Dynojet 424 Installation Manual
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Dynojet 424 Installation Manual

Automotive dynamometers
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Summary of Contents for Dynojet 424

  • Page 2 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.

  • Page 3: Table Of Contents

    ......1-12 Model 424 4WD Dynamometer With Bridge and Deck ....1-13 DynoWare RT Electronics .
  • Page 4 TA B L E O F C O N T E N T S Chapter 3 4WD Dyno Installation Unpacking and Inspecting the Dyno ........3-2 Track Assembly .
  • Page 5 TA B L E O F C O N T E N T S Chapter 5 424 Linx Installation Linx Belt Drive Specifications ..........5-2 Unpacking the Linx Parts .
  • Page 6 TA B L E O F C O N T E N T S Chapter 7 Basic Dyno Operation Loading the Vehicle ........... . . 7-2 Connecting the RPM Pickup .
  • Page 7 TA B L E O F C O N T E N T S Appendix D Bridge Extension Assembly Bridge Extension Installation ..........D-2 Appendix E Interface Roller Assembly Installation Interface Roller Assembly Installation .

  • Page 9: Warnings

    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.
  • Page 10 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.
  • Page 11 W A R N I N G S Grounding Requirements Always ground the vehicle to the dynamometer. Never operate the dynamometer without properly grounding the vehicle to the dyno. 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.
  • Page 13 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.

  • Page 14: Introduction

    C H A P T E R 1 Introduction INTRODUCTION Before installing your dyno, please take a moment to read this guide for installation instructions, dyno features, and other important information. This guide is designed to be a reference tool in your everyday work and includes the following chapters and information: PECIFICATIONS AND PERATING...
  • Page 15 S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S Introduction NTERFACE OLLER SSEMBLY NSTALLATION This appendix describes the procedures for installing the interface roller assembly.

  • Page 16: File Menu

    Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081. Visit us on the World Wide Web at www.dynojet.com www.winpep.com where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product lines. Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 17: Dynamometer Specifications And Requirements

    S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S Dynamometer Specifications and Requirements DYNAMOMETER SPECIFICATIONS AND REQUIREMENTS 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.
  • Page 18 218.44 cm (86.00 in.) 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 Figure 1-1: Model 424 Stationary Dyno Dimensions Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...
  • Page 19 S P E C I F I C AT I O N S A N D O P E R AT I N G R E Q U I R E M E N T S Dynamometer Specifications and Requirements Figure 1-2: Model 424 4WD Dyno with Track Assembly Dimensions Version 3...
  • Page 20 C H A P T E R 1 Dynamometer Specifications and Requirements Figure 1-3: Model 424 4WD Dyno with Bridge and Deck Dimensions Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 21: Compressed Air

    • 1/4-inch NPT pipe thread compressed air connector • optional air regulator OMPUTER PECIFICATIONS You will need to provide a computer system to run the Power Core software. Refer to www.dynojet.com for the latest computer requirements. description minimum specifications recommended specifications...

  • Page 22: Electrical Requirements

    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.

  • Page 23: Grounding Requirements

    NTERNET CCESS Dynojet recommends you have a phone close to the dyno to call for assistance in an emergency. You may also wish to contact Dynojet to troubleshoot your dyno. Internet access on your computer is desirable for contacting Dynojet and downloading new information and updates.

  • Page 24: Model 424 Stationary And 4Wd Dynamometer

    Hydraulic Motor Track Assembly Air Brake A 601 Eddy Current Brake with stiffener plate and eddy current brake driver 4WD Dyno Cradle Assembly Figure 1-4: Model 424 Stationary and 4WD Dynamometer Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 1-12...

  • Page 25: Model 424 4Wd Dynamometer With Bridge And Deck

    Center Cover Stationary Dyno 4WD Dyno Bridge and Center Cover Linx Option 4WD Dyno Runner Support Tie-Down Pillar Deck Figure 1-5: Model 424 4WD Dynamometer with Bridge and Deck Version 3 Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 1-13...

  • Page 26: Dynoware Rt Electronics

    C H A P T E R 1 DynoWare RT Electronics DYNOWARE RT ELECTRONICS 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.

  • Page 27: Main Module Connections

    Connect to the drum 1 and Refer to Do not press this button unless drum 2 speed inputs and Instructions instructed to do so by a Dynojet digital brake outputs. Technician. This button may need to be pressed to update the device.

  • Page 28: Network Connections

    ETWORK ONNECTIONS The Dynojet DynoWare RT dyno electronics connects to your computer directly or over a Local Area Network. If you have an existing network, connect the 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.

  • Page 29: Lift Specifications And Requirements

    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.
  • Page 31 HAPTER TATIONARY NSTALLATION 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 •...

  • Page 32: Unpacking And Inspecting The Dyno

    UNPACKING AND INSPECTING THE DYNO When you receive your dyno, examine the exterior of the shipping container for any visible damage. If damage is detected at this stage, contact the shipper or Dynojet before proceeding with unpacking. Use the following steps to unload your dyno. You will need to provide equipment capable of lifting a minimum of 2,114 kg (4,660 lb.) to move the crated dyno into...
  • Page 33 S T AT I O N A R Y D Y N O I N S T A L L AT I O N Unpacking and Inspecting the Dyno part description part description runner tie slide (2) remote atmos assembly P/N 21214705 P/N 66400011 side deck...
  • Page 34 C H A P T E R 2 Unpacking and Inspecting the Dyno part description part description axle strap, 21" (4) bolt kit, 424 bridge P/N 30AS21 P/N 79110002 power cord, 125V, 10A bolt kit, 4WD above ground P/N 318110301 P/N 79110004 bolt, 3/8-16 x 1.5", flange,...
  • Page 35 S T AT I O N A R Y D Y N O I N S T A L L AT I O N Unpacking and Inspecting the Dyno part description part description The following parts are included in the Above Ground Kit P/N 78112001: ground hook/D-ring (6) ...
  • Page 36 C H A P T E R 2 Unpacking and Inspecting the Dyno part description part description support angel, deck (2) interface guide assembly P/N 21610807 P/N 71300000 brace mount, deck (2) P/N bolt kit, 224-2 above ground 21614102 P/N 79110003 deck tube...

  • Page 37: Dyno Installation

    (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 1-10.
  • Page 38 C H A P T E R 2 Dyno Installation With the dyno on the forklift, secure the four feet to the bottom of the dyno using the four 3/8 x 1.5-inch flange bolts removed earlier. Note: If the feet are already installed, skip this step. feet AD540 Figure 2-2: Install the Feet...

  • Page 39: Placing The Dyno In Front Of The Lift

    S T AT I O N A R Y D Y N O I N S T A L L AT I O N Dyno Installation LACING THE YNO IN RONT OF THE Verify the interface bracket faces the lift as shown in Figure 2-3. Verify the lift is in the down position.

  • Page 40: Installing The Interface Guide

    C H A P T E R 2 Dyno Installation NSTALLING THE NTERFACE UIDE 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 You will need the following parts:...
  • Page 41 S T AT I O N A R Y D Y N O I N S T A L L AT I O N Dyno Installation Align the interface guide pin on the lift cross member with the interface bracket on the dyno.
  • Page 42 C H A P T E R 2 Dyno Installation Verify the interface guide clears the interface bracket by 1/8-inch to 1/4-inch as shown in Figure 2-6. 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.

  • Page 43: Anchoring The Dyno

    S T AT I O N A R Y D Y N O I N S T A L L AT I O N Dyno Installation NCHORING THE 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: •...

  • Page 44: Installing The Air Fittings

    C H A P T E R 2 Dyno Installation NSTALLING THE ITTINGS 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: •...

