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DynoWare RT Upgrade for Model 424x Dynamometers Installation Guide

T A B L E O F C O N T E N T S

DynoWare RT Upgrade for Model 424x Dynamometers Installation Guide

Chapter 3

Model 424 DynoWare RT Upgrade



with Eddy Current Brake

Unpacking the DynoWare RT Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Remove the DynoWare EX Electronics

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

DynoWare RT Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Installing the Split Disk and Speed Pickup Card  . . . . . . . . . . . . . . . . . . . . . . . . . .  3-12
Aligning the Speed Pickup Card  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-14
Installing the Eddy Current Brake Driver—Above Ground Dynos  . . . . . . . . . . . .  3-15
Installing the Eddy Current Brake Driver—In Ground Dynos  . . . . . . . . . . . . . . . .  3-16

Cable Routing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Identifying the Cables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-17
Removing the DynoWare EX Cables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-19
Routing the Cables   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  3-21

Testing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

Replace Covers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28

Replacing the Covers—Above Ground Dynos . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Replacing the Covers—In Ground Dynos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Load Cell Calibration

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

Chapter 4

Basic Dyno Operation

Loading the Vehicle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Connecting the RPM Pickup

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

RPM Pickup Descriptions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-6
Connecting the Secondary Inductive Pickup  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-7
Connecting the Primary Inductive Pickup   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-8

Grounding the Vehicle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Pre-Run Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Before Starting the Engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-10
Engine Warm Up  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-11
After Engine Warm Up   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-11

Making a Test Run

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Preventative Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Things to Check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-13
Verifying the SAAR Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-14
Maintaining the SAAR Brake Shoe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4-15
Dynos with 4WD Attachment—Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . .  4-17

Index

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

Summary of Contents for Dynoware RT

Page 1: ......

Page 2: ...esponsibility or liability for any error or inaccuracies that may appear in this manual Except as permitted by such license no part of this manual may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical recording or otherwise without the prior written permission of Dynojet The Dynojet logo is a trademark of Dynojet Research Inc Any trademarks...

Page 3: ...ke Unpacking the DynoWare RT Parts 2 2 Remove the DynoWare EX Electronics 2 3 Removing the Pit Covers In Ground Dynos 2 3 Removing the Logo Panels Above Ground Dynos 2 5 Removing the Pickup Card Bracket and Cable 2 6 Removing the Breakout Board 2 7 DynoWare RT Installation 2 8 Installing the Speed Pickup Card and Bracket 2 8 Aligning the Speed Pickup Card 2 9 Cable Routing 2 10 Identifying the Cab...

Page 4: ... Pickup Card 3 14 Installing the Eddy Current Brake Driver Above Ground Dynos 3 15 Installing the Eddy Current Brake Driver In Ground Dynos 3 16 Cable Routing 3 17 Identifying the Cables 3 17 Removing the DynoWare EX Cables 3 19 Routing the Cables 3 21 Testing 3 27 Replace Covers 3 28 Replacing the Covers Above Ground Dynos 3 28 Replacing the Covers In Ground Dynos 3 29 Load Cell Calibration 3 30 ...

Page 5: ...ynamometer Dynojet is not responsible for damage incurred due to alteration of the dynamometer or components use of unapproved parts or abuse to the dynamometer Do not connect or disconnect cables or components on the dynamometer with the power on Always wear protective clothing ear protection and eye protection goggles safety glasses when using and servicing the dynamometer CAUTION Equipment Powe...

Page 6: ...omeone touch that person with your hand first then hand them the component Always carry circuit boards in anti static bags when the boards are exposed removed from the dynamometer CAUTION Battery Fire and Explosion Hazards There is a danger of explosion if the battery is incorrectly replaced Replace only with the same or equivalent type recommended by the manufacturer Discard used batteries accord...

Page 7: ... stand behind the dynamometer when in operation Never operate the dynamometer when there is excessive vibration or noise Resolve these problems before proceeding Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken Verify brake operation before beginning any dynamometer testing Verify the vehicle is properly secured to the dynamometer Verify the vehicle is properl...

Page 8: ......

Page 9: ...iagnostic tools of Power Core software and a Dynojet dynamometer will give you the professional results you require This document provides instructions for removing the DynoWare EX and installing the DynoWare RT upgrade to Dynojet s model 424 dynamometers dyno This document will walk you through the installation and basic dyno operation using DynoWare RT and Power Core software To ensure safety an...

Page 10: ...port assistance or watch one of our informative videos Access the electronic version of this guide along with additional accessory guides software guides and the latest technical bulletins at www dynojet com downloads example of convention description CAUTION The Caution icon indicates a potential hazard to the dynamometer equipment Follow all procedures exactly as they are described and use care ...

Page 11: ...age 4 9 CAUTION Never operate the dyno without properly grounding the vehicle to the dyno description minimum specifications recommended specifications Operating System Windows 7 or later Windows 7 or later Processor Dual Core Processor 2GHz or faster Intel Core i5 2 8GHz or faster Memory 4GB System Ram 8GB System Ram or more Hard Drive 100GB or larger 54MB required for program 500GB or larger 54 ...

Page 12: ...ule and a speed pickup Optional modules include the Air Fuel Ratio AFR module and the Eddy Current Brake ECB driver Use this section to identify the modules and connections More detailed information for configuring the DynoWare RT electronics can be found in the Power Core Help Figure 1 1 DynoWare RT Electronics air fuel ratio module eddy current brake driver main module speed pickup ...

Page 13: ...s Communication I O Connect to auxiliary dyno electronics such as the pendant atmospheric module etc Emergency Stop Connects the dyno electronics to the emergency stop input on the 200i 250i dynos Communication I O Connect to internal dyno electronics and controllers such as the ECB controller and AFR module Network Connection Connects the dyno electronics to your computer or computer network Drum...

Page 14: ...DynoWare RT on a network a single dedicated computer for the dyno is no longer required Any computer on the network can connect and operate the dyno A wireless connection allows you to control the dyno from inside the vehicle without a cable running to the DynoWare RT main module Note The DynoWare RT allows only one computer at a time to connect When the DynoWare RT main module is on a network con...

Page 15: ...ynoWare RT upgrade on your model 424 Dynojet Dynamometer without the eddy current brake To ensure safety and accuracy in the procedures perform the procedures as they are described This chapter is divided into the following categories Unpacking the DynoWare RT Parts page 2 2 Remove the DynoWare EX Electronics page 2 3 DynoWare RT Installation page 2 8 Cable Routing page 2 10 Testing page 2 17 Repl...

Page 16: ...6100007 network cable P N 42900000 vehicle grounding kit P N 76100015 connector P N 44329902 CAN termination plug P N 76423045 socket 2 P N 44359120 primary inductive pickup 2 P N 76950201 ferrule 2 P N 44997102 secondary inductive pickup 2 P N 76950203 DynoWare RT main module P N 66100016 cable speed pickup brake 35 2 P N 76950547 remote atmos assembly P N 66400011 cable CAN dyno user 15 P N 7695...

Page 17: ...bolt securing the stationary bridge cover and set aside 7 Remove the two 3 8 16 x 1 2 inch button head flange bolts securing the stationary bridge cover to each runner support pillar and set aside 8 Remove the stationary bridge cover and set aside 9 Remove the 3 8 x 1 5 inch flange bolt from each runner mount Loosen the other runner mount bolts this allows you to remove the drum guard 10 Remove th...

Page 18: ...gure 2 1 Remove the Pit Covers stationary bridge cover 4WD bridge cover stationary runner mount stationarydrum guard 4WD runner mount runner extension runner assembly 4WD drum guard left forward pit cover runner tie strap slide runner assembly back to access bolts runner extension runner extension support leg support pillar ...

Page 19: ...llation Guide REMOVING THE LOGO PANELS ABOVE GROUND DYNOS Remove the logo panel from the speed pickup end of your above ground dynos 1 Remove the five screws securing each logo panel and set aside 2 Remove the logo panels and set aside 3 You may wish to remove the bridge covers for easier access to the air hoses Figure 2 2 Remove the Logo Panels logo panel bridge covers ...

Page 20: ...t 2 Rotate each drum until the pickup tab is aligned with the pickup card 3 Set the brake and turn the dyno electronics off Note You must line the pickup tab with the pickup card before removing the Breakout board The drum will not rotate once the Breakout board is removed 4 Mark the position of the bracket The new pickup card bracket must line up with the position of the existing bracket Be sure ...

Page 21: ...he black wires running from the air solenoid to the Breakout board 2 DynoWare RT does not support the Breakout board controlled Gen 4 AFR 4 air pump and O2 sensors used with DynoWare EX and WinPEP 7 Disconnect and remove the Gen 4 relay and wires from the Breakout board Remove the Gen 4 components from the dyno You may replace the Gen 4 air pump and sensor s with the optional DynoWare RT Air Fuel ...

Page 22: ...structions to install the speed pickup card and bracket on both the above and in ground dynos Be sure to install the speed pickup card and bracket on the stationary and 4WD dyno 1 Secure the speed pickup card to the bracket using the two screws removed earlier 2 Attach the black 3 pin connector from the DynoWare RT speed pickup brake cable P N 76950547 to the speed pickup card Figure 2 6 Secure th...

Page 23: ...stationary and 4WD dyno 1 While looking through the optical pickup window note the position of the tab in the optical pickup The tab should be centered in the optical pickup and not contacting it 2 If the tab is not centered adjust by loosening the mounting screws CAUTION The optical pickup is very delicate Be careful not to damage the optical pickup Figure 2 8 Align the Optical Pickup Card Tab AD...

Page 24: ...remote atmos cable assembly connects to the DynoWare RT D 76100007 CAN pendant cable assembly connects to the DynoWare RT E 76950201 primary RPM pickup cable 76950203 secondary pickup cable connects to the DynoWare RT F 76950547 speed pickup brake cable connects the brake solenoid and speed pickup to the DynoWare RT G 76950665 Linx detect sensor cable connects the Linx to the DynoWare RT the Linx ...

Page 25: ... track you will need to disconnect them from the stationary dyno Be sure to note or mark the air hose positions before disconnecting the hoses The hoses must be reconnected in the same position 2 Pull the cable track out from under the dyno 3 Using a screwdriver open the crossbar on each link Figure 2 9 Open the Crossbar I 76950807 CAN control cable adapter 2 connects the DynoWare RT to the CAN dy...

Page 26: ...5 Remove the brake signal cable from the cable track and discard 6 Disconnect the 4WD dyno speed pickup cable from the DRUM 2 terminals on the Breakout board 7 If not already done disconnect the 4WD dyno speed pickup cable from the pickup card on the 4WD dyno 8 Remove the 4WD dyno speed pickup cable from the cable track and discard 9 Continue with Routing the Cables on page 2 13 Figure 2 10 4WD Mo...

Page 27: ...6 for routing and connecting the cables 1 Locate the white 2 pin connector on the 4WD speed pickup brake cable F 2 Cut the 2 pin connector off the speed pickup brake cable 3 For dynos without the Linx option Strip a 1 4 inch of the housing off the wires crimp a ferrule P N 44997102 onto each bare wire and connect these wires to the BRK IN terminals on the 4WD board Figure 2 11 4WD Movement Board C...

Page 28: ...he crossbars on the cable track links 7 Route the cable track back underneath the dyno 8 Secure the cable track to the front rail tie assembly using the two 1 4 20 x 1 inch hex head screws and two washers removed earlier 9 On the stationary dyno locate the two black brake solenoid leads These wires were disconnected from the Breakout board earlier 10 Clip the ferrules off the brake solenoid leads ...

Page 29: ... termination plug J when using the optional air fuel module 15a Attach the CAN adapter cable I to the back of the DynoWare RT main module 15b Attach the CAN dyno user cable H to the CAN adapter cable I and route to the AFR assembly Attach the CAN dyno user cable H to the AFR assembly Note The AFR module is an optional accessory 15c Insert the CAN termination plug J in the CAN dyno user cable H Fig...

Page 30: ...C H A P T E R 2 Cable Routing DynoWare RT Upgrade for Model 424x Dynamometers Installation Guide 2 16 Figure 2 14 Routing the Cables ...

Page 31: ...odel 424x Dynamometers Installation Guide TESTING 1 Turn on the DynoWare RT module This switch is located on the rear of the module 2 Using the pendant release the brake 3 Spin each drum Look for the LED on the speed pickup cards to flash 4 Apply the brake Figure 2 15 Use the Pendant to Release the Brake release brake ...

Page 32: ...WD dyno using the 3 8 x 5 inch bolt and 3 8 nut removed earlier 5 Secure the runner tie strap using the 1 4 x 5 8 inch torx bolt removed earlier 6 Slide the stationary drum guard back under the runner mount Secure the left drum guard to the stationary dyno using the 3 8 16 x 1 25 inch button head bolt removed earlier Note The stationary drum guards are longer 88 90cm 35 00 in than the drum guards ...

Page 33: ...Installation Guide Figure 2 16 Install the Pit Covers stationary bridge cover 4WD bridge cover stationary runner mount stationarydrum guard 4WD runner mount runner extension runner assembly 4WD drum guard left forward pit cover runner tie strap slide runner assembly back to access bolts runner extension runner extension support leg support pillar ...

Page 34: ... Model 424x Dynamometers Installation Guide 2 20 INSTALLING THE LOGO PANEL ABOVE GROUND DYNOS 1 Secure each logo panel using the five screws removed earlier 2 Replace the bridge covers if removed Figure 2 17 Install the Logo Panels logo panel bridge covers ...

Page 35: ...ade on your model 424 Dynojet Dynamometer with eddy current brakes To ensure safety and accuracy in the procedures perform the procedures as they are described This chapter is divided into the following categories Unpacking the DynoWare RT Parts page 3 2 Remove the DynoWare EX Electronics page 3 5 DynoWare RT Installation page 3 12 Cable Routing page 3 17 Testing page 3 27 Replace Covers page 3 28...

Page 36: ...r 8 P N 134490301 vehicle grounding kit P N 76100015 screw 4 40 x 1 4 ph pan zinc 8 P N 1904004 CAN termination plug P N 76423045 bracket eddy current brake driver 4 P N 21200068 primary inductive pickup 2 P N 76950201 power cord 125V 10A P N 318110301 secondary inductive pickup 2 P N 76950203 network cable P N 42900000 cable speed pickup brake 35 2 P N 76950547 connector P N 44329902 cable IR tem...

Page 37: ... module P N 66100016 cable CAN dyno user 15 P N 76950798 included with the optional air fuel module remote atmos assembly P N 66400011 cable CAN control adapter P N 76950807 eddy current brake driver 2 P N 66400019 screw mach 8 32 x 1 2 8 P N 8 32 X 5 SCREW speed pickup 2 P N 68300002 bumper 3 8 x 1 2L 8 P N A10Z 2 304A pendant assembly P N 76100007 DynoWare RT speed upgrade kit split disk 2 P N 7...

Page 38: ... Speed Upgrade Kit P N 78100057 inner bracket speed pickup card P N 21600085 screw 1 4 20 x 1 1 8 socket head 2 P N 36562094 outer bracket speed pickup card P N 21600086 screw mach 8 32 x 1 2 8 P N 8 32 X 5 SCREW split disk 2 P N 22300009 nut 3 8 16 hex 2 P N DM150 011 004 split hub 2 P N 22400016 bolt 3 8 16 x 1 hex 2 P N DM150 019 012 part description part description ...

Page 39: ...Refer to Figure 3 20 on page 3 25 for routing the cables with one eddy current brake REMOVING THE PIT COVERS IN GROUND DYNOS 1 Remove the two 3 8 16 x 3 inch bolts and seven 3 8 16 x 1 2 inch button head bolts securing the left pit cover and set aside 2 Remove the left pit cover and set aside 3 Remove the three 3 8 x 1 5 inch bolts and three 3 8 inch flat washers securing each eddy current brake p...

Page 40: ...the stationary and 4WD dynos 1 Remove the six screws securing the logo panel and set aside 2 Remove the logo panel and set aside 3 Remove the four screws securing the small top cover and set aside 4 Remove the small top cover and set aside 5 Remove the eight screws securing the large top cover and set aside 6 Remove the large top cover and set aside Figure 3 2 Remove the Logo Panel and ECB Top Cov...

Page 41: ...t the power cable from the theta controller Leave this cable in place 2 Disconnect the controller cable from the theta controller Leave this cable in place 3 Disconnect the signal cable from the Breakout board and remove this cable from the cable track Refer to Removing the DynoWare EX Cables on page 3 19 4 Remove the four screws securing the theta controller to the bracket and set aside 5 Remove ...

Page 42: ...controller Leave this cable in place 2 Disconnect the controller cable from the theta controller Leave this cable in place 3 Disconnect the signal cable from the Breakout board and remove this cable from the cable track Refer to Removing the DynoWare EX Cables on page 3 19 4 Remove the four screws securing the theta controller to the brake and set aside 5 Remove the theta controller Figure 3 4 Rem...

Page 43: ...Gen 4 relay and wires from the Breakout board Remove the Gen 4 components from the dyno You may replace the Gen 4 air pump and sensor s with the optional DynoWare RT Air Fuel Ratio module kit P N 77000008 Please contact Dynojet for more information 5 Disconnect the brake solenoid leads from the Breakout board These are the black wires running from the air solenoid to the AIR BRAKE terminal on the ...

Page 44: ...nnect the speed pickup cable Note Remove the pickup card bracket pickup card and speed pickup cable from both the stationary and 4WD dyno 4 DynoWare RT does not support the Breakout board controlled Gen 4 AFR 4 air pump and O2 sensors used with DynoWare EX and WinPEP 7 Disconnect and remove the Gen 4 relay and wires from the Breakout board Remove the Gen 4 components from the dyno You may replace ...

Page 45: ...he Breakout board 6 Disconnect the brake signal cable twisted pair of wires from the BRAKE SIGNAL terminals on the Breakout board 7 Disconnect the temperature sensor cables from the TEMP FROM DRUM 1 and TEMP FROM DRUM 2 terminals on the Breakout board Do not disconnect the sensors from the eddy current brake 8 Remove the four nuts securing the Breakout board to the bumpers and remove the board 9 R...

Page 46: ...ke Driver 2 68300002 Speed Pickup Card 2 8 32 X 5 SCREW Screw Mach 8 32 x 1 2 24 A10Z 2 304A Bumper 3 8 x 1 2L 8 DM150 011 004 Nut 3 8 16 Hex 4 DM150 019 012 Bolt 3 8 16 x 1 Hex 4 INSTALLING THE SPLIT DISK AND SPEED PICKUP CARD Use the following instructions to install the split disk and speed pickup card on the stationary and 4WD dynos for both above ground and in ground installations 1 Secure th...

Page 47: ...ade for Model 424x Dynamometers Installation Guide 4 Secure the split hub and disk to the dyno shaft using two 1 4 20 x 1 1 8 socket head screws 5 Secure the inner bracket to the dyno using two 3 8 16 x 1 inch bolts and two 3 8 inch nuts Figure 3 9 Installing the Split Disk and Speed Pickup Card split disk inner bracket split disk ...

Page 48: ...kup and not contacting it 2 If the tab is not centered adjust the tab by loosening the inner bracket mounting screws and sliding the optical window into position 3 Be sure to tighten the inner bracket mounting screws once aligned 4 Attach the black 3 pin connector from the DynoWare RT speed pickup brake cable P N 76950547 to the speed pickup card on the stationary and 4WD dyno CAUTION The optical ...

Page 49: ...tationary and 4WD dyno 1 Secure the mounting brackets to the eddy current brake driver using two 4 40 x 1 4 inch screws each 2 Secure the four bumpers to the mounting brackets using four 8 32 x 3 8 inch screws Figure 3 11 Install the Mounting Brackets and Bumpers 3 Install the eddy current brake driver to the cover using four 8 32 nuts Figure 3 12 Install the Eddy Current Brake Driver Above Ground...

Page 50: ... mounting brackets to the eddy current brake driver using two 4 40 x 1 4 inch screws each 2 Secure the four bumpers to the mounting brackets using four 8 32 x 3 8 inch screws Figure 3 13 Install the Mounting Brackets and Bumpers 3 Install the eddy current brake driver to the bracket using four 8 32 nuts Figure 3 14 Install the Eddy Current Brake Driver In Ground install bumpers install mounting br...

Page 51: ...power outlet B 42900000 network cable connects the DynoWare RT to your local network C 66400011 remote atmos cable assembly connects to the DynoWare RT D 76100007 CAN pendant cable assembly connects to the DynoWare RT E 76950201 primary RPM pickup cable 76950203 secondary pickup cable connects to the DynoWare RT F 76950547 speed pickup brake cable connects the brake solenoid and speed pickup to th...

Page 52: ...fuel module to the DynoWare RT using the CAN adapter cable the air fuel ratio module is an optional accessory M 76950807 CAN control cable adapter 2 connects the DynoWare RT to the CAN control and CAN dyno user cables N controller cable existing connects the eddy current brake to the eddy current brake driver O power cable existing connects the eddy current brake driver to a power outlet P 7642304...

Page 53: ...e hoses must be reconnected in the same position 2 Pull the cable track out from under the dyno 3 Using a screwdriver open the crossbar on each link Figure 3 15 Open the Crossbar 4 Disconnect each torque cell cable from the DynoWare EX hardware stack 5 Remove the 4WD dyno torque cell cable from the cable track Coil this cable up and place it near the 4WD dyno 6 If not already done disconnect the s...

Page 54: ...e 4WD board 9 Remove the brake signal cable from the cable track and discard 10 Disconnect the 4WD dyno speed pickup cable from the DRUM 2 terminals on the Breakout board 11 If not already done disconnect the 4WD dyno speed pickup cable from the pickup card on the 4WD dyno 12 Remove the 4WD dyno speed pickup cable from the cable track and discard 13 Continue with Routing the Cables on page 3 21 Fi...

Page 55: ...n page 3 26 for routing the cables 1 Locate the white 2 pin connector on the 4WD speed pickup brake cable F 2 Cut the 2 pin connector off the speed pickup brake cable 3 For dynos without the Linx option Strip a 1 4 inch of the housing off the wires crimp a ferrule P N 44997102 onto each bare wire and connect these wires to the BRK IN terminals on the 4WD board Figure 3 17 4WD Movement Board Connec...

Page 56: ... 8 Close the crossbars on the cable track links 9 Route the cable track back underneath the dyno 10 Secure the cable track to the front rail tie assembly using two 1 4 20 x 1 inch hex head screws and two washers 11 On the stationary dyno locate the two black brake solenoid leads These wires were disconnected from the Breakout board earlier 12 Clip the ferrules off the brake solenoid leads strip a ...

Page 57: ... RT module 19 Connect the remote atmos cable C to the DynoWare RT module 20 Attach the CAN adapter cable M to the back of the DynoWare RT main module 21 Attach the CAN dyno user cable L to the CAN adapter cable M and route to the AFR assembly Attach the CAN dyno user cable L to the AFR assembly Note The AFR assembly is an optional accessory 22 Attach the CAN control cable J to the T on the CAN dyn...

Page 58: ...rrent brake driver Attach the load cell cable adapter to the eddy current brake driver 27 Connect the controller cable N to each eddy current brake driver This cable was unplugged from the theta controller 28 Connect the power cable O to each eddy current brake driver This cable was unplugged from the theta controller 29 Connect the power cable A to the DynoWare RT module Plug the power cable into...

Page 59: ...L 4 24 D YN OWA R E R T UP G R A DE W IT H ED DY C U RR ENT B R A KE Cable Routing Version 5 DynoWare RT Upgrade for Model 424x Dynamometers Installation Guide Figure 3 20 Routing the Cables One Eddy Current Brake ...

Page 60: ...C H A P T E R 3 Cable Routing DynoWare RT Upgrade for Model 424x Dynamometers Installation Guide 3 26 Figure 3 21 Routing the Cables Two Eddy Current Brakes ...

Page 61: ...r Model 424x Dynamometers Installation Guide TESTING 1 Turn on the DynoWare RT module This switch is located on the rear of the module 2 Using the pendant release the brake 3 Spin each drum Look for the LED on the speed pickup cards to flash 4 Apply the brake Figure 3 22 Use the Pendant to Release the Brake release brake ...

Page 62: ...COVERS ABOVE GROUND DYNOS Replace the logo panel and eddy current brake top covers on both the stationary and 4WD dynos 1 Secure the small top cover using the four screws removed earlier 2 Secure the large top cover using the eight screws removed earlier 3 Secure the logo panel using the six screws removed earlier Figure 3 23 Install the Logo Panel and ECB Top Covers AD634 logo panel small top cov...

Page 63: ... 16 x 3 inch bolts and seven 3 8 16 x 1 2 inch button head bolts removed earlier 2 Secure each eddy current brake pit cover to the support leg using the 3 8 x 1 inch bolt removed earlier 3 Secure each eddy current brake pit cover to the floor using the three 3 8 x 1 5 inch bolts and three 3 8 inch flat washers removed earlier Figure 3 24 Install the Pit Covers AD633 left pit cover eddy current bra...

Page 64: ...eight 4 61319001 Calibration Arm Assembly 1 Double click the Power Core program icon 2 Click Dyno Control from the Application Launcher 3 Verify you are connected to the DynoWare RT Note For more information on connecting to the DynoWare RT refer to the Power Core Quick Start Guide included with your dyno or the Power Core Help 4 Click the Configuration tab 5 Click Load Cell Calibration Note Befor...

Page 65: ...ion click Finish Figure 3 26 Calibration Mass Window Enter the calibration number stamped near the bolt pattern at the end of the calibration arm in the Mass box If you do not have enough room to use the bolt pattern closest to the end of the calibration arm use the number stamped near the bolt pattern in the center of the arm Note Dynojet recommends you secure the calibration arm using the bolt p...

Page 66: ... the rear of the vehicle Note Calibration arm placement determines positive direction for torque Place the weights towards the rear of the vehicle Refer to step 9 and Figure 3 29 on page 3 33 for calibration arm installation instructions Figure 3 28 Calibration Bar Placement direction of rotation direction of rotation direction of torque ...

Page 67: ...er of the arm 9a Secure the calibration arm to the eddy current brake by tightening the bolt using the handle 9b Gently place the weights on the calibration arm Note Verify the calibration arm is not contacting the cover CAUTION The calibration weights are very heavy The weights must be set on the arm gently to avoid damaging the load cell Figure 3 29 Install Calibration Arm and Weights weights we...

Page 68: ... click Next to continue 11 Once sending the torque cell calibration is complete click Next to continue Figure 3 30 Sending Torque Cell Calibration Window 12 Remove the calibration arm and weights and click Finish Figure 3 31 Calibration Is Complete Window Refer to your Power Core Help for more information on creating a torque gauge and viewing torque values ...

Page 69: ...surements a technician needs to make quick and accurate evaluations of engine performance and drivetrain problems This chapter includes instructions for basic dyno operation For more detailed instructions refer to the Power Core Help This chapter is divided into the following categories Loading the Vehicle page 4 2 Connecting the RPM Pickup page 4 6 Grounding the Vehicle page 4 9 Pre Run Inspectio...

Page 70: ...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 tire chock 4 P N 2A092 car tie down 2 x 10 4 P N 500 C10 short axle strap 10M 2 x 21 4 P N 30AS21 car tie down high performance 2 x 10 2 P N 500 C10W S long axle strap 10M 2 x 72 4 P N 30AS72 ...

Page 71: ... the same height as the dyno 4 Drive the vehicle onto the dyno and align the vehicle straight with the dyno 5 Stop the vehicle when the drive axles are centered on the drums Figure 4 1 Center the Drive Axles on the Drums 6 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 pl...

Page 72: ...front of the vehicle Attach additional tie down straps across the front of the vehicle to form a crisscross With front wheel drive vehicles always use longitudinal and cross straps at the front of the vehicle Four Wheel All Wheel Drive Attach two tie down straps from secure anchor points to the rear of the vehicle Attach additional tie down straps across the rear of the vehicle to form a crisscros...

Page 73: ...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 11 Release the brake on the vehicle and the dyno 12 Start the vehicle and put the transmission into first gear or drive 13 Press the accelerator pedal so the drums begin turning slowly While the drums are slowly turning ...

Page 74: ...pping vibration and heat can all damage the ferrite core The DynoWare RT contains the electronics that sense the RPM pulses You will need the following parts RPM PICKUP DESCRIPTIONS part description part description inductive primary pickup 2 P N 76950201 inductive secondary pickup 2 P N 76950203 RPM pickup description Secondaries Non wasted spark system Use one secondary pickup Set the degrees be...

Page 75: ...PM port on the DynoWare RT module making sure the cable is clear of devices that produce electronic noise spark plug wires coil wire coil etc Note Inductive pickup placement is important Position the inductive pickup so that it is not making contact with any other spark plug wires Separate the spark plug wire from the spark plug wire bundle for proper operation Note You must ground the vehicle to ...

Page 76: ...nce may result 1 Clip the primary inductive pickup around the negative side of the coil 2 Route the primary wire cable to the RPM port on the DynoWare RT module making sure the cable is clear of devices that produce electronic noise spark plug wires coil wire coil etc Note You must ground the vehicle to the dyno for the electronics to function properly Refer to Grounding the Vehicle on page 4 9 Fi...

Page 77: ...no without first grounding the vehicle to the dyno You will need the following parts 21600084 Grounding Bracket 36560834 Screw 1 4 20 x 1 2 76950788 Vehicle Grounding Cable 1 Choose any location on your dyno with a black 1 4 20 x 5 8 inch torx screw that threads directly into the sheet metal and remove this screw 2 Secure the grounding bracket to this location using one 1 4 20 x 1 2 inch screw 3 A...

Page 78: ...down straps to make sure that they are tight and secured Check the drive tires to be sure that they are aligned correctly on the dyno drums Keep all rotating components clear at all times Only the operator should be near the dyno or the vehicle during the test Never allow any person s to stand behind the dyno or vehicle when it is being operated Perform any other safety inspections appropriate to ...

Page 79: ... runs are repeatable AFTER ENGINE WARM UP 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 Fix any fuel oil or coolant leaks that may have shown up after engine warm up and check the carburetor for leaks Any loud or unusual engine noises or exc...

Page 80: ...umber is incorrect 5b Select Run File Information to enter vehicle information 6 Place the vehicle in a low gear and release the dyno brake using the hand held pendant 7 Slowly accelerate the vehicle to 20 m p h 8 Press the red brake button to apply 100 braking and slow down the vehicle CAUTION Using the vehicle s own brakes to slow or stop the drum at speeds over 30 m p h can severely overheat th...

Page 81: ...ure gauge reads 100psi 690kPa Adjust the regulator if the pressure is out of specification Refer to page 4 14 for more information Check the brake shoe clearance Refer to page 4 15 for more information Dyno Bearing Grease Under steady use over 25 runs per day each bearing should receive 65oz 19 ml of a recommended grease every two months Under occasional use less than 25 runs per day each bearing ...

Page 82: ...Verify the SAAR brake pressure gauge reads 100psi 690kPa 2 Using the knob adjust the regulator until the correct pressure is achieved Figure 4 6 Verify the SAAR Brake Pressure and Adjust the Regulator AB096 use the knob to adjust the regulator until the correct pressure is achieved brake pressure regulator 0 AB095 brake pressure gauge 100psi 690kPA ...

Page 83: ...l release the SAAR brake by moving the brake shoe away from the drum Keep hands and fingers clear when operating the dyno 4 Measure the gap between the brake shoe and the drum surface This gap should be between 125 inch 375 inch 3mm 10mm Note For clarity the dyno frame is shown transparently to reveal the drum Note The mounting bracket shown is used with the SAAR upgrade Factory installed SAAR bra...

Page 84: ...6 Adjust the lower nut until the brake shoes are 25 inch 6mm away from the dyno drum 7 Tighten the upper nut on the air can rod down onto the brake actuating tube 8 Torque the lower nut to 110 foot pounds If you cannot adjust the brakes to specification you will need new brake shoes Contact Dynojet for more information Figure 4 8 Adjust the Brake Shoe Clearance BR032 lower nut air can rod upper nu...

Page 85: ...once every six months fill as necessary Remove the cap on the hydraulic motor Add additional AW 68 hydraulic fluid as needed Replace the cap Figure 4 9 Fill the Hydraulic Motor with Oil Inspect the hoses connecting the hydraulic motor to the ram Replace as necessary P N 11100000 Inspect the 4WD dyno movement rails for debris once per month Clear any debris from the rails AD502 remove cap on hydrau...

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Page 87: ...ontroller cable 3 18 conventions 1 2 crossbar 2 11 3 19 D disclaimers iii document part number 1 1 dyno electronics 1 4 DynoWare EX removing 2 3 3 5 removing breakout board 2 7 3 9 3 10 removing pickup card 2 6 3 9 3 10 DynoWare RT eddy current brake driver 3 15 3 16 installing 2 8 3 12 main module 1 5 network connections 1 6 overview 1 4 power cable 2 10 2 15 3 17 3 24 speed pickup 2 8 3 12 speed...

Page 88: ...rake solenoid leads 2 14 3 22 CAN control 2 11 3 18 CAN dyno user 2 10 3 18 CAN pendant 2 10 2 15 3 17 3 23 CAN termination plug 2 11 3 18 controller cable 3 18 DynoWare RT power 2 10 2 15 3 17 3 24 eddy current brake power 3 18 identifying cables 3 17 IR temp sensor 3 17 3 24 linx detect sensor cable 2 10 3 18 load cell cable 3 17 3 24 network 2 10 3 17 opening crossbar 2 11 3 19 remote atmos 2 1...

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Summary of Contents for Dynoware RT

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Dynojet Dynoware RT, Installation Manual, Page: 4 / 88

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Summary of Contents for Dynoware RT

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