch torx

head bolt

cover

reserved bolts

runner tie strap

runner tie slide

1 Secure the cover to the runner mounts using the two reserved bolts from earlier. 2 Secure the cover to the runner assemblies using two 1/4 x 5/8-inch torx head

bolts.

3 Secure one runner tie strap and one plastic runner tie slide to e ach set of moveable

runner assemblies using six 1/4 x 5/8-inch torx head bolts each.

Figure 3-30: Install the Cover and Runner Tie Straps

4WD DYNO INSTALLATION

Deck Installation

DECK INSTALLATION

Use the following instructions to install the deck.

Note: Refer to Appendix C for instructions on upgrading an existing deck.

You will need the following parts:

• 1011 Ground Hook/D-Ring (6)

• 10112 D-Ring Bracket, Surface Mount (6)

• 21214300 Center Panel

• 21214301 Outer Panel (2)

• 21610807 Support Angle (2)

• 21614102 Deck Brace Mount (2)

• 21619103 Tube

•21714200 Deck Brace (4)

• 35521420 Cap Plug (2)

• 36561045 Screw, 1/4-20 x 5/8", Pan-Head, Torx (12)

• 36488100 Nut, 3/8-16, Nylock (22)

• 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (30)

• 36584871 Bolt, 3/8-16 x 3", Flange-Hex (4)

• 36923100 Washer, 3/8", Hardened, Flat, Steel, (22)

• DM150-020-005 Nut, Crush, 1/4-20 (12)

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-45

CHAPTER 3

Deck Installation

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

3-46

1 Verify the drum guards are installed. Refer to page 3-41 for installation

A619

mounting bracket

instructions.

2 Verify the front and rear eddy current brake covers are installed. Refer to page 4-

16 for installation instructions.

3 Install the deck brace mounting bracket using two 3/8-16 x 1.5-inch flange hex

bolts. Note: If you do not have an eddy current brake, you will need to install one deck

mounting bracket on each side of the dyno.

Figure 3-31: Install the Deck Brace Mounting Bracket

4WD DYNO INSTALLATION

Deck Installation

4 Loosely install the inner deck braces to the dyno using two 3/8-16 x 1.5-inch

A620

mounting bracket

outer brace

inner brace

outer brace

right drum guard

left drum guard

flange hex bolts each.

5 Loosely install one outer deck brace to the eddy current brake using two

3/8-16 x 1.5-inch flange hex bolts, washers, and nuts.

6 Loosely install one outer deck brace to the mounting bracket using two

3/8-16 x 1.5-inch flange hex bolts, washers, and nuts. Note: If you do not have an eddy current brake, the outer deck brace will secure

to a mounting bracket.

7 Remove one 3/8-16 x 1.25-inch button-head flange bolt from the left and right

drum guards.

Figure 3-32: Install the Deck Braces

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-47

CHAPTER 3

Deck Installation

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

3-48

8 Install the outside panels.

A621

panel

tie-down

inside bolt

step 8c

outer brace

inner brace

reserved bolt

step 8a

8a Secure the panel to the dyno frame using the 3/8-16 x 1.5-inch button-head

flange bolt removed in step #7 and two additional 3/8-16 x 1.5-inch button-

head flange bolts. 8b Secure the three tie downs to the panel and to the deck braces using two 3/8-

16 x 1.5-inch flange hex bolts, two 3/8-inch washers, and two 3/8-inch

nylock nuts each.

Verify the panel is sandwiched between the tie-downs and the brace. 8c Secure the inside of the panel to the inner brace using one 3/8-16 x 1.5-inch

flange hex bolt, one 3/8-inch washer, and one 3/8-inch nylock nut. 8d Tighten the bolts securing the braces to the dyno frame.

Figure 3-33: Install the Outside Panels

4WD DYNO INSTALLATION

Deck Installation

9 Remove the center bolt from the drum guard.

A622

center panel

support

outer panel

center bolt

10 Secure the supports to the outer panels using three 1/4-20 x 5/8-inch screws and

crush nuts each.

11 Secure the center panel to each support using three 1/4-20 x 5/8-inch screws and

crush nuts each.

12 Secure center panel to dyno with the center bolt removed earlier.

Figure 3-34: Install the Center Panel

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-49

CHAPTER 3

Deck Installation

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

3-50

13 Install the tube to the outer panels and deck supports using four 

A 623

tube

plug

3/8-16 x 3-inch flange hex bolts, four 3/8-inch flat washers, and four 3/8-inch nylock nuts.

14 Install a plastic plug in each end of the tube.

Figure 3-35: Install the Tube

4WD DYNO INSTALLATION

Logo Panel Installation

LOGO PANEL INSTALLATION

A624D

lower mounting

bracket

If you did not install the eddy current brakes, you will install four logo panels, two on the stationary dyno and two on the 4WD dyno using the instructions in this section. If you installed the eddy current brakes, use the following instructions to install one logo panel on each dyno. Refer to “Installing the Top and Logo Panel Covers” on page 4-18 to install the logo panel covers on the eddy current brake.

You will need the following parts:

• 21200004 Mounting Bracket (4)

• 21200009 Lower Mounting Bracket (2)

• 36491100 Nut, 7/16-14, Hex, Grade-5 (4)

• 36561045 Screw, 1/4-20 x 5/8", Pan-Head, Torx (10)

• 36591670 Bolt, 7/16-14 x 1", Hex (4)

• 36933100 Washer, 7/16", Flat, Steel (4)

• 61100001 Logo Panel Assembly (2)

• DM150-011-002 Washer, 3/8", Flat (8)

• DM150-019-008 Bolt, 3/8-16 x 3/4", Hex (8)

Repeat the following steps for each logo panel being installed to the dyno. 1 Secure each lower mounting bracket to the dyno using two 7/16-14 x 1-inch hex

bolts, two 7/16-inch flat washers, and two 7/16-14 nuts.

Figure 3-36: Install the Lower Mounting Bracket

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-51

CHAPTER 3

Logo Panel Installation

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

3-52

2 Secure each mounting bracket to the dyno using two 3/8-16 x 3/4-inch hex bolts

A625D

mounting bracket

and two 3/8-inch flat washers. Use two mounting brackets per logo panel.

Figure 3-37: Install the Mounting Brackets

4WD DYNO INSTALLATION

Logo Panel Installation

3 Secure each logo panel to the mounting brackets using five 1/4-20 x 5/8-inch pan-

A 626D

logo panel

head torx screws.

Figure 3-38: Install the Logo Panel

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

3-53

CHAPTER 4

The eddy current brake along with the torque module, when added to Dynojet's market leading inertia dynamometer, results in a complete vehicle performance test.

This chapter provides instructions for installing the eddy current brake (retarder) to the stationary and 4WD dynos. This chapter also provides instructions for installing the torque module and load cell along with load cell calibration procedures. To ensure safety and accuracy in the procedures, perform the procedures as they are described.

This chapter is divided into the following categories:

• Eddy Current Brake Installation, page 4-2

• Load Cell Calibration, page 4-19

DDY

URRENT

RAKE INSTALLATION

Above Ground Model 424x/424xLC

Automotive Dynamometer Installation Guide

4-1

CHAPTER 4

Eddy Current Brake Installation

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

4-2

EDDY CURRENT BRAKE INSTALLATION

arrow on rotor

direction of

rotation

load cell

stationary dyno 4WD dyno

front of dyno

This section will walk you through removing the eddy current brake from the crate, installing the eddy current brake to the dyno, and installing the theta controller.

These instructions will show the stationary dyno, but the instructions are the same for both the stationary and 4WD dynos.

You will need to provide equipment capable of lifting the eddy current brake off the crate and into position in your dyno room. You will also need a pair of straps. Dynojet recommends using single loop style straps.

Refer to Appendix B for information on the power requirements for the eddy current brake.

BEFORE INSTALLING THE EDDY CURRENT BRAKE: VERIFY OPTIMAL BRAKE COOLING

Placing the eddy current brake on the left or right side of the dyno will determine the direction that it turns.

Note: The Linx system can only be installed on one side of the dyno. Refer to the Linx installation guide.

For optimal eddy current brake cooling, the brake should turn in the direction of the arrows on the rotor.

Note: The dyno will perform correctly in either direction, but cooling of the rotors may be less effective when turning in the direction opposite of the arrows.

The example below shows the brake turning in the direction of the arrows on the rotors.

Figure 4-1: Optimal Brake Cooling

EDDY CURRENT BRAKE INSTALLATION

Eddy Current Brake Installation

BEFORE INSTALLING THE EDDY CURRENT BRAKE: VERIFY MOUNTING HOLES

A 566

1.59 cm

(0.625 in.)

