©1993-2005 Dynojet Research, Inc. All Rights Reserved. Installation Guide For Model 248 Four Post Lift Automotive Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual, as well as the software described in it, is furnished under license and may only be used or copied in accordance with the terms of such license.
Contents Chapter 1 .......................................................1-1 Initial Setup and Requirements Introduction................................................................................. 1-1 Four Post Lift/Dyno Placement ................................................. 1-2 DynoWare EX+ Placement ......................................................... 1-3 Requirements to Unload Truck.................................................. 1-4 Requirements to Install the Dynamometer .............
Contents Chapter 4 .......................................................4-1 Basic Dyno Operation Loading the Vehicle .................................................................... 4-2 Connecting the RPM Pickup...................................................... 4-5 RPM Pickup Descriptions ...........................................................................4-6 Connecting the Secondary Inductive Pickup ..............................................4-7 Connecting the Primary Inductive Pickup .
Chapter 1 Initial Setup and Requirements Thank you for purchasing the Dynojet Dynamometer. This document will give you the information you need to install the Dynojet Dynamometer (four post model). If you have any questions please call Dynojet at (800) 992-4993. Introduction Before installing your Dynojet Dynamometer, there are a few factors to consider.
Four Post Lift/Dyno Placement Four Post Lift Placement Before you install the Four Post Lift, you need to think about the position of the lift relative to the garage and the dynamometer. • For AMCO lifts you may place the dynamometer on either end of the lift but it is recommended that you place the dyno on the end of the lift with the hydraulics. • For BENWIL lifts you place the dyno on the opposite end of the hydraulic controls.
DynoWare EX+ Placement The DynoWare EX+ system is comprised of four modules: the CPU module, the Dynamometer Input/Output module, the RPM module and the Atmospheric module. The Dynamometer Input/Output module connects to the dynamometer. (A 20 foot (6.1 meter) long cable is provided.) The CPU module connects to a personal computer. (A 12 foot (3.7 meter) long cable is provided.) RPM Pickups and a Hand Held Pendant also connect to the modules.
Requirements to Unload Truck When your dyno arrives, you must provide equipment to unload the dynamometer from the truck, with skids or forks a minimum of 6 inchs wide by 6 feet long. It must be capable of lifting and moving at least 8000 pounds (3642 KG). The dyno has 2 C-Channels that run lengthwise along the bottom of the dyno. Unload the dynamometer using these channels.
Other Requirements Shop Air The dyno air brake requires a 3/8-inch air hose with a minimum pressure of 60 psi. You must provide 3/8-inch air line that will reach from the dynamometer to the Air Pressure Regulator and another air hose to connect the regulator to your shop air supply. Computer Requirements You will need to provide a computer system to run the WinPEP software. WinPEP 7 includes complete documentation in online Help. From the WinPEP 7 menu bar, choose Help WinPEP 7 Help or visit www.winpep.
Uncrating the Dyno Step 1 Use a crowbar or the like to remove the plywood shipping shell from the dynamometer. • Remove catwalk pallet from the top of the crate (if purchased). • Remove the top of the crate. • Remove the sides of the crate. • Remove the bottom skids and discard. Step 2 Remove the front and back dyno covers. Step 3 Carefully remove the cardboard boxes and brake weldments that are stored within the dynamometer’s frame.
Step 4 Verify the hardware contents as follows: Brake Hardware: • 2 brake weldments (The following are attached to the dyno frame) • six 5/8" bolts • six lock washers • six flat washers • six nuts Mounting Hardware: • • • • • • • • • 444444441- Foot Stands 7/16” x 1” Bolts 7/16” Flat Washers 7/16” Lock Washers 3/8” x 1” Bolts 3/8” Flat Washers 3/8” Lock Washers Anchors Set Tool Document #98219101 1-7
Electronic Hardware: Pictures and descriptions on page 3- 6 : Lift Hooks: • 6 Catwalk Hooks Straps: • 2 axle straps • 2 Long axle straps (not shown) • 4 ratchet straps • 2 ratchet straps with sleeves Chocks (4): 1-8 Document #98219101
Chapter 2 Hardware Installation DynoWare EX+ The standard dynamometer electronics package is comprised of 4 interconnected modules: System Expansion Connector Atmospheric Sensing Module RPM Module Dynamometer Input/Output Module CPU Module Atmospheric Sensing Module: The atmospheric sensing module measures absolute pressure, air temperature and relative humidity.
RPM Module: The RPM module receives and processes signals from up to 2 inductive pickups for measurement of engine RPM. Each input has an automatic gain circuit to compensate for a wide variance of ignition systems. The green LED glows when the RPM module is receiving power. The amber LED flashes when an RPM signal is detected. A steady flash rate, proportional to engine RPM, indicates a good RPM signal. These connectors are the inputs for both primary and secondary inductive pickup clips.
Dynamometer Input/Output Module: The dynamometer I/O module sends and receives data from the dynamometer and the hand held pendant. The module also contains a buzzer and light which are activated when either the vehicle or dynamometer speed limit is approached. The green LED glows when the dynamometer input/output module is receiving power. The amber LED flashes proportionally to dynamometer drum RPM. This 25-pin receptacle connects to the shielded cable from the dynamometer.
CPU Module: The CPU module contains a 32-bit processor which acquires data from the expansion modules and communicates to the main computer running the WinPEP software. The processor queries the expansion modules to determine their identity and capabilities. The green LED glows when the CPU module is receiving power. The blue LED is lighted when data from the modules is being acquired and saved. One of these connectors is used to communicate to the main computer.
CPU Module: ..... Continued This connector provides a synchronization signal to a 3rd-party data acquisition system. This connector provides 12 Volt DC power to a 3rd-party data acquisition system. This connector accepts 12 Volt DC power from a power supply or battery. The adjacent LED glows bright green when power is properly connected. When this switch is on, power is supplied to all connected modules.
Primary Inductive Pickup Cable (not shown) Remote Switch Breakout Board to DynoWare Cable Cord from Power Supply Computer Serial Port Cable 2-6 Document #98219101
Chapter 3 Installing Dynamometer Now that you have the dynamometer and the Four Post Lift unpacked you may begin the installation.. Install Lift Four Post Lift Installation Refer to the installation guide of the Four Post Lift for installation. Install Dynamometer After complete assembly of the Four Post Lift, raise and lower the lift a few times to insure proper operation. Whichever side of the lift you choose to put the dynamometer on, the short ramps on the lift must be removed from that side.
Step 2 Install the Feet on the four corners of the dyno. Use the 7/16” x 1” bolts with flat and lock washers to secure the feet to the dyno frame. The bolts should be installed through the slotted hole in the foot. Do Not Tighten the Bolts. The hardware should go through the slotted hole in the foot. Step 3 Once you have the four feet mounted to the dyno, use a marker to mark the floor mounting holes. When you have marked all the holes, remove the feet. Mark the holes with a felt tip marker.
Step 4 Using a carbide bit designed for concrete (see instructions included with anchors) , drill four 1/2” holes in the floor where you made your marks. The holes should ideally be as deep as the length of the anchors (approx. 1 5/8”). Note: Be sure to clean the debris out of the holes that you drilled. Step 5 Place the slotted end of the anchors in the holes that you drilled. They will most likely be very snug, so use a brass drift punch and hammer to drive them down.
dyno gets the 7/16” bolt, lock washer, and flat washer. The 3/8” bolt, lock washer and flat washer go into the anchor in the floor. Step 8 Raise the lift and put the roller assembly portion of the interface kit on the cross beam of lift at its center line. Refer to the Interface Assembly Drawing in Appendix A. Position the roller wheel part of the interface on the lift so it passes through the tube part of the interface on the dynamometer.
Step 9 Tighten the roller part of the interface to the lift’s cross beam. Make sure that it runs smoothly in the receiver part of the kit. Installing the Brakes Use the following steps to install the brakes on your Dynojet Dyno: Step 1 Locate the brake hardware. You should have six 5/8" bolts, six lock washers, six flat washers, six nuts (mounted on the dyno) and two brakes. Left Right Step 2 The brakes mount on the inside of the dyno frame with the air canister on the top.
Mount the brakes on the dyno frame. Use three bolts, three nuts, and three lock washers on each brake weldment. - Remove the nuts and lock washers from the dyno frame leaving the bolts in place. - Place the brake weldments over the bolts on the frame. - Finish the installation of the brake weldments with the nuts and lock washers. Step 4 Install the air hose between the brakes, using the ports on the sides of the air canisters.
Wiring the Dyno Part 1 The following hardware and wires are shipped in boxes with the dyno except the DynoWare EX+ (A) that is shipped separately with the WinPEP software. Refer to the following page for item descriptions.
Basic Kit: A: DynoWare EX+ Modules B: Air Brake Pressure Regulator C: Air Brake Control Valve (Replaced by N with Proportional Air brake systems) D: DynoWare EX+ Power Supply and Cord E: Wall Mount for DynoWare EX+ F: DynoWare Cable G: Dynamometer Control Pendant H: Serial Port Cable I: Primary Inductive Cable J1&2: Secondary Inductive Cables K: Mounting Hardware L: Pickup Card Optional Proportional Air Brake Systems: (M) Booster Valve Assembly (Replaces C) (N) Electronic Pressure Regulator (EPR) (O) DIN Ra
Step 1 Install the pickup card. - Remove the pickup card and the 2 screws from the bubble bag. - Attach to the pickup bracket on the dyno so the optical pickup is facing the axle and the 3 pronged plug is facing away. - Turn the drum carefully and check to see that both pickup tabs on the dyno axle go through the center of the optical pickup on the pickup card. Step 2 Prepare the Breakout Board - Remove the Bubble Bag from the Breakout Board and bracket.
- The Data Acquisition Cable is coiled around the Breakout Board. Uncoil the cable and Plug the cable into the Pickup Card on the dyno. Note: 3 - 10 The rest of the instructions for wiring the dyno follows the catwalk installation.
Catwalk Installation The following steps will explain how to put the catwalks on the dyno. The three pictures above identify the components referred to in these steps. Step 1 Place the catwalk (A) on the dynamometer above the brakes, so the lip of the catwalk lays on the dynamometer frame and butts up against the deck plate on the dynamometer. Using the 3/8" x 1" slotted truss head machine screws, secure it to the top of the dynamometer frame.
Step 2 Using the 3/8" x 1" bolts, loosely secure each of the four support braces to the dynamometer and the bottom of the back catwalk. When the support tubes have been attached, tighten the bolts on the bottom of the support tubes. Tighten the bolts at the top of the support tubes where they attach to the catwalk. Step 3 Place the side-catwalks on the dynamometer so the Dynojet stickers are upright and visible when looking from the brake side of the dynamometer.
Step 5 To adjust the side catwalks so they are level, the support arms can be turned while on the pegs and the screw will raise or lower the side catwalks. Step 6 Place the railing posts in the pockets and secure them with the 1/4“ bolts and nuts. Step 7 String the chain through the holes (using the end with the bolt) in the top of the railing post. The chain should start on one end of the side catwalks, pass through all the posts and terminate on the opposite side catwalk.
Wiring the Dyno Part 2 Standard Air Step 1 (Go on to step 2) Proportional Air Step 1 Install the electronic regulator. Measure down and mark 16" and 193/4" from the top of the right center deck support. Drill a 7/32" hole in each spot marked above.
Fasten the DIN rail to the support using two 1/4" self tapping screws (provided). The electronic pressure regulator snaps onto the DIN rail, hook one side on the DIN rail then rotate electronic pressure regulator toward the DIN rail until it snaps into place. Standard Air Step 2 Screw the Air Brake Control Switch into the top of the right hand air canister.
Proportional Air Step 2 Install the Booster Valve Assembly. Screw the booster valve assembly into the right side brake canister. Tighten it so the air gauge is facing out as shown below. There are two air lines coming from the electronic pressure regulator labeled "IN" and "OUT". The line labeled "OUT" is connected to the 3-way valve. Push the hose in then hand tighten the fitting. Pull on the hose to ensure it is seated properly. If it moves, tighten the fitting more.
The line labeled "IN" is connected to the brass cross. Push the hose in then hand tighten the fitting. Pull on the hose to ensure it is seated properly. If it moves, tighten the fitting more. Standard Air Step 3 (Go on to step 4) Proportional Air Step 3 Install the Temperature Sensor on the left rear panel. Loosely install the left side back cover over the brake so the Dynojet stickers face out and upright. (Use the self tapping screws provided.
Measure from the left side of the dyno to the right edge of the knurled drum surface as shown below. Using the above distance and beginning 24" from the top of the dyno , measure over and mark the left rear panel as shown below. Measure down 24" from the top of the dyno and mark the mark the left rear panel where it intersects the previous mark as shown below.
Center punch and drill a 7/32" pilot hole and then expand it to a 3/4" hole for the temperature sensor. Mount the temperature sensor in the 3/4" hole and adjust it so that it’s tip is approximately 3" from the surface of the drum.
Standard Air Step 4 Connect the remaining wires to the Breakout Board. Fasten the two black wires into the connecting block in the connectors marked with the word BRAKE. (The 2 wires can go in either order.) Connect the yellow and black wires from the Brake Control to the two connectors marked with the letters -SIG-. (The 2 wires can go in either order.
Proportional Air Step 4 Complete the breakout board wiring as in the following descriptions: A B C D E (A) Data acquisition cable coming from the optical pickup on the dyno shown on the left. These four wires go to the section of the card Labeled “DRUM”: The red wire connects to R1. The white wire connects to W1. The black wire connects to B1. The silver wire connects to S1. (B) One yellow and one black wire go to the two connections Labeled “PRESS”.
(C) There are five wires in the cable that connects the EPR (shown left) to the breakout board in the spot labeled “Load Control”: The black wire connects to V-. The red wire connects to V+. The clear wire connects to 0+. The green wire connects to 0-. The silver or ground wire connects to SH. (D) The brake wires (shown left) come from the air switch on the Booster Valve Assembly. They connect to the two connectors on the breakout board labeled “BRAKE”. They can connect in either order.
Step 2 Thread the DynoWare Cable under the dyno frame. Proportional Air Step 3 Attach the center panel and tie up the cables as shown below. Standard Air Step 3 Attach all the side panels so that the Dynojet Stickers face outward and the brake wires go through a slot in the center panel as shown below.
Step 4 Connect your shop air to the dyno. Mount the Air Pressure Regulator on the wall in the shop with the bracket provided. Connect a supply air hose to the inlet of the regulator from your shop air supply. Note: Make sure the arrow on the regulator is the same as the direction of the air flow! Connect a 3/8" air hose to the outlet side of the regulator.
Step 6 Check the brakes. The DynoWare Stack must be on to release the brakes. Slowly rotate the drums (this can be done manually) then press the brake button (the red button on the Hand Held Pendant). The button should light up and engage the brakes stopping the drums. Press the button again and the light will go off, disengaging the brake. If the brakes do not engage, make sure the pressure gauge Air Brake Regulator is set to 60 PSI (276 kPa), and check all connections.
Chapter 4 Basic Dyno Operation The Dynojet Dynamometer gives 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. This chapter includes instructions for basic dyno operation. For more detailed instructions, refer to the WinPEP 7 User Guide. This manual can also be found on your WinPEP CD or at www.dynojet.com.
Loading the Vehicle Use the following steps to load a vehicle on the dyno. 1. Verify your computer is running. Set the dyno brake on by pressing the red button on the hand held pendant. 2. For four or all-wheel drive vehicles, measure the wheel base on the vehicle and adjust the 224-4WD dyno to that dimension before driving the vehicle on the dyno. CAUTION: Do not make any adjustments with the vehicle on the dyno. 3. Drive the vehicle onto the dyno and align the vehicle straight with the dyno. 4.
5. When the vehicle is positioned properly on the dyno, shut the engine off. • If the vehicle has an automatic transmission, place it in park. • If the vehicle has a manual transmission, place it in gear. 6. Set the vehicle’s emergency brake. 7. Secure the non-drive wheels using the provided tire chocks. Do not use tire chocks for four wheel drive vehicles. 8. Attach the tie-down straps. Rear Wheel Drive • Attach two tie-down straps from secure anchor points to the rear of the vehicle.
9. Tighten the tie-down straps evenly making sure that the drive wheels remain centered on the drum. CAUTION: The tie-down straps should always be connected to the vehicle’s solid axle or the suspension control arms. Factory tie-down hooks connected to the vehicle’s frame may be used on the end opposite the drive wheels (for example: the front end of a rear driven vehicle). 10. Release the brake on the vehicle and the dyno. 11. Start the vehicle and put the transmission into first gear or drive. 12.
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. Generally you will use one secondary wire inductive pickup on a spark plug wire. Vehicles with wasted spark ignition systems may require two secondary inductive pickups.
RPM Pickup Descriptions RPM pickup Secondaries (Non- wasted spark system) Secondaries (Wasted spark ignition system) Primary pickup Optional Optical RPM Sensor 4-6 description Use one secondary pickup. Unplug the other pickup from the RPM module and set the degrees between plug fires to 720° in WinPEP 7. Use two secondary pickups. Attach one pickup on each spark plug wire on the same coil and set the degrees between plug fires to 360° in WinPEP 7.
Connecting the Secondary Inductive Pickup The secondary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray RF interference may result. 1. Clip the secondary inductive pickup around one spark plug wire. 2. Route the inductive pickup cable clear of devices that produce electronic noise (spark plug wires, coil wire, coil etc.) to the dyno electronics RPM module. Note: Inductive pickup placement is important.
Connecting The Primary Inductive Pickup The primary inductive pickup cannot be in contact with, or it’s connecting wire be crossing, other engine electrical wires or stray RF interference may result. 1. Clip the primary inductive pickup around the wire to the primary side of the coil. 2. Route the primary wire cable clear of devices that produce electronic noise to the dyno electronics RPM module. Note: You must ground the vehicle to the dyno for the electronics to function properly.
Pre-run Inspection Perform a vehicle inspection before making a run. • Check the radiator coolant (if applicable) and oil levels. • Check the fuel source. • Rotate the drum and check for rocks caught in the tire tread that could fly out. • Check the tire pressure and tire speed rating. Improperly inflated tires or exceeding the maximum speed rating can result in premature wear or severe tire damage. Make sure the tire has no major deficiencies (cracks in sidewalls, tread life, etc.).
Engine Warm Up Warm the vehicle’s engine and drivetrain before beginning testing. Consistent engine temperatures will assure your runs are repeatable. After Engine Warm Up Always leave the vehicle in neutral (automatic transmission) or in first gear (manual transmission), with the engine off, and make sure the park brake and the dyno brake are on when you get off the vehicle on the dyno. • Fix any fuel, oil, or coolant leaks that may have shown up after engine warm up and check the carburetor for leaks.
Making a Test Run Dyno runs provide safe, reliable road testing right in the shop. The dyno allows you to measure, record, and diagnose performance problems quickly. The dyno combined with WinPEP 7 produces consistent, easily interpretable power graphs. Use the following instructions to ensure repeatable and accurate measurements. 1. Verify the vehicle is secured properly. 2. Place the vehicle in a low gear and release the dyno brake using the hand held pendant. 3. Slowly accelerate the vehicle to 20 m.p.h.
Appendix A - Square the face of the dyno up to the face of the four post lift. The distance between the two is 4”.
Appendix A A-2 Document #98219101
