Dynojet 424xLC2 Installation Guide
©2006-2014 Dynojet Research, Inc. All Rights Reserved.
#
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)
2
Automotive
Stationary Dynamometer Number: ______________________________________________
Eddy Current Brake
(Retarder) Number:____________________________________________________________
4WD Dynamometer Number: ___________________________________________________
Eddy Current Brake
(Retarder) Number:_________________________________________________________
T
ABLE OF
C
ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Chapter 1 Specifications and Operating Requirements
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
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
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TABLE OF CONTENTS
Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
ii
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
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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
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Automotive Dynamometer Installation Guide
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TABLE OF CONTENTS
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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
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Above Ground Model 424x/424xLC2 Automotive Dynamometer Installation Guide
W
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.
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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
2
Automotive Dynamometer Installation Guide
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CHAPTER 1
S
PECIFICATIONS AND
O
PERATING
R
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
2
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
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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
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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
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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
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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
1
2
1
2
12
Linx
!
C
Dynojet Research, Inc.
2191 Mendenhall Drive
N. Las Vegas, NV 89081
100-240 VAC
50-60 Hz
1.0 A
1
2
1234
Analog
Status
B
A
A
B
!
C
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
S
TATIONARY
D
YNO INSTALLATION
Above Ground Model 424x/424xLC
2
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
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