Dynojet 424 User manual

©2006-2016 Dynojet Research, Inc. All Rights Reserved.
Installation Guide For Above Ground Model 424x and 424xLC2Automotive
Dynamometers.
This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet,
and all rights are reserved. This manual, and the software described in it, is furnished
under license and may only be used or copied in accordance with the terms of such
license. This manual is furnished for informational use only, is subject to change without
notice, and should not be construed as a commitment by Dynojet. Dynojet assumes no
responsibility or liability for any error or inaccuracies that may appear in this manual.
Except as permitted by such license, no part of this manual may be reproduced, stored in
a retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
recording, or otherwise, without the prior written permission of Dynojet.
The Dynojet logo is a trademark of Dynojet Research, Inc.
Any trademarks, trade names, service marks, or service names owned or registered by any
other company and used in this guide are the property of their respective companies.
Dynojet Research, Inc., 2191 Mendenhall Drive, North Las Vegas, Nevada 89081, USA.
Printed in USA.
Part Number: 98200054 Version 3 (05/2016)
#
RECORD
Stationary Dynamometer Number: ______________________________________________
Eddy Current Brake
(Retarder) Number:____________________________________________________________
4WD Dynamometer Number: ___________________________________________________
Eddy Current Brake
(Retarder) Number:_________________________________________________________

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Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
T ABLE OF C ONTENTS
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Chapter 1 Specifications and Operating Requirements
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Dynamometer Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Computer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Forklift Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Phone and Internet Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Tie-Down Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Tool Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Model 424 Stationary and 4WD Dynamometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Model 424 4WD Dynamometer With Bridge and Deck . . . . . . . . . . . . . . . . . . . 1-13
DynoWare RT Electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Main Module Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Network Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Lift Specifications and Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
Chapter 2 Stationary Dyno Installation
Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Placing the Dyno in Front of the Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Installing the Interface Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Anchoring the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Installing the Air Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

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Chapter 3 4WD Dyno Installation
Unpacking and Inspecting the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Installing the Track Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Removing the Dyno from the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Placing the Dyno on the Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Identifying the Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Routing the Cables—Without the Eddy Current Brakes . . . . . . . . . . . . . . . . . . . . 3-15
Routing the Cables—With One Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . 3-19
Routing the Cables—With Two Eddy Current Brakes . . . . . . . . . . . . . . . . . . . . . . 3-23
Hydraulic Movement Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Rotating the Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Wiring the Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Filling the Hydraulic Motor with Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Air Can Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
4WD Dyno Movement Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Bridge Installation—Stationary Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38
Installing the Drum Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
Installing the Runner Mounts and Runner Supports . . . . . . . . . . . . . . . . . . . . . . 3-40
Installing the Runner Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Installing the Bridge Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Bridge Installation—4WD Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Installing the Drum Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Installing the Runner Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Installing the Runner Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
Installing the Cover and Runner Tie Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
Linx Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49
Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
Logo Panel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56
Chapter 4 Eddy Current Brake Installation
Eddy Current Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Before Installing the Eddy Current Brake: Verify Optimal Brake Cooling . . . . . . 4-2
Before Installing the Eddy Current Brake: Verify Mounting Holes . . . . . . . . . . . . 4-3
Unpacking the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Installing the Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Installing the Bearing, Splined Shaft, and Driveline Assembly . . . . . . . . . . . . . . 4-11
Installing the Eddy Current Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installing the Load Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Installing the Front and Rear Brake Covers and Eddy Current Brake Driver . . . 4-16
Installing the Top and Logo Panel Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Load Cell Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

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Version 3 Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
Chapter 5 424 Linx Installation
Linx Belt Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Unpacking the Linx Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Inner Mounting Plate Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installing the Inner Mounting Plate—Moveable Dyno . . . . . . . . . . . . . . . . . . . . . . . 5-7
Installing the Inner Mounting Plate—Stationary Dyno . . . . . . . . . . . . . . . . . . . . . . 5-9
Flange Bearing, Outer Shaft, and Splined Shaft Installation . . . . . . . . . . . . . . . 5-10
Drive Pulley Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Idler Pulley Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Belt and Tensioner Pulley Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Pulley Mounting Plates and Outer Bearings Installation . . . . . . . . . . . . . . . . . . 5-17
Installing the Idler Pulley Outer Bearing, Bearing Mounting Plate,
Linx Detect Sensor, and Lower Pulley Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Installing the Moveable Dyno Pulley Outer Bearing, Bearing Mounting Plate,
and Lower Pulley Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Installing the Upper Moveable Dyno and Idler Pulley Mounts . . . . . . . . . . . . . . 5-22
Installing the Stationary Dyno Pulley Outer Bearing, Bearing Mounting Plate,
and Lower Pulley Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Installing the Upper Stationary Dyno Pulley Mount . . . . . . . . . . . . . . . . . . . . . . . 5-26
Routing the Linx Detect Sensor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Brake Signal Relay Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
Tension the Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Above Ground Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Installing the Right Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
Installing the Left Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37
Installing the Lid and Door Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Continue Dyno Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Disconnect the Belt Drive from the Dyno Drums . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Reconnecting the Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Chapter 6 Side Deck Assembly Installation
Side Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Installing the Side Deck Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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Chapter 7 Basic Dyno Operation
Loading the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Connecting the RPM Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
RPM Pickup Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Connecting the Secondary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Connecting the Primary Inductive Pickup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Grounding the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Pre-run Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
After Engine Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Making a Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Verifying the SAAR Brake Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Maintaining the SAAR Brake Shoe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Dynos with 4WD Attachment—Things to Check . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Appendix A Red Head Anchor Installation
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Contact Information for ITW Ramset/Red Head . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Appendix B Power Requirements and Installation
Power Requirements and Installation—North America, Japan,
and Locations Using 60 Hz Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Power Requirements and Installation—Excluding North America and Japan B-5
Installing the Wall Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Testing for Correct Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Hard Wiring to the Building . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Appendix C Stationary Dyno Upgrade
Deck Relocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Removing the Early Style Deck from an Early Model Dyno . . . . . . . . . . . . . . . . . . C-2
Removing the New Style Deck from a New Model Dyno . . . . . . . . . . . . . . . . . . . . C-6
Installing the Early Style Deck on the 4WD Dyno . . . . . . . . . . . . . . . . . . . . . . . . . C-11
Installing the New Style Deck on the 4WD Dyno . . . . . . . . . . . . . . . . . . . . . . . . . C-15
Lift Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-16
Air Fittings Upgrade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-17

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Version 3 Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
Appendix D Bridge Extension Assembly
Bridge Extension Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Appendix E Interface Roller Assembly Installation
Interface Roller Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Appendix F Linx Belt Drive—Early Version Shafts
Disconnect the Belt Drive from the Dyno Drums . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Appendix G Shaft Safety Wire Installation
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Appendix H D-Lok Bearing Installation
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Contact Information for Baldor•Dodge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Appendix I Torque Values
Standard Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
Grade 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
Grade 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3
Metric Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Grade 8.8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Grade 10.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-i

vii
Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
W ARNINGS
Disclaimers
Dynojet Research, Inc. (Dynojet) makes no representation or warranties with respect to the contents
hereof and specifically disclaims any implied warranties of merchantability for any particular purpose.
Dynojet reserves the right to revise this publication and to make changes from time to time in the
content hereof without obligation of Dynojet to notify any person of such revision or changes.
Dynojet is not responsible for false operation due to unexpected dynamometer operation such as may
be caused by static, software bugs, hardware failure, etc.
Dynojet is not responsible for damage resulting from improper installation of the dynamometer or
from improper service rendered to the dynamometer. Dynojet is not responsible for damage incurred
due to alteration of the dynamometer or components, use of unapproved parts, or abuse to the
dynamometer.
Do not connect or disconnect cables or components on the dynamometer with the power on.
Alwayswearprotectiveclothing,earprotection,andeyeprotection(goggles,safetyglasses)whenusing
and servicing the dynamometer.
Equipment Power Requirements
The dynamometer has specific power requirements. Connecting the dynamometer to the incorrect
voltage will void the dynamometer warranty. Installation may require a licensed electrician.
Potentially Lethal Voltages
Components attached to and within the dynamometer operate with potentially lethal voltages. To
provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power
source before servicing electrical components or wiring. Disconnect all power cords before servicing
electrical components for the greatest assurance of safety.

Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
viii
WARNINGS
Electrostatic Discharge Precautions
Electrostatic Discharge
Electrostatic Discharge (ESD), or static shock, can damage electronic components within the
dynamometer. The damage may occur at the time of an ESD occurrence, or the shock may degrade the
component, resulting in a premature component failure later. To avoid ESD damage, always practice
good ESD control precautions when servicing the dynamometer. Dynojet designs its dynamometers
to be very tolerant of static shocks by the users, but the electronics are vulnerable when the electronics
areexposed.ESDoccursasaresultofadifferenceofpotentialbetweentwoobjectswhenthetwoobjects
touch. Damage occurs as a result of the energy released when the discharge (touch) occurs. The
difference of potential can accumulate by as simple an action as a user moving across carpet or a seat.
If that person’s energy is discharged directly to the electronics, the electronics can be damaged.
Precautions
To protect against ESD damage, you must eliminate the difference of potential before the electronics
arehandled. Touchthe chassisof the dynamometerbefore touchingany oftheelectronics.By touching
the chassis, you discharge any static shocks to the chassis instead of to the electronics.
If you are holding a circuit board or dynamometer component in your hand when you approach the
machine, touch the chassis of the dynamometer with your hand before installing the circuit board or
component.
When handing a circuit board or component to someone, touch that person with your hand first, then
hand them the component.
Always carry circuit boards in anti-static bags when the boards are exposed (removed from the
dynamometer).
Battery Fire and Explosion Hazards
There is a danger of explosion if the battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Discard used batteries according to the
manufacturer’s instructions.
Automotive Batteries
In operation, batteries generate and release flammable hydrogen gas. They must always be assumed
to contain this gas which, if ignited by burning cigarette, naked flame or spark, may cause battery
explosion with dispersion of casing fragments and corrosive liquid electrolyte. Carefully follow
manufacturer's instructions for installation and service. Keep away all sources of gas ignition and do
not allow metallic articles to simultaneously contact the negative and positive terminals of a battery.
Do not allow the positive and negative terminals to short-circuit. The dynamometer chassis is tied to
the negative side of the battery. Do not short between the positive battery terminal or the starter
connections to the chassis. In addition, make sure metal tools such as screw drivers, wrenches, and
torque wrenches do not come in contact with the negative and positive terminals of the battery. Short
circuiting the terminals of the battery can cause burn injuries, damage to the dynamometer, or trigger
explosions.
Charging
Batteries being charged will generate and release flammable hydrogen gas. Charging space should be
ventilated.Keepbatteryventcapsinposition.Prohibitsmokingandavoidcreationofflamesandsparks
nearby.
Wear protective clothing, eye and face protection, when charging or handling batteries.

ix
Version 3 Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
WARNINGS
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.
The dynamometer should be located in a well ventilated area. There is a carbon monoxide hazard with
all internal combustion engines. Engine exhaust contains poisonous carbon monoxide gas. Breathing
it could cause death.
Any dyno room design must incorporate sufficient exhaust extraction.
Equipment is intended for indoor use only. The dynamometer is not designed to be installed or
operated in an outdoor environment.
Always wear proper ear and eye protection when operating the dynamometer.
Never operate the dynamometer with the covers removed.
Never stand behind the dynamometer when in operation.
Never operate the dynamometer when there is excessive vibration or noise. Resolve these problems
before proceeding.
Never fuel the vehicle on the dynamometer unless appropriate safety measures are taken.
Verify brake operation before beginning any dynamometer testing.
Verify the vehicle is properly secured to the dynamometer.
Verify the vehicle is properly grounded to the dynamometer.
Never operate the blowers without the guards installed.
Exercise care with any dynamometer testing; portions of the dynamometer and vehicle may become
hot.
As with any equipment using electricity and having moving parts, there are potential hazards. To use
this dynamometer safely, the operator should become familiar with the instructions for operation of
the dynamometer and always exercise care when using it.
Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically
recommended in published user-repair instructions that you understand and have the skills to carry
out.