6.67 cm

(2.625 in.)

24.13 cm

(9.50 in.)

36.83 cm

(14.50 in.)

60.96 cm

(24.00 in.)

1.59 cm

(0.625 in.)

Dynos with the serial number 2240308 and lower will need to have mounting holes drilled into the dyno frame before installing the eddy current brake.

Using a 5/8-inch or 1/2-inch drill, mark and drill the four holes as shown in  Figure 4-2.

Figure 4-2: Eddy Current Brake Mounting Holes

Version 1 Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide

4-3

CHAPTER 4

Eddy Current Brake Installation

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

4-4

UNPACKING THE EDDY CURRENT BRAKE

1 Remove the top and sides of the crate. 2 Remove any hardware and parts boxes from the crate and verify the box contents.

part description part description

screw, 4-40 x 1/4", panhead, phil (4) P/N 1904004

calibration arm assembly P/N 61319002

bracket, eddy current brake driver (2) P/N 21200068

splined shaft P/N 22117130

bearing, flange P/N 32355056

weight, 25 lb. (4) P/N 35430899

screw, 8-32 x 3/8", phsems, phil (4) P/N 36540647

driveline assembly P/N 62240130

eddy current brake assembly P/N 62900000

eddy current brake driver P/N 66400012

cable, CAN control P/N 76950568

temperature sensor P/N 76950569

included in P/N 37700000

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

load cell assembly P/N 76950574

Dynojet 424xLC2 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

CONVENTIONS USED IN THIS MANUAL

TECHNICAL SUPPORT

Dynamometer Specifications and Requirements

CHASSIS SPECIFICATIONS

COMPRESSED AIR

COMPUTER SPECIFICATIONS

DRILL AND DRILL BIT REQUIREMENTS

ELECTRICAL REQUIREMENTS

ENVIRONMENTAL REQUIREMENTS

FIRE SUPPRESSION

FORKLIFT REQUIREMENTS

HYDRAULIC MOTOR

PHONE AND INTERNET ACCESS

TIE-DOWN STRAPS

Model 424 Stationary and 4WD Dynamometer

Model 424 4WD Dynamometer With Bridge and Deck

DynoWare RT Electronics

MAIN MODULE CONNECTIONS

NETWORK CONNECTIONS

Lift Specifications and Requirements

Unpacking and Inspecting the Dyno

Dyno Installation

REMOVING THE DYNO FROM THE CRATE

PLACING THE DYNO IN FRONT OF THE LIFT

INSTALLING THE INTERFACE GUIDE

ANCHORING THE DYNO

INSTALLING THE AIR FITTINGS

Eddy Current Brake Installation

Unpacking and Inspecting the Dyno

Track Assembly

INSTALLING THE TRACK ASSEMBLY

Dyno Installation

REMOVING THE DYNO FROM THE CRATE

PLACING THE DYNO ON THE TRACK

Eddy Current Brake Installation

Cable Routing

IDENTIFYING THE CABLES

ROUTING THE CABLES—WITHOUT THE EDDY CURRENT BRAKES

ROUTING THE CABLES—WITH ONE EDDY CURRENT BRAKE

ROUTING THE CABLES—WITH TWO EDDY CURRENT BRAKES

Hydraulic Movement Installation

ROTATING THE HYDRAULIC MOTOR

WIRING THE HYDRAULIC MOTOR

FILLING THE HYDRAULIC MOTOR WITH HYDRAULIC FLUID

Air Can Sleeve

4WD Dyno Movement Test

Bridge Installation—Stationary Dyno

INSTALLING THE DRUM GUARDS

INSTALLING THE RUNNER MOUNTS AND RUNNER SUPPORTS

INSTALLING THE RUNNER ASSEMBLIES

INSTALLING THE BRIDGE COVER

Bridge Installation—4WD Dyno

INSTALLING THE DRUM GUARDS

INSTALLING THE RUNNER MOUNTS

INSTALLING THE RUNNER ASSEMBLIES

INSTALLING THE COVER AND RUNNER TIE STRAPS

Deck Installation

Logo Panel Installation

Eddy Current Brake Installation

BEFORE INSTALLING THE EDDY CURRENT BRAKE: VERIFY OPTIMAL BRAKE COOLING

BEFORE INSTALLING THE EDDY CURRENT BRAKE: VERIFY MOUNTING HOLES

UNPACKING THE EDDY CURRENT BRAKE