  • Page 45: Eddy Current Brake Installation

    S T AT I O N A R Y D Y N O I N S T A L L AT I O N Eddy Current Brake Installation EDDY CURRENT BRAKE INSTALLATION Refer to Chapter 4 for eddy current brake installation instructions and install your eddy current brake at this time.
  • Page 47 HAPTER 4WD D NSTALLATION 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 •...

  • Page 48: Unpacking And Inspecting The Dyno

    UNPACKING AND INSPECTING THE DYNO When you receive your dyno, examine the exterior of the shipping container for any visible damage. If damage is detected at this stage, contact the shipper or Dynojet before proceeding with unpacking. Use the following steps to unload your dyno. You will need to provide equipment capable of lifting a minimum of 2,495 kg (5,500 lb.) to move the crated dyno into...
  • Page 49 4 W D D Y N O I N S T A L L AT I O N Unpacking and Inspecting the Dyno part description part description spacer, 424 hydraulic rail tie assembly (2) movement (2) P/N 61314300 P/N 26100000 spacer, rail clamp (8)...
  • Page 50 C H A P T E R 3 Unpacking and Inspecting the Dyno Remove the crate braces that support the top portion of the crate. 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.

  • Page 51: Track Assembly

    4 W D D Y N O I N S T A L L AT I O N 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.
  • Page 52 153.67 cm stationary dyno and (60.50 in.) track assembly with extension (requires extension parts, inquire with Dynojet sales) 184.15 cm (72.5 in.) track layout first rail tie assembly 49.37 cm (19.438 in.) first rail tie 103.82 cm (40.875 in.)

  • Page 53: Installing The Track Assembly

    4 W D D Y N O I N S T A L L AT I O N Track Assembly NSTALLING THE RACK SSEMBLY Once all the holes are marked and drilled, install the track assembly. You will need the following parts: •...
  • Page 54 C H A P T E R 3 Track Assembly Loosely install the ten rail tie clips using one 3/8-16 x 1.5-inch flange-hex bolt per clip. There are five rail tie clips on each side of the track assembly. Verify the track assembly is square and make any necessary adjustments. Tighten all ten bolts.

  • Page 55: Dyno Installation

    (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.

  • Page 56: Placing The Dyno On The Track

    C H A P T E R 3 Dyno Installation LACING THE YNO ON THE RACK 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) •...
  • Page 57 4 W D D Y N O I N S T A L L AT I O N Dyno Installation Secure the rail clamps to the cradle assembly on the dyno using two 3/8-inch shoulder bolts and two spacers each. Replace the pins and cotter pins removed earlier from the four cradle assemblies as shown in Figure 3-5.

  • Page 58: Eddy Current Brake Installation

    C H A P T E R 3 Eddy Current Brake Installation EDDY CURRENT BRAKE INSTALLATION Refer to Chapter 4 for eddy current brake installation instructions and install your eddy current brake at this time. AD606 Figure 3-7: Eddy Current Brake Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-12...

  • Page 59: Cable Routing

    4 W D D Y N O I N S T A L L AT I O N Cable Routing CABLE ROUTING Use the following instructions to identify and route the cables for dynos with and without eddy current brakes. •...
  • Page 60 C H A P T E R 3 Cable Routing cable brief routing description J - 76950311 power cable connects the eddy current brake driver to a power outlet K - 76950547 speed pick up/brake cable connects the brake solenoid and speed pick up to the DynoWare RT L - 76950569 IR temp sensor cable connects the temp sensor to the eddy current brake...
  • Page 61 4 W D D Y N O I N S T A L L AT I O N Cable Routing cable brief routing description R - 76950807 CAN control cable, adapter, 2' connects the DynoWare RT to the CAN control and CAN dyno user cables S - 76952008 4WD power supply with cable connects the 4WD board to the 4WD power cable (B)
  • Page 62 C H A P T E R 3 Cable Routing Place the pickup/brake cable (K), the Linx detect sensor cable (N), and the air hose (W) in the second cable track. Note: Keep the power cables in a separate cable track from the signal cables. Note: The Linx system is an optional accessory.
  • Page 63 4 W D D Y N O I N S T A L L AT I O N Cable Routing 14 Attach the CAN adapter cable (R) to the back of the DynoWare RT main module. 15 Attach the CAN dyno user cable (Q) to the CAN adapter cable (R) and route to the AFR assembly.
  • Page 64 C H A P T E R 3 Cable Routing Figure 3-10: Routing the Cables—Without the Eddy Current Brakes Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-18...
  • Page 65 4 W D D Y N O I N S T A L L AT I O N Cable Routing —W OUTING THE ABLES URRENT RAKE Use the following instructions along with Figure 3-13 on page 3-22 for routing cables with one eddy current brake.
  • Page 66 C H A P T E R 3 Cable Routing Route the air hose (V) from the 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.
  • Page 67 4 W D D Y N O I N S T A L L AT I O N Cable Routing 18 Attach the CAN adapter cable (R) to the back of the DynoWare RT main module. 19 Attach the CAN dyno user cable (Q) to the CAN adapter cable (R) and route to the AFR assembly.
  • Page 68 C H A P T E R 3 Cable Routing Figure 3-13: Routing the Cables—With One Eddy Current Brake Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-22...
  • Page 69 4 W D D Y N O I N S T A L L AT I O N Cable Routing —W OUTING THE ABLES URRENT RAKES Use the following instructions along with Figure 3-16 on page 3-26 for routing cables with two eddy current brakes.
  • Page 70 C H A P T E R 3 Cable Routing Attach the CAN adapter cable (R) to the back of the DynoWare RT main module. 10 Attach the CAN dyno user cable (Q) to the CAN adapter cable (R) and route to the AFR assembly.
  • Page 71 4 W D D Y N O I N S T A L L AT I O N Cable Routing 17 Route the hydraulic pump power cable (H) from the first cable track and connect to a 110VAC or 220VAC outlet. The pump motor is wired for 110VAC, refer to Figure 3-24 on page 3-34 for more information on wiring the hydraulic pump motor.
  • Page 72 C H A P T E R 3 Cable Routing Figure 3-16: Routing Cables—With Two Eddy Current Brakes Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-26...

  • Page 73: Hydraulic Movement Installation

    HYDRAULIC MOVEMENT INSTALLATION 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) •...
  • Page 74 C H A P T E R 3 Hydraulic Movement Installation Secure the hydraulic ram to the dyno cylinder mount using one clevis pin and hairpin cotter. AD343 dyno cylinder mount hydraulic ram clevis pin hairpin cotter Figure 3-18: Secure the Hydraulic Ram to the Dyno Cylinder Mount Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-28...
  • Page 75 4 W D D Y N O I N S T A L L AT I O N Hydraulic Movement Installation Temporarily hold the floor cylinder mount to the hydraulic ram using two spacers and one clevis pin. spacers AD485 clevis pin floor cylinder mount...
  • Page 76 C H A P T E R 3 Hydraulic Movement Installation Using the floor cylinder mount as a template, mark each hole needed to secure the mount to the floor. Remove the clevis pin, spacers, and floor cylinder mount. Move the hydraulic ram out of the way. Drill the holes marked in step #4.

  • Page 77: Rotating The Hydraulic Motor

    4 W D D Y N O I N S T A L L AT I O N Hydraulic Movement Installation OTATING THE YDRAULIC OTOR 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”...
  • Page 78 C H A P T E R 3 Hydraulic Movement Installation Rotate the motor as shown in Figure 3-22. Secure the motor using the bolts and washers removed earlier. motor AD487 Figure 3-22: Rotate and Secure the Hydraulic Motor Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-32...

  • Page 79: Wiring The Hydraulic Motor

    4 W D D Y N O I N S T A L L AT I O N Hydraulic Movement Installation IRING THE YDRAULIC OTOR Verify the motor is wired for your needs. The motor is wired for 110V but can be changed to 220V.
  • Page 80 C H A P T E R 3 Hydraulic Movement Installation Figure 3-24: Hydraulic Movement Wiring Diagram Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-34...

  • Page 81: Filling The Hydraulic Motor With Hydraulic Fluid

    4 W D D Y N O I N S T A L L AT I O N Hydraulic Movement Installation ILLING THE YDRAULIC OTOR WITH YDRAULIC LUID Remove the cap on the hydraulic motor. Add four quarts of AW-68 hydraulic fluid. Replace the cap.

  • Page 82: Air Can Sleeve

    C H A P T E R 3 Air Can Sleeve AIR CAN SLEEVE 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.

  • Page 83: 4Wd Dyno Movement Test

    4 W D D Y N O I N S T A L L AT I O N 4WD Dyno Movement Test 4WD DYNO MOVEMENT TEST Verify the movement of the 4WD dyno before installing the bridge. Verify the hydraulic motor is filled with hydraulic fluid. Refer to “Filling the Hydraulic Motor with Hydraulic Fluid”...

  • Page 84: Bridge Installation-Stationary Dyno

    C H A P T E R 3 Bridge Installation—Stationary Dyno 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) •...
  • Page 85 4 W D D Y N O I N S T A L L AT I O N Bridge Installation—Stationary Dyno NSTALLING THE UARDS Secure the left and right drum guards using one 3/8-16 x 1.25-inch button-head flange bolt each. Secure the drum guard (closest to the interface assembly) using five 3/8-16 x 1.25- inch button-head flange bolts.
  • Page 86 C H A P T E R 3 Bridge Installation—Stationary Dyno NSTALLING THE UNNER OUNTS AND UNNER UPPORTS Refer to Appendix D for bridge extension kit installation instructions. Place the runner mount (z-shaped) with eight round holes on top of the drum guard.
  • Page 87 4 W D D Y N O I N S T A L L AT I O N Bridge Installation—Stationary Dyno NSTALLING THE UNNER SSEMBLIES Place the plastic runner slide on top of the runner support. Slide each runner assembly into the runner mount. Verify the plastic end faces away from the stationary dyno.
  • Page 88 Tighten the bolts securing the runner assemblies to the runner mounts. Tighten the bolts securing the runner mounts to the dyno. Dynojet recommends you anchor the support pillars to the dyno room floor, however this step is optional. Using the support pillars as a template, mark and drill each hole needed to secure the four pillars to the floor.
  • Page 89 4 W D D Y N O I N S T A L L AT I O N Bridge Installation—Stationary Dyno NSTALLING THE RIDGE OVER Remove the center bolt from the rear drum guard. Place the cover on the drum guard while supporting the other end of the cover. Replace the center bolt.
  • Page 90 C H A P T E R 3 Bridge Installation—4WD Dyno 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) •...

  • Page 91: Installing The Drum Guards

    4 W D D Y N O I N S T A L L AT I O N Bridge Installation—4WD Dyno NSTALLING THE UARDS Secure the left and right drum guards using one 3/8-16 x 1.25-inch button-head flange bolt each. 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.
  • Page 92 C H A P T E R 3 Bridge Installation—4WD Dyno NSTALLING THE UNNER OUNTS The runner mounts and runner clamps are shorter for the moveable dyno. Place the runner mount (z-shaped) with seven round holes on top of the drum guard.

  • Page 93: Installing The Runner Assemblies

    4 W D D Y N O I N S T A L L AT I O N Bridge Installation—4WD Dyno NSTALLING THE UNNER SSEMBLIES Slide each runner assembly into the runner mount.Verify the plastic end faces away from the 4WD dyno. 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.

  • Page 94: Installing The Cover And Runner Tie Straps

    C H A P T E R 3 Bridge Installation—4WD Dyno NSTALLING THE OVER AND UNNER TRAPS Secure the cover to the runner mounts using the two reserved bolts from earlier. Secure the cover to the runner assemblies using two 1/4 x 5/8-inch torx head bolts.

  • Page 95: Linx Installation

    4 W D D Y N O I N S T A L L AT I O N Linx Installation LINX INSTALLATION Refer to Chapter 5 for Linx installation instructions and install your Linx at this time. Figure 3-36: Linx System Version 3 Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 96: Deck Installation

    C H A P T E R 3 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) •...
  • Page 97 4 W D D Y N O I N S T A L L AT I O N Deck Installation Verify the drum guards are installed. Refer to page 3-45 for installation instructions. Verify the front and rear eddy current brake covers are installed. Refer to page 4- 16 for installation instructions.
  • Page 98 C H A P T E R 3 Deck Installation Loosely install the inner deck braces to the dyno using two 3/8-16 x 1.5-inch flange hex bolts each. 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.
  • Page 99 4 W D D Y N O I N S T A L L AT I O N Deck Installation Install the outside panels. 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.
  • Page 100 C H A P T E R 3 Deck Installation Remove the center bolt from the drum guard. 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.
  • Page 101 4 W D D Y N O I N S T A L L AT I O N Deck Installation 13 Install the tube to the outer panels and deck supports using four  3/8-16 x 3-inch flange hex bolts, four 3/8-inch flat washers, and four 3/8-inch nylock nuts.

  • Page 102: Logo Panel Installation

    C H A P T E R 3 Logo Panel Installation LOGO PANEL INSTALLATION 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.
  • Page 103 4 W D D Y N O I N S T A L L AT I O N Logo Panel Installation Secure each mounting bracket to the dyno using two 3/8-16 x 3/4-inch hex bolts and two 3/8-inch flat washers. Use two mounting brackets per logo panel.
  • Page 104 C H A P T E R 3 Logo Panel Installation Secure each logo panel to the mounting brackets using five 1/4-20 x 5/8-inch pan- head torx screws. A 626 logo panel Figure 3-44: Install the Logo Panel Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 3-58...

  • Page 105: Chapter 4 Eddy Current Brake Installation

    URRENT RAKE NSTALLATION 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.

  • Page 106: Eddy Current Brake Installation

    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.
  • Page 107 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation EFORE NSTALLING THE URRENT RAKE ERIFY OUNTING OLES 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.

  • Page 108: Unpacking The Eddy Current Brake

    C H A P T E R 4 Eddy Current Brake Installation NPACKING THE URRENT RAKE Remove the top and sides of the crate. Remove any hardware and parts boxes from the crate and verify the box contents. part description part description screw, 4-40 x 1/4", pan-...
  • Page 109 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation part description part description bolt, 1/2-13 x 1.5", flange cable, CAN control, 15'...
  • Page 110 C H A P T E R 4 Eddy Current Brake Installation Remove the uprights and cross members from the crate. crate top uprights and cross members remove boxes Figure 4-3: Remove the Crate Top Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...
  • Page 111 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation Remove the four screws securing the small top cover to the brake. Set the screws and the cover aside.
  • Page 112 C H A P T E R 4 Eddy Current Brake Installation Remove the five screws and nuts securing the front and rear covers. Set the screws, nuts, and covers aside. RECORD Be sure you record the dynamometer and/or eddy current brake number on the inside cover of this manual.
  • Page 113 Remove the four lag bolts securing the brake to the crate. Place the nylon loop strap around the shaft on either side of the brake. Dynojet recommends using single loop style straps. 10 Using a forklift, lift the eddy current brake from the crate and place the brake near the dyno.