1-1
Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
CHAPTER 1
S PECIFICATIONS AND O PERATING
R EQUIREMENTS
Thank you for purchasing Dynojet’s Above Ground Model 424x/424xLC2Automotive
Dynamometer (dyno). Dynojet’s software and dynamometers will give you the power
to get the maximum performance out of the vehicles you evaluate. Whether you are
new to the benefits of a chassis dynamometer or an experienced performance leader,
the repeatability and diagnostic tools of Power Core software and a Dynojet
dynamometer will give you the professional results you are looking for.
This document provides instructions for installing the stationary dyno, the four wheel
drive (4WD) dyno, the eddy current brakes, and the Linx option. This document will
walk you through operating requirements, hardware installation, electronics set up,
and basic dyno operation. To ensure safety and accuracy in the procedures, perform
the procedures as they are described.
Document Part Number: 98200054
Version 3
Last Updated: 05-17-2016
This chapter is divided into the following categories:
• Introduction, page 1-2
• Dynamometer Specifications and Requirements, page 1-5
• Model 424 Stationary and 4WD Dynamometer, page 1-12
• Model 424 4WD Dynamometer with Bridge and Deck, page 1-13
• DynoWare RT Electronics, page 1-14
• Lift Specifications and Requirements, page 1-17

CHAPTER 1
Introduction
Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
1-2
INTRODUCTION
Before installing your dyno, please take a moment to read this guide for installation
instructions, dyno features, and other important information. This guide is designed
to be a reference tool in your everyday work and includes the following chapters and
information:
SPECIFICATIONS AND OPERATING REQUIREMENTS
This chapter describes the specifications and requirements for the dyno.
STATIONARY DYNO INSTALLATION
This chapter describes the procedures for installing the stationary dyno.
4WD DYNO INSTALLATION
This chapter describes the procedures for installing the 4WD dyno.
EDDY CURRENT BRAKE INSTALLATION
This chapter describes the procedures for installing the eddy current brake, torque
module, and load cell. This chapter also includes the procedures for load cell
calibration.
LINX INSTALLATION
This chapter describes the procedures for installing the Linx option.
SIDE DECK ASSEMBLY INSTALLATION
This chapter describes the procedures for installing the side deck assembly.
BASIC DYNO OPERATION
This chapter describes basic dyno operating procedures and maintenance.
RED HEAD INSTALLATION
This appendix describes the procedures for installing the Red Head anchors.
POWER REQUIREMENTS
This appendix describes the power requirements and installation instructions for the
eddy current brake.
STATIONARY DYNO UPGRADE
This appendix describes the procedures for upgrading an existing stationary dyno to
be used with the 4WD dyno.
BRIDGE EXTENSION ASSEMBLY
This appendix describes the procedures for installing the bridge extension assembly.

1-3
SPECIFICATIONS AND OPERATING REQUIREMENTS
Introduction
Version 3 Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
INTERFACE ROLLER ASSEMBLY INSTALLATION
This appendix describes the procedures for installing the interface roller assembly.
LINX BELT DRIVE—EARLY VERSION SHAFTS
This appendix describes the procedures for disconnecting the belt drive from the dyno
drums using early version shafts with the Linx option.
SHAFT SAFETY WIRE INSTALLATION
This appendix describes the procedures for installing the shaft safety wire with the
Linx option.
D-LOK BEARING INSTALLATION
This appendix describes the procedures for installing the Dodge® D-Lok Mounted
Ball Bearings.
TORQUE VALUES
This appendix describes the standard and metric torque values.

CHAPTER 1
Introduction
Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
1-4
CONVENTIONS USED INTHIS MANUAL
The conventions used in this manual are designed to protect both the user and the
equipment.
TECHNICAL SUPPORT
For assistance, please contact Dynojet Technical Support at 1-800-992-3525, or write
to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.
Visit us on the World Wide Web at www.dynojet.com and www.winpep.com where
Dynojet provides state of the art technical support, on-line shopping, and press
releases about our latest product lines.
example of convention description
The Caution icon indicates a potential hazard to the
dynamometer equipment. Follow all procedures
exactly as they are described and use care when
performing all procedures.
The Warning icon indicates potential harm to the
person performing a procedure and/or the
dynamometer equipment.
#
RECORD
The Record # icon reminds you to record your
dynamometer and/or eddy current brake (retarder)
number on the inside cover of this manual.
Bold Highlights items you can select on in the software
interface, including buttons and menus.

The arrow indicates a menu choice. For example,
“select File
 Open”means “select the File menu,
then select the Open choice on the File menu.”
Blue Highlights items you can click on directing you to a
location with additional information.

1-5
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
Version 3 Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
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.
CHASSIS SPECIFICATIONS
description specifications
Length
of frame 73.66 cm (29.00 in.)
including cradle assembly 130.18 cm (51.25 in.)
including air brake 93.83 cm (36.94 in.)
both frames, deck, bridge—full in 397.00 cm (156.30 in.)
both frames, deck, bridge—full in
with extension kit 422.40 cm (166.30 in.)
both frames, deck, bridge—full out 487.68 cm (192.00 in.)
both frames, deck, bridge—full out
with extension kit 513.08 cm (202.00 in.)
Linx option 470.00 cm (185.00 in.)
Height
to top of frame 58.42 cm (23.00 in.)
to top of frame with feet/track
assembly 72.07 cm (28.375 in.)
floor to top of eddy current brake 80.00 cm (31.50 in.)
Width
of frame 218.44 cm (86.00 in.)
of frame with eddy current brake 321.23 cm (126.47 in.)
of frame with eddy current brake and
Linx option 385.00 cm (151.47 in.)
of Linx option 63.50 cm (25.00 in.)
Track Assembly
Length 224.15 cm (88.25 in.)
Width 218.44 cm (86.00 in.)
Weight
stationary crated dyno 2,114 kg (4,660 lb.)
4WD crated dyno 2,495 kg (5,500 lb.)
eddy current brake 635 kg (1,400 lb.)
Drum
diameter 61.00 cm (24.00 in.)
width 206.00 cm (81.00 in.)
Frame structural steel channel and angle
Maximum Speed 322 kph (200 mph)
Maximum Axle Weight 1361 kg (3000 lb.)
Remote Switches remote software control

CHAPTER 1
Dynamometer Specifications and Requirements
Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
1-6
Figure 1-1: Model 424 Stationary Dyno Dimensions
A598D
93.83 cm
(36.94 in.)
frame and
air brake
115.49 cm (45.47 in.)
frame, air brake, and
interface kit
321.23 cm (126.47 in.)
frame and brake
65.58 cm (25.82 in.)
brake only
80.01 cm (31.50 in.)
brake to floor
106.93 cm (42.10 in.)
brake
218.44 cm (86.00 in.)
73.66 cm (29.00 in.)
72.02 cm (28.375 in.)
frame to floor
58.42 cm (23.00 in.)
frame only

1-7
SPECIFICATIONS AND OPERATING REQUIREMENTS
Dynamometer Specifications and Requirements
Version 3 Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
Figure 1-2: Model 424 4WD Dyno with Track Assembly Dimensions

CHAPTER 1
Dynamometer Specifications and Requirements
Above Ground Model 424x/424xLC2Automotive Dynamometer Installation Guide
1-8
Figure 1-3: Model 424 4WD Dyno with Bridge and Deck Dimensions