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2009-2013 Dynojet Research, Inc. All Rights Reserved.

Hydraulic Upgrade for Model 224-4WD Automotive 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: 98200019 Version 02 (01/2013)

TABLE OF CONTENTS

224-4WD Hydraulic UpgradeIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Conventions Used In This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Hydraulic Movement Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Drill and Drill Bit Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Fluid Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Unpacking the Hydraulic Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Prepare the Dyno . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

In Ground DynoRemoving the Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . 6Above Ground DynoRemoving the Rear Deck Panels . . . . . . . . . . . . . . . . 8Removing the Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Removing the Air Motor, Bracket, and Hoses . . . . . . . . . . . . . . . . . . . . . . . 13

Hydraulic Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Installing the Motor Mounting Brackets and Motor . . . . . . . . . . . . . . . . . . 14Installing the Hydraulic Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Installing the Control Assembly Mounting Bracket . . . . . . . . . . . . . . . . . . . 19Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Filling the Hydraulic Motor with Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . 23Testing the Hydraulic Motor and Dyno Movement . . . . . . . . . . . . . . . . . . 24

Replace the Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Replacing the Pit Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Replacing the Rear Deck Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Appendix A Red Head Anchor InstallationInstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Appendix B Control Box RemovalRemove the Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

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

Hydraulic Upgrade for Model 224-4WD Automotive Dynamometersi

224-4WD HYDRAULIC UPGRADE

Thank you for your interest in Dynojets Automotive Dynamometers. Dynojets software and dynamometers will give you the power to get the maximum performance out of 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 WinPEP 7 software and a Dynojet dynamometer (dyno) will give you the professional results you are looking for.

This document is designed to help you upgrade your model 224-4WD automotive dyno from compressed air movement to hydraulic movement. To ensