©2004-2008 Dynojet Research, Inc. All Rights Reserved. Maintenance Guide For Model 224, Model 224 with 4WD, Model 424x, and Model 248 Automotive Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual is furnished under license and may only be used or copied in accordance with the terms of such license.
TABLE OF CONTENTS Auto Dyno Maintenance Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems . . . . . . . 3 Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AUTO DYNO MAINTENANCE This document provides instructions for performing maintenance on the model 224 dynamometer (dyno), the model 224 dyno with the four wheel drive (4WD) attachment, the model 224-2 dyno, the model 424x dyno, and the model 248 dyno. To ensure safety and accuracy in the procedures, perform the procedures as they are described.
AUTO DYNO MAINTENANCE Introduction INTRODUCTION ................................... You may have a model 224 dyno configured with one drum for testing two-wheel drive vehicles, or with two drums for testing four-wheel drive vehicles. Model 224 dynos also may use either the Air Over Hydraulic (AOH) brake or the Spring Applied Air Release brake (SAAR). Model 424x dynos all use the SAAR brake and have two dyno drums for testing four-wheel drive cars. Or you may have a model 248 dyno.
AUTO DYNO MAINTENANCE Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems MODEL 224 DYNOS WITH AIR OVER HYDRAULIC (AOH) BRAKE SYSTEMS ................................... This section covers maintenance items for model 224 dynos with a single drum and AOH braking. AD203 Figure 1: Model 224 with Air Over Hydraulic (AOH) Brakes THINGS TO CHECK • Check all air fittings for leaks monthly. Correct any leaks found.
AUTO DYNO MAINTENANCE Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems MAINTAINING THE MODEL 224 AOH DRUM BRAKE SHOE CLEARANCE The 224 AOH drum brake shoe clearance must be checked once per month. If you have upgraded your 224 dyno to use the Spring Applied Air Release (SAAR) braking system, refer to “Maintaining the SAAR Brake Shoe Clearance” on page 8. 1 2 3 4 Remove the air from the system. 1a Shut off or disconnect the air supply to the dyno, and follow lock out procedure.
AUTO DYNO MAINTENANCE Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems 4b Pull the slave cylinder away from the dyno being careful not to kink the brake line. 4c Screw the brake piston rod in to increase brake shoe clearance or out to decrease brake shoe clearance. Refer to Figure 3. 4d Attach the slave cylinder using the bolts and washers removed earlier. 4e Recheck the brake shoe clearance. No part of the brake shoe should touch the drum.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System MODEL 224 DYNOS WITH SPRING APPLIED AIR RELEASE (SAAR) BRAKE SYSTEM ................................... This section covers maintenance items for model 224 dynos with the SAAR brake. THINGS TO CHECK • Check all air fittings for leaks monthly. Correct any leaks found. • Once per month verify the drum brake pressure gauge reads 100psi (690kPa). Adjust the regulator if the pressure is out of specification.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System VERIFYING THE SAAR BRAKE PRESSURE 1 2 Verify the SAAR brake pressure gauge reads 100psi (690kPa). Using the knob, adjust the regulator until the correct pressure is achieved.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System MAINTAINING THE SAAR BRAKE SHOE CLEARANCE 1 2 3 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. This will release the SAAR brake by moving the brake shoe away from the drum. Keep hands and fingers clear when operating dyno. 4 Measure the gap between the brake shoe and the drum surface. This gap should be between .
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 5 6 7 8 If the brake shoe clearance is out of specification, loosen the upper nut on the air can rod. Adjust the lower nut until the brake shoes are .25 inch (6mm) away from the dyno drum. 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.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System CHANGING THE SAAR BRAKE SHOES 1 Apply air to the brake system. Air pressure to the brake system must be maintained while changing the SAAR brake shoes. 2 Release the brakes. 2a Turn on the dyno electronics. 2b 3 Verify the brake button on the pendant is not lit. Remove the nut from the bottom air can rod and set aside.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 4 Slowly lower the pressure using the regulator. The air can rod will retract from the tube. Note: Verify the rod does not bind on the tube.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 5 Slide the tube out and set aside. tube Figure 9: 224 SAAR Brake—Slide the Tube Out 6 7 Using the access holes in the dyno frame, remove the cotter key from each brake. Remove the pin from each brake. Note: For clarity, the drum is not shown.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 8 Remove each brake arm assembly. brake arm assembly Figure 11: 224 SAAR Brake—Remove the Brake Arm Assembly 9 10 11 12 Remove the cotter key from the brake arm assembly. Remove the pin. Remove the retainer and shoe. Install the new brake shoe and replace the retainer. Note: Verify the brake shoe is secure. 13 Replace the pin and cotter key.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 14 Replace each brake arm assembly using the pin and cotter key removed earlier. Refer to Figure 10. 15 Slide the tube in. 16 Slowly raise the pressure using the regulator. The air can rod will go through the tube. Note: Verify the rod does not bind on the tube.
AUTO DYNO MAINTENANCE Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 17 Replace the nut, removed earlier, on the bottom air can rod. 18 Adjust the brake shoe clearance as necessary. Refer to “Maintaining the SAAR Brake Shoe Clearance” on page 8 for more information. 19 Press the red button on the pendant to activate the drum brakes; the button will be lit.
AUTO DYNO MAINTENANCE 4WD Attachment for Model 224 Dynos 4WD ATTACHMENT FOR MODEL 224 DYNOS ................................... This section covers maintenance items for model 224 dynos with the 4WD attachment. THINGS TO CHECK • Check customer supplied air filter/dryer daily, empty and clean as necessary. • Inspect the 4WD dyno movement rails for debris once per month. Clear any debris from the rails. • Check all air fittings for leaks monthly. Correct any leaks found.
AUTO DYNO MAINTENANCE 4WD Attachment for Model 224 Dynos FILLING THE AIR MOTOR LUBRICATOR Check the air motor lubricator once per month and fill as necessary. 1 2 3 4 Disconnect the air before removing the lubricator bowl. Shut off or disconnect the air supply to the dyno, and follow lock out procedure. Press and hold the dyno in or out movement switch until you cannot hear any air going through the movement motor. Before running the Gast Air Motor, remove the lubricator bowl and fill the bowl with oil.
AUTO DYNO MAINTENANCE 4WD Attachment for Model 224 Dynos ADJUSTING THE AIR MOTOR LUBRICATOR Use the following steps to adjust the amount of oil provided by the air motor lubricator. 1 2 3 Turn the top knob on the air motor lubricator clockwise until it shuts off the flow of oil. Back off the knob one turn counter-clockwise to start the flow of oil. Adjust the knob as needed between one turn and fully on (turning counterclockwise) as needed for the particular environment in your dyno room.
AUTO DYNO MAINTENANCE 4WD Attachment for Model 224 Dynos INSPECTING THE RAIL BRAKE CLEARANCE Inspect the rail brake clearance once per month. 1 2 3 4 5 6 7 Shut off or disconnect the air supply to dyno, and follow your company’s lock out procedure. Press the red button on the pendant to activate the drum brakes; the button will be lit. Press and hold the dyno movement switch in either the in or out position until you cannot hear any air going through the movement motor.
AUTO DYNO MAINTENANCE Model 424x All-Wheel Drive Dynos MODEL 424X ALL-WHEEL DRIVE DYNOS ................................... This section covers maintenance items for model 424x dynos. THINGS TO CHECK • Check all air fittings for leaks monthly. Correct any leaks found. • Check the air motor lubricator once per month and fill as necessary. Refer to “Filling the Air Motor Lubricator” on page 21 for more information. • Once per month verify that the SAAR brake pressure gauge reads 100psi (690kPa).
AUTO DYNO MAINTENANCE Model 424x All-Wheel Drive Dynos FILLING THE AIR MOTOR LUBRICATOR Check the air motor lubricator once per month and fill as necessary. 1 2 3 4 Disconnect the air before removing the lubricator bowl. Shut off or disconnect the air supply to the dyno, and follow lock out procedure. Press and hold the dyno in or out movement switch until you cannot hear any air going through the movement motor. Before running the Gast Air Motor, remove the lubricator bowl and fill the bowl with oil.
AUTO DYNO MAINTENANCE Model 424x All-Wheel Drive Dynos ADJUSTING THE AIR MOTOR LUBRICATOR Use the following steps to adjust the amount of oil provided by the air motor lubricator. 1 2 3 Turn the top knob on the air motor lubricator clockwise until it shuts off the flow of oil. Back off the knob one turn counter-clockwise to start the flow of oil. Adjust the knob as needed between one turn and fully on (turning counterclockwise) as needed for the particular environment in your dyno room.
AUTO DYNO MAINTENANCE Model 424x All-Wheel Drive Dynos VERIFYING THE SAAR BRAKE PRESSURE 1 2 Verify the SAAR brake pressure gauge reads 100psi (690kPa). Using the knob, adjust the regulator until the correct pressure is achieved.
AUTO DYNO MAINTENANCE Model 424x All-Wheel Drive Dynos MAINTAINING THE SAAR BRAKE SHOE CLEARANCE 1 2 3 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. This will release the SAAR brake by moving the brake shoe away from the drum. Keep hands and fingers clear when operating dyno. 4 Measure the gap between the brake shoe and the drum surface. This gap should be between .125 inch - .375 inch (3mm - 10mm).
AUTO DYNO MAINTENANCE Model 424x All-Wheel Drive Dynos 5 6 7 8 If the brake shoe clearance is out of specification, loosen the upper nut on the air can rod. Adjust the lower nut until the brake shoes are .25 inch (6mm) away from the dyno drum. 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.
AUTO DYNO MAINTENANCE Model 424x All-Wheel Drive Dynos CHECKING THE AIR CAN SLEEVE RETRACTION The SAAR brake’s air can sleeve must be positioned correctly for safe operation. If the air can sleeve is not in the correct location, use a wrench and loosen the nut as far as you can. The sleeve will drop down as shown in Figure 23. Check all four air cans. Note: Verify that the brakes are operating properly before replacing the covers and using the dyno.
AUTO DYNO MAINTENANCE Model 248 Dynos MODEL 248 DYNOS ................................... This section covers maintenance items for model 248 dynos. THINGS TO CHECK • Check all air fittings for leaks monthly. Correct any leaks found. • Once per month verify the drum brake pressure gauge is reading 55 to 65psi (450kPa). Adjust the regulator if the pressure is out of specification. • Maintain the brake shoe clearance. Refer to “Checking the 248 Drum Brake Shoe Clearance” on page 28 for more information.
AUTO DYNO MAINTENANCE Model 248 Dynos CHECKING THE 248 DRUM BRAKE SHOE CLEARANCE The 248 drum brake shoe clearance needs to be checked once per month. Use the following steps. 1 Remove the air from the system. 1a Shut off or disconnect the air supply to the dyno, and follow lock out procedure. 1b Press the red button on the pendant to activate the drum brakes; the button will be lit. 1c Press and hold the dyno in or out movement switch until you cannot hear any air going through the movement motor.
AUTO DYNO MAINTENANCE Model 248 Dynos 4 If the brake shoe clearance is out of specification perform the following steps: 4a Remove the cotter key from the clevis pin and remove clevis pin. 4b Remove the two 5/8-inch nuts and washers securing the air can to the brake bracket. 4c Loosen the jam nut. 4d Pull the air can up so that the clevis can be turned. Screwing the clevis down the air can rod will decrease brake shoe clearance. 4e With the clevis adjusted, secure the jam nut.