  • Page 114: Installing The Temperature Sensor

    C H A P T E R 4 Eddy Current Brake Installation NSTALLING THE EMPERATURE ENSOR Use the following instructions to secure the temperature sensor to the eddy current brake in the location shown. You will need the following part: •...
  • Page 115 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation NSTALLING THE EARING PLINED HAFT RIVELINE SSEMBLY The eddy current brake can be installed on either side of your dyno, the installation instructions are the same.
  • Page 116 C H A P T E R 4 Eddy Current Brake Installation Insert the splined shaft through the bearing and into the spline hub of drum. Note: Make sure the short splined end faces out. Push the splined shaft in until the shoulder is flush with the bearing. Torque the bearing mounting bolts to 57 foot-pounds.
  • Page 117 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation NSTALLING THE URRENT RAKE You will need the following parts: •...
  • Page 118 C H A P T E R 4 Eddy Current Brake Installation Secure the side of the brake frame to the dyno using eight 3/8-16 x 1-inch hex bolts and eight 3/8-inch hardened flat washers. Not all of the bolts and washers are visible from this view.

  • Page 119: Installing The Load Cell

    E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation NSTALLING THE You will need the following part: • 76950574 Load Cell Assembly Verify the main dyno power is disconnected.

  • Page 120: Installing The Front And Rear Brake Covers And Eddy Current Brake Driver

    C H A P T E R 4 Eddy Current Brake Installation NSTALLING THE RONT AND RAKE OVERS AND URRENT RAKE RIVER You will need the following part: • 21200068 Bracket, Eddy Current Brake Driver (2) • 36500029 Screw, 4-40 x 1/4", Ph-Phil (4) •...
  • Page 121 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Eddy Current Brake Installation Secure the mounting brackets to the eddy current brake driver using two  4-40 x 1/4-inch screws each.

  • Page 122: Installing The Top And Logo Panel Covers

    C H A P T E R 4 Eddy Current Brake Installation NSTALLING THE OP AND ANEL OVERS Note: Before installing the top and logo panel side covers, verify all cables have been routed and you have completed the 4WD dyno installation. Refer to “Cable Routing”...

  • Page 123: Load Cell Calibration

    Verify you are connected to the dyno electronics. Note: For more information on connecting to the dyno electronics, refer to the Power Core Quick Start Guide (on your Power Core CD or at www.dynojet.com) or the Power Core Online Help.
  • Page 124 Note: Dynojet recommends you secure the calibration arm using the bolt pattern closest to the end of the arm unless space constraints in your dyno room do not allow you to.
  • Page 125 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Load Cell Calibration Place the weights towards the rear of the vehicle. Note: Calibration arm placement determines positive direction for torque. Place the weights towards the rear of the vehicle.
  • Page 126 C H A P T E R 4 Load Cell Calibration Install the calibration arm and weights using the bolts at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm.
  • Page 127 E D D Y C U R R E N T B R A K E I N S T A L L AT I O N Load Cell Calibration If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in ...
  • Page 128 C H A P T E R 4 Load Cell Calibration 11 Once sending the torque cell calibration is complete, click Next to continue. Figure 4-25: Calibration Is Complete Window 12 Remove the calibration arm and weights and click Finish. Figure 4-26: Calibration Is Complete Window Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 129: Linx Installation

    The Linx belt drive system synchronizes the speed of the front and rear drums for testing sensitive all-wheel drive and two-wheel drive vehicles with traction control. This chapter provides instructions for installing the Linx system on your model 424 automotive dyno. To ensure safety and accuracy in the procedures, perform the procedures as they are described.

  • Page 130: Linx Belt Drive Specifications

    C H A P T E R 5 Linx Belt Drive Specifications LINX BELT DRIVE SPECIFICATIONS The following specifications specific to the Linx belt drive dyno application will help you set up your dyno area and verify you have met the requirements necessary to operate your dyno safely.

  • Page 131: Unpacking The Linx Parts

    4 2 4 L I N X I N S T A L L AT I O N Unpacking the Linx Parts UNPACKING THE LINX PARTS Use the following steps to unload your Linx system parts. Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the top and sides of the crate.
  • Page 132 C H A P T E R 5 Unpacking the Linx Parts part description part description screw, 1/4-20 x 1.75",  lower moveable pulley shcs, drilled (4) mount P/N 36500016 P/N 61300026 stamped 4 screw, 1/4-20 x 1.25",  inner moveable dyno shcs, drilled (4)...
  • Page 133 4 2 4 L I N X I N S T A L L AT I O N Unpacking the Linx Parts part description part description washer, 9/16", flat (24) nut, 3/8-16, hex (2) P/N 36943101 P/N DM150-011-004 anchor, red head, 3/8" (10) bolt, 3/8-16 x 1.25", hex (4)...
  • Page 134 C H A P T E R 5 Unpacking the Linx Parts part description part description The following parts are included in the Linx Belt Covers, Above Ground P/N 61300069: door magnet, 2 x 1" (4) belt cover right support P/N 11700001 P/N 21600082 letter O...

  • Page 135: Inner Mounting Plate Installation

    4 2 4 L I N X I N S T A L L AT I O N Inner Mounting Plate Installation INNER MOUNTING PLATE INSTALLATION Use the following instructions to install the moveable dyno and stationary dyno inner mounting plates. You will need the following parts: •...
  • Page 136 C H A P T E R 5 Inner Mounting Plate Installation Using the access holes, secure the bottom of the inner mounting plate to the moveable dyno using two 3/8-16 x 1.5-inch flange bolts, two 3/8-inch flat washers, and two 3/8-inch nuts. access hole XD007 Figure 5-3: Secure the Bottom of the Inner Mounting Plate to the Moveable Dyno...
  • Page 137 4 2 4 L I N X I N S T A L L AT I O N Inner Mounting Plate Installation —S NSTALLING THE NNER OUNTING LATE TATIONARY Secure the inner mounting plate to the stationary dyno using eight 3/8 x 1-inch bolts and eight 3/8-inch flat washers.

  • Page 138: Flange Bearing, Outer Shaft, And Splined Shaft Installation

    C H A P T E R 5 Flange Bearing, Outer Shaft, and Splined Shaft Installation FLANGE BEARING, OUTER SHAFT, AND SPLINED SHAFT INSTALLATION Use the following instructions to install the flange bearing, splined shaft, and outer shaft on both the moveable and stationary dynos. You will need the following parts: •...
  • Page 139 4 2 4 L I N X I N S T A L L AT I O N Flange Bearing, Outer Shaft, and Splined Shaft Installation Apply a small amount of grease to the first two inches of the splined shaft. Slide the splined shaft through the outer shaft and into the splines in the dyno drum.

  • Page 140: Drive Pulley Installation

    C H A P T E R 5 Drive Pulley Installation DRIVE PULLEY INSTALLATION Use the following instructions to install the drive pulleys for both the moveable and stationary dynos. You will need the following parts: • 32300002 Bushing (2) includes three bolts and lock washers each •...
  • Page 141 4 2 4 L I N X I N S T A L L AT I O N Drive Pulley Installation The outer face of the pulley should be approximately 27.5 cm (10-13/16 in.) from the face of the inner plate. Slowly tighten the bolts until the hub starts to pull into the pulley, checking that it is approximately 27.5 cm (10-13/16 in.) from the inner plate before the pulley is locked on the shaft.

  • Page 142: Idler Pulley Assembly Installation

    C H A P T E R 5 Idler Pulley Assembly Installation IDLER PULLEY ASSEMBLY INSTALLATION You will need the following parts: • 32300001 Flange Bearing with Lock Collar • 36711100 Nut, 9/16-12, Hex (4) • 36943101 Washer, 9/16", Flat (4) •...

  • Page 143: Belt And Tensioner Pulley Assembly Installation

    4 2 4 L I N X I N S T A L L AT I O N Belt and Tensioner Pulley Assembly Installation BELT AND TENSIONER PULLEY ASSEMBLY INSTALLATION You will need the following parts: • 36923100 Washer, 3/8", Flat (8) •...
  • Page 144 C H A P T E R 5 Belt and Tensioner Pulley Assembly Installation XD104 tensioner pulley towards stationary dyno extended wheelbase option 12.7 cm (5.0 in.) apply grease to ACME threads standard wheelbase 10.2 cm (4.0 in.) welded nuts towards back Figure 5-12: Install the Belt and Tensioner Pulley Assembly Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 145: Pulley Mounting Plates And Outer Bearings Installation

    4 2 4 L I N X I N S T A L L AT I O N Pulley Mounting Plates and Outer Bearings Installation PULLEY MOUNTING PLATES AND OUTER BEARINGS INSTALLATION Note: The inner pulley mounting plates and the pulley mounts are stamped with numbers to help match the parts and guide you in the installation process.
  • Page 146 C H A P T E R 5 Pulley Mounting Plates and Outer Bearings Installation NSTALLING THE DLER ULLEY UTER EARING EARING OUNTING LATE ETECT ENSOR OWER ULLEY OUNT Secure the Linx detect sensor to the mounting plate using two #8-32 screws. Loosely secure the Linx detect sensor and mounting plate assembly to the mounting bracket using two #8-32 screws.
  • Page 147 4 2 4 L I N X I N S T A L L AT I O N Pulley Mounting Plates and Outer Bearings Installation Secure the Linx detect sensor tab to the pickup collar using one #8-32 screw. Note: Verify the tab is positioned perpendicular to the pickup collar as shown in Figure 5-15.
  • Page 148 C H A P T E R 5 Pulley Mounting Plates and Outer Bearings Installation 11 Tighten all the bolts. idler bearing plate pulley mount P/N 61300023 stamped 2 Figure 5-16: Install the Pulley Mount Under the Idler Pulley 12 With the mounting bracket screws loose, slide the mounting plate and sensor until the Linx detect sensor tab is centered in the sensor window.
  • Page 149 4 2 4 L I N X I N S T A L L AT I O N Pulley Mounting Plates and Outer Bearings Installation NSTALLING THE OVEABLE ULLEY UTER EARING EARING OUNTING LATE OWER ULLEY OUNT Secure the outer moveable dyno pulley bearing to the moveable dyno pulley bearing plate using four 9/16-12 x 2-inch bolts, four 9/16-inch flat washers, and four 9/16-inch nuts.
  • Page 150 C H A P T E R 5 Pulley Mounting Plates and Outer Bearings Installation NSTALLING THE PPER OVEABLE YNO AND DLER ULLEY OUNTS Place a lower stationary dyno pulley mount (P/N 61300023, stamped 2) over the moveable dyno pulley and loosely secure the mount to the inner plate using  five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers (one of the holes in the pulley mount is not used).
  • Page 151 4 2 4 L I N X I N S T A L L AT I O N Pulley Mounting Plates and Outer Bearings Installation Place the upper moveable dyno pulley mount (P/N 61300025, stamped 3) over the idler pulley and loosely secure the mount to the inner plate using five  3/8-16 x 1-inch bolts and five 3/8-inch flat washers.
  • Page 152 C H A P T E R 5 Pulley Mounting Plates and Outer Bearings Installation Remove the 1/4-20 x 1.75-inch cap screws from the splined shaft. Verify the splined shaft will slide in and out of the dyno splines easily once all the bolts are tightened.
  • Page 153 4 2 4 L I N X I N S T A L L AT I O N Pulley Mounting Plates and Outer Bearings Installation NSTALLING THE TATIONARY ULLEY UTER EARING EARING OUNTING LATE OWER ULLEY OUNT Secure the outer stationary dyno pulley bearing to the stationary dyno pulley bearing plate using four 9/16-12 x 2-inch bolts, four 9/16-inch flat washers, and ...
  • Page 154 C H A P T E R 5 Pulley Mounting Plates and Outer Bearings Installation NSTALLING THE PPER TATIONARY ULLEY OUNT Place the upper stationary dyno pulley mount (P/N 61300022, stamped 1) over the stationary dyno pulley and loosely secure the mount to the inner plate using  five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers (one of the holes on the pulley mount is not used).
  • Page 155 4 2 4 L I N X I N S T A L L AT I O N Pulley Mounting Plates and Outer Bearings Installation Remove the 1/4-20 x 1.75-inch cap screws from the splined shaft. Verify the splined shaft will slide in and out of the dyno splines easily once all the bolts are tightened.

  • Page 156: Routing The Linx Detect Sensor Cable

    C H A P T E R 5 Routing the Linx Detect Sensor Cable ROUTING THE LINX DETECT SENSOR CABLE Use the following instructions to route the Linx detect sensor cable to the  DynoWare RT module. You will need the following parts: •...
  • Page 157 4 2 4 L I N X I N S T A L L AT I O N Routing the Linx Detect Sensor Cable Remove the two screws and washers securing the cable track (containing the signal cables) to the front rail tie assembly. Pull the cable track out from under the dyno.

  • Page 158: Brake Signal Relay Installation

    C H A P T E R 5 Brake Signal Relay Installation BRAKE SIGNAL RELAY INSTALLATION Use the following instructions along with Figure 5-29 on page 5-31 if you are upgrading an existing dyno. If you are installing a new dyno, skip these instructions and continue with “Tension the Belt”...
  • Page 159 4 2 4 L I N X I N S T A L L AT I O N Brake Signal Relay Installation secure relay to 4WD board using existing nut drum brake to main box GR N WH T power supply movement switch rail brake pressure switch WH T...

  • Page 160: Tension The Belt

    C H A P T E R 5 Tension the Belt TENSION THE BELT You will need the following part: • 62100003 Tension Arm Assembly Use the following instructions along with Figure 5-30 on page 5-33. Verify the drum brakes are released. The dyno wheel base should only be adjusted with the brakes released or the Linx belt drive system disengaged.
  • Page 161 4 2 4 L I N X I N S T A L L AT I O N Tension the Belt mark 50.50 in. from center of drum angle on underside of bridge tube weights tension arm lock nuts XD088 ACME screws Figure 5-30: Tension the Belt Version 3...

  • Page 162: Above Ground Covers

    C H A P T E R 5 Above Ground Covers ABOVE GROUND COVERS You will need the following parts: • 11700001 Door Magnet (4) • 21200103 Letter O • 21200187 End Panel (2) • 21200188 Lid Assembly (2) • 21600076 Center Leg (2) •...
  • Page 163 4 2 4 L I N X I N S T A L L AT I O N Above Ground Covers Secure the belt cover center support to the right cover assembly using three  1/4-20 x 5/8-inch torx screws, three 1/4-inch flat washers, and three 1/4-20 nuts. Secure the belt cover right support to the right cover assembly using one ...
  • Page 164 C H A P T E R 5 Above Ground Covers Remove the 1/4-20 x 5/8-inch torx screw from the outer most tube of the dyno bridge as shown in Figure 5-33. Remove the screw from the drum guard on the stationary dyno as shown  in Figure 5-33.

  • Page 165: Installing The Left Cover Assembly

    4 2 4 L I N X I N S T A L L AT I O N Above Ground Covers NSTALLING THE OVER SSEMBLY Use the following instructions to assemble and install the left Linx cover assembly. Place two braces on the floor. Secure the end panel to the braces using two 1/4-20 nuts.
  • Page 166 C H A P T E R 5 Above Ground Covers Turn the cover assembly over and move towards the dyno. Secure the left cover assembly to the center support leg using two 1/4-20 nuts and the existing nut and washer. Note: The center support leg is shown in a cutaway view to better show the installation.

  • Page 167: Installing The Lid And Door Assemblies

    4 2 4 L I N X I N S T A L L AT I O N Above Ground Covers NSTALLING THE ID AND SSEMBLIES Secure each lid assembly to the cover assembly using sixteen 1/4-20 x 5/8-inch torx screws, fourteen 1/4-inch flat washer, and fourteen 1/4-20 nuts. Figure 5-36: Install the Lid Assemblies Version 3 Above Ground Model 424x/424xLC...
  • Page 168 C H A P T E R 5 Above Ground Covers Secure the left and right door assemblies using eight 1/4-20 nuts each. right door assembly left door assembly Figure 5-37: Install the Left and Right Door Assemblies Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 5-40...
  • Page 169 4 2 4 L I N X I N S T A L L AT I O N Above Ground Covers Carefully remove the tape backing from the door magnets. Note: The door magnets are fragile until installed. Use care when handling the magnets.

  • Page 170: Continue Dyno Installation

    C H A P T E R 5 Above Ground Covers Secure the letter O to the cover assembly using two 1/4-20 nuts. letter O Figure 5-39: Install the Letter O ONTINUE NSTALLATION Continue the dyno installation with “Deck Installation” on page 3-50. Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide 5-42...

  • Page 171: Disconnect The Belt Drive From The Dyno Drums

    4 2 4 L I N X I N S T A L L AT I O N Disconnect the Belt Drive from the Dyno Drums DISCONNECT THE BELT DRIVE FROM THE DYNO DRUMS The Linx belt can be disengaged by pulling the splined shafts out of the dyno splines. Loosen the three finger screws and lower the access panel.

  • Page 172: Reconnecting The Belt Drive

    C H A P T E R 5 Disconnect the Belt Drive from the Dyno Drums ECONNECTING THE RIVE Remove the 1/4-20 x 1.25-inch cap screws from the threaded holes in the splined shaft. Slide the shaft into the dyno drum aligning the two unthreaded holes in the splined shaft flange with the two threaded holes in the outer shaft.
  • Page 173 HAPTER SSEMBLY NSTALLATION This chapter will walk you through installing the optional side deck assembly. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This chapter is divided into the following categories: • Side Deck Installation, page 6-2 Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 174: Side Deck Installation

    C H A P T E R 6 Side Deck Installation SIDE DECK INSTALLATION This section describes how to install the side deck assembly. The side deck assembly is an optional accessory; if you did not order this accessory skip this chapter. You will need the following parts: •...

  • Page 175: Installing The Side Deck Assembly

    S I D E D E C K A S S E M B LY I N S T A L L AT I O N Side Deck Installation NSTALLING THE SSEMBLY Lay the platform assembly on it’s side. Secure the two front step leg assemblies to the platform using two 3/8-16 x 3-inch hex bolts, four 3/8-inch flat washers, two 3/8-inch lock washers, and two 3/8- inch nuts each.
  • Page 176 C H A P T E R 6 Side Deck Installation Turn the side deck assembly over and stand upright. Secure the step assemblies to the front legs using four 1/4-20 x 1.5-inch hex bolts, eight 1/4-inch flat washers, four 1/4-inch lock washers, and four 1/4-inch nuts each.
  • Page 177 S I D E D E C K A S S E M B LY I N S T A L L AT I O N Side Deck Installation Place the side deck assembly next to your dyno in a position that makes access to the vehicle convenient.
  • Page 179 HAPTER ASIC PERATION The Dynojet dynamometer gives you the state of the art technology, durability, and accuracy that you need. Dynojet’s advanced engineering delivers the precise horsepower measurements a technician needs to make quick and accurate evaluations of engine performance and drive train problems.

  • Page 180: Loading The Vehicle

    C H A P T E R 7 Loading the Vehicle LOADING THE VEHICLE Use the following steps to load a vehicle on the dyno. Refer to your lift instructions for lift operation. You will need the following parts: part description part description...
  • Page 181 B A S I C D Y N O O P E R AT I O N Loading the Vehicle Verify your computer is running. Set the dyno brake on by pressing the red button on the hand-held pendant. For four or all-wheel drive vehicles, measure the wheel base on the vehicle and adjust the 4WD dyno to that dimension before driving the vehicle on the dyno.
  • Page 182 C H A P T E R 7 Loading the Vehicle Attach the tie-down straps. Rear Wheel Drive • Attach two tie-down straps from secure anchor points to the rear of the vehicle. Attach additional tie-down straps from the rear of the vehicle as shown in Figure 7-2.
  • Page 183 B A S I C D Y N O O P E R AT I O N Loading the Vehicle 10 Tighten the tie-down straps evenly making sure that the drive wheels remain centered on the drum. The tie-down straps should always be connected to the vehicle’s solid axle or the suspension control arms.

  • Page 184: Connecting The Rpm Pickup

    Connecting the RPM Pickup CONNECTING THE RPM PICKUP Your Dynojet dynamometer includes a primary wire inductive pickup and two secondary wire inductive pickups. These small “clothespin like” inductive pickups are used to sense RPM. An RPM pickup is required if you want to view torque graphs.

  • Page 185: Connecting The Secondary Inductive Pickup

    B A S I C D Y N O O P E R AT I O N Connecting the RPM Pickup ONNECTING THE ECONDARY NDUCTIVE ICKUP The secondary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray electrical interference may result.

  • Page 186: Connecting The Primary Inductive Pickup

    C H A P T E R 7 Connecting the RPM Pickup ONNECTING THE RIMARY NDUCTIVE ICKUP The primary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray electrical interference may result. Clip the primary inductive pickup around the primary side of the coil.

  • Page 187: Grounding The Vehicle

    B A S I C D Y N O O P E R AT I O N Grounding the Vehicle GROUNDING THE VEHICLE You will need to ground your vehicle to the dyno before every run. Use the following steps to install the grounding bracket and ground the vehicle to the dyno. Always ground the vehicle to the dynamometer.

  • Page 188: Pre-Run Inspection

    C H A P T E R 7 Pre-run Inspection PRE-RUN INSPECTION Perform a vehicle inspection before making a run. • Check the radiator coolant and oil levels. • Check the fuel source. • Rotate the drum(s) and check for rocks caught in the tire tread that could fly out. •...

  • Page 189: Engine Warm Up

    B A S I C D Y N O O P E R AT I O N Pre-run Inspection NGINE Warm the vehicle’s engine and drivetrain before beginning testing. Consistent engine temperatures will assure your runs are repeatable. FTER NGINE Always leave the vehicle in park (automatic transmission) or in first gear (manual transmission), with the engine off, and make sure the emergency brake and the dyno brake are on when you get out of the vehicle.

  • Page 190: Making A Test Run

    Using the vehicle’s own brakes to slow or stop the drum at speeds over 30 m.p.h. can severely over heat the brake parts. Dynojet dynamometers with the air brake or eddy current brake accessory can be used to slow the vehicle and drum to a full stop at any speed.

  • Page 191: Preventative Maintenance

    B A S I C D Y N O O P E R AT I O N Preventative Maintenance PREVENTATIVE MAINTENANCE This section covers maintenance items for all model 424 dynos with the Spring Applied Air Release (SAAR) brake and the 4WD attachment. For more detailed maintenance instructions, refer to the Maintenance Guide for Automotive Dynamometers (P/N 98119101).

  • Page 192: Verifying The Saar Brake Pressure

    C H A P T E R 7 Preventative Maintenance SAAR B ERIFYING THE RAKE RESSURE Verify the SAAR brake pressure gauge reads 100psi (690kPa). Using the knob, adjust the regulator until the correct pressure is achieved. brake pressure regulator AB096 use the knob to adjust the regulator until the correct...
  • Page 193 B A S I C D Y N O O P E R AT I O N Preventative Maintenance SAAR B AINTAINING THE RAKE LEARANCE Verify the area is clear and the dyno can be operated safely. Power up the dyno electronics. Using the pendant, turn the brake to the OFF position.
  • Page 194 Tighten the upper nut on the air can rod down onto the brake actuating tube to sandwich the tube between the two nuts. Torque the lower nut to 110 foot-pounds. If you cannot adjust the brakes to specification, you will need new brake shoes. Contact Dynojet. air can rod upper nut brake actuating tube...
  • Page 195 B A S I C D Y N O O P E R AT I O N Preventative Maintenance 4WD A —T YNOS WITH TTACHMENT HINGS TO HECK • Check the hydraulic motor fluid once every six months, fill as necessary. •...

  • Page 197: Appendix A Red Head Anchor Installation

    PPENDIX NCHOR NSTALLATION This appendix contains instructions for installing the Red Head Multi-Set™II Anchors. The anchors will be used to secure the dyno to concrete. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Be sure to read and understand the warnings included in this appendix.
  • Page 198 A P P E N D I X A Installation INSTALLATION Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number. minimum hole setting tool catalog number drill bit size depth catalog number Carbon Steel...
  • Page 199 R E D H E A D A N C H O R I N S T A L L AT I O N Installation Using a hammer, drive the anchor flush with the surface of the concrete, or below the surface if the hole depth exceeds minimum embedment.

  • Page 201: Appendix B Power Requirements And Installation

    PPENDIX OWER EQUIREMENTS AND NSTALLATION This appendix contains power requirements and installation instructions for the eddy current brake. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Be sure to read and understand the warnings included in this appendix.

  • Page 202: Power Requirements And Installation-North America, Japan, And Locations Using 60 Hz Power

    UL and NEC safety standards. Note: If you are installing your brake in North American or Japan and the brake is not equipped with twist lock four wire grounded plug, contact Dynojet before attempting to connect the brake.

  • Page 203: Testing For Correct Voltages

    You must have a licensed electrician correct the power connection. Connecting the brake to the incorrect voltage can result in damage to the brake and will void the brake warranty. Contact Dynojet with any questions. Using a voltmeter that is capable of measuring AC voltage, measure between the points listed below and verify that the correct voltages are present.

  • Page 204: Hard Wiring To The Building

    A P P E N D I X B Power Requirements and Installation—North America, Japan, and Locations Using 60 Hz Power IRING TO THE UILDING Use the following instructions to wire the brake directly to the building. The brake must connect to a two pole disconnect switch to allow the removal of all power to the brake for servicing.

  • Page 205: Power Requirements And Installation-Excluding North America And Japan

    Failure to follow these instructions could result in personal injury or damage to the brake. Connecting the brake to the incorrect voltage will void the brake warranty. Contact Dynojet with any questions. The dedicated wall receptacle is a three-pin IEC grounded 30A type and must be wired in accordance with local building codes and requirements.

  • Page 206: Installing The Wall Receptacle

    A P P E N D I X B Power Requirements and Installation—Excluding North America and Japan NSTALLING THE ECEPTACLE The wall receptacle is a single 240 volt 30A dedicated circuit with a ground. Note: The actual wall receptacle may be different from the image shown in  Figure B-2;...

  • Page 207: Testing For Correct Voltages

    P O W E R R E Q U I R E M E N T S A N D I N S T A L L AT I O N Power Requirements and Installation—Excluding North America and Japan ESTING FOR ORRECT OLTAGES You must test the receptacle for proper voltages before the eddy current brake is...

  • Page 209: Appendix C Stationary Dyno Upgrade

    PPENDIX TATIONARY PGRADE This appendix contains instructions for upgrading an existing stationary dyno to be used with the 4WD dyno including relocating the deck, adding the lift kit, and adjusting the air fittings. To ensure safety and accuracy in the procedures, perform the procedures as they are described.

  • Page 210: Deck Relocation

    A P P E N D I X C Deck Relocation DECK RELOCATION Before installing the 4WD dyno with an existing 2WD 224 dyno, the deck must be removed from the stationary dyno to be installed on the 4WD dyno later. The following instructions will guide you through removing your existing deck and installing that deck on your 4WD dyno.
  • Page 211 S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation Remove the two side drum guard bolts and three front drum guard bolts securing the deck lip to the dyno and set aside. Remove the deck and set aside.
  • Page 212 A P P E N D I X C Deck Relocation Remove the two 3/8 x 1-inch bolts and two 3/8 x 1-inch nylock nuts securing the two outside deck braces to the mounting brackets and set aside. Remove the two outside deck braces and set aside. Remove the two 3/8 x 1-inch bolts and two 3/8-inch lock washers securing the two inside deck braces to the dyno and set aside.
  • Page 213 S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation Remove the two 3/8-16 x 1-inch bolts and two washers securing each mounting bracket and set aside. 10 Remove the mounting bracket and set aside. Note: If you have an eddy current brake, there will be only one mounting bracket.

  • Page 214: Removing The New Style Deck From A New Model Dyno

    A P P E N D I X C Deck Relocation EMOVING THE TYLE ECK FROM A ODEL This section will guide you through removing the new style deck from a new model dyno. For instructions on installing this deck to your 4WD dyno, refer to page 3-50. Remove the four 3/8-16 x 3-inch bolts, four flat washers, and four nylock nuts securing the tube to the outer panels and deck supports and set aside.
  • Page 215 S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation Remove the center bolt securing the center panel to the dyno and set aside. Remove the six 1/4-20 x 5/8-inch screws and six crush nuts securing the center panel and supports to the outer panels and set aside.
  • Page 216 A P P E N D I X C Deck Relocation Remove the outside panels. Remove the 3/8-16 x 1-inch button-head flange bolt, washer, and nut securing the inside of the panel to the inner brace and set aside. Remove the two 3/8-16 x 1-inch button-head flange bolts, two 3/8-inch washers, and two 3/8-inch nylock nuts securing each tie down to the panel and deck braces and set aside.
  • Page 217 S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation Remove the two 3/8-16 x 1-inch bolts, washers, and nuts securing each outer deck brace to the mounting bracket and set aside. Remove the outer deck braces and set aside.
  • Page 218 A P P E N D I X C Deck Relocation 12 Remove the two 3/8-16 x 1-inch bolts and two washers securing each deck brace mounting bracket and set aside. 13 Remove the mounting bracket and set aside. Note: If you have an eddy current brake, there will be only one mounting bracket. 14 Continue with installing the lift kit on page C-16.

  • Page 219: Installing The Early Style Deck On The 4Wd Dyno

    S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 4WD D NSTALLING THE ARLY TYLE ECK ON THE Before installing the deck, make sure to complete the 4WD dyno and bridge installation found in Chapter 3 along with the optional eddy current brake installation...
  • Page 220 A P P E N D I X C Deck Relocation Install the deck mounting bracket using two 3/8-16 x 1-inch bolts and two washers. Note: If you do not have and eddy current brake, you will need to install an additional deck mounting bracket.
  • Page 221 S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation Loosely attach one outside brace to the mounting bracket using two 3/8 x 1-inch bolts and two 3/8-inch nylock nuts. Loosely attach one outside brace to the eddy current brake using two 3/8 x 1-inch bolt and two 3/8-inch lock washers.
  • Page 222 A P P E N D I X C Deck Relocation If not already removed, remove the three 3/8-16 x 1-inch button-head flange bolts from the front drum guard. 10 If not already removed, remove the two 3/8-16 x 1.25-inch button-head flange bolts from the side drum guards.

  • Page 223: Installing The New Style Deck On The 4Wd Dyno

    S T AT I O N A R Y D Y N O U P G R A D E Deck Relocation 14 Secure the deck to each deck brace using two 3/8 x 1-inch bolts and two 3/8-inch lock washers each. Make sure to use one 3/8-inch flat washer and one 3/8-inch nut on the inside of each outer deck brace.

  • Page 224: Lift Kit Installation

    A P P E N D I X C Lift Kit Installation LIFT KIT INSTALLATION Once the rear deck has been removed, the lift kit must be installed. The lift kit will raise the stationary dyno to match the 4WD dyno. You will need the following parts: •...

  • Page 225: Air Fittings Upgrade

    S T AT I O N A R Y D Y N O U P G R A D E Air Fittings Upgrade AIR FITTINGS UPGRADE Before the stationary dyno can be used with the 4WD dyno, the existing air fittings on the stationary dyno must be upgraded.

  • Page 227: Appendix D Bridge Extension Assembly

    PPENDIX RIDGE XTENSION SSEMBLY This appendix contains instructions for installing the bridge extension assembly to the stationary dyno. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 228: Bridge Extension Installation

    A P P E N D I X D Bridge Extension Installation BRIDGE EXTENSION INSTALLATION The optional bridge extension assembly (P/N 61119183) is used to extend the bridge range from an 88-130 inch wheel base to a 98-140 inch wheel base. Secure the extended runner mount (z-shaped bracket) to the drum guard using three 3/8 x 1.5-inch flange hex allen bolts.
  • Page 229 B R I D G E E X T E N S I O N A S S E M B LY Bridge Extension Installation When there is no eddy current brake, secure both outer brace mounts to the dyno using two 3/8 x 1.5-inch flange head bolts each.
  • Page 230 A P P E N D I X D Bridge Extension Installation Place the runner clamp on top of the extended runner mount. Note: The extended runner clamps used with the bridge extension are smaller and rectangular shaped compared to the standard runner clamps. Be sure to use the correct runner clamps.
  • Page 231 B R I D G E E X T E N S I O N A S S E M B LY Bridge Extension Installation Secure the two support arms to the brackets using two 1/2 x 1.5-inch bolts,  two 1/2-inch lock washers, and two 1/2-inch nuts each brackets A 564...
  • Page 232 A P P E N D I X D Bridge Extension Installation Secure the center mount extension to the extended runner mounts using four  3/8 x 1/2-inch pan hex bolts. Continue with installing the runner supports, step 4 on page 3-40. A 565 center mount extension Figure D-5: Secure the Center Mount Extension...

  • Page 233: Interface Roller Assembly Installation

    PPENDIX NTERFACE OLLER SSEMBLY NSTALLATION This appendix contains instructions for installing the interface roller assembly to the four-post lift. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...
  • Page 234 A P P E N D I X E Interface Roller Assembly Installation INTERFACE ROLLER ASSEMBLY INSTALLATION The roller assembly secures the dyno to the four-post lift. It is a good idea to install your interface roller assembly before anchoring your dyno to the ground. If you have the interface guide, refer to “Installing the Interface Guide”...
  • Page 235 I N T E R F A C E R O L L E R A S S E M B LY I N S T A L L AT I O N Interface Roller Assembly Installation Align the rollers on the interface roller assembly with the interface tube on the dyno.
  • Page 237 PPENDIX —E RIVE ARLY ERSION HAFTS This appendix contains instructions for disconnecting the belt drive from the dyno drums using early version shafts with the Linx option. Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 238: Disconnect The Belt Drive From The Dyno Drums

    A P P E N D I X F Disconnect the Belt Drive from the Dyno Drums DISCONNECT THE BELT DRIVE FROM THE DYNO DRUMS The Linx belt can be disengaged by pulling the splined shafts out of the dyno splines. You will need the following part: •...
  • Page 239 L I N X B E L T D R I V E — E A R LY V E R S I O N S H A F T S Disconnect the Belt Drive from the Dyno Drums If you are unable to pull the shaft out by hand, remove the top access cover and use the shaft puller as shown.

  • Page 241: Appendix G Shaft Safety Wire Installation

    PPENDIX HAFT AFETY NSTALLATION This appendix contains instructions for installing the shaft safety wire with the Linx option. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...
  • Page 242 A P P E N D I X G Installation INSTALLATION Use the following instructions to install the shaft safety wire. Failure to secure the cap screws with safety wire can result in damage to the dyno and/or the vehicle. Torque the cap screws to 7 ft.-lb.

  • Page 243: Appendix H D-Lok Bearing Installation

    PPENDIX EARING NSTALLATION This appendix contains instructions for installing the Dodge® D-Lok Mounted Ball Bearings. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Be sure to read and understand the warnings included in this appendix.

  • Page 244: Bearing Lubrication

    A P P E N D I X H Installation INSTALLATION Before installing the D-Lok bearings, please take a moment to read these instructions for proper installation and operation procedures. To ensure safety and accuracy in the procedures, perform the procedures as they are described. You will need to provide a long hex bit socket to tighten the bearing screws to the torque specifications.

  • Page 245: Appendix I Torque Values

    PPENDIX ORQUE ALUES This appendix contains tables for standard and metric torque values. Use these values when specified values are not given in other sections of this manual. Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide...

  • Page 246: Standard Bolt Torque Values

    • The following tables include values for plain finish and plated fasteners. • Reduce torque by 10% when engine oil is used as a lubricant. The following tables are meant to be used as guidelines for Dynojet product torque values only. Always use caution when torquing fasteners.
  • Page 247 TO R Q U E VA L U E S Standard Bolt Torque Values RADE size torque, plain torque, plated threads/in in•lb ft•lb N•m in•lb ft•lb N•m 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1277 1/2-20 1439 1079 9/16-12 1843 1382...

  • Page 248: Metric Bolt Torque Values

    • The following tables include values for plain finish and plated fasteners. • Reduce torque by 10% when engine oil is used as a lubricant. The following tables are meant to be used as guidelines for Dynojet product torque values only. Always use caution when torquing fasteners.

  • Page 249: Index

    NDEX 4WD board power cable 3-13 bridge, 4WD 4WD power cable cover 3-48 routing 3-16, 3-20, 3-25 drum guards 3-45 4WD power supply with cable 3-15 installing 3-44 runner assemblies 3-47 runner mounts 3-46 runner tie straps 3-48 above ground kit bridge, stationary deck 3-50 cover 3-43...
  • Page 250 I N D E X u-joint 4-12 unpacking 4-4 deck zero calibration 4-19 center panel 3-54 eddy current brake driver 4-17 inner brace 3-52 electrical requirements 1-10 installing 3-50 electrostatic discharge viii mounting bracket 3-51 environmental requirements 1-10 outer brace 3-52 ESD precautions viii outside panels 3-53 tube 3-55...
  • Page 251 I N D E X length 1-5 making a test run 7-12 length, linx 5-2 maximum power 5-2 lift maximum speed 5-2 cross member 2-12, E-3 metric torque values dyno placement 2-9, 2-11, E-3 grade 10.9 I-4 interface guide 2-10 grade 8.8 I-4 interface roller assembly E-2 movement test 3-37...
  • Page 252 I N D E X red head anchor runner mounts, extended D-2 contact information A-1 runner supports 3-40 installation A-2, G-2 runner tie straps 3-48 setting tool A-3 warnings A-1 remote atmos cable 3-13 SAAR brake requirements pressure gauge 7-13, 7-14 chassis 1-5 regulator 7-13, 7-14 compressed air 1-9...
  • Page 253 I N D E X u-joint 4-12 upgrade air fittings C-17 deck relocation C-2 lift kit C-16 vehicle ground cable 7-9 warnings vii weight 1-5 width 1-5 width, linx 5-2 wiring diagram, hydraulic movement 3-34 zero calibration 4-19 Version 3 Above Ground Model 424x/424xLC Automotive Dynamometer Installation Guide Index-v...

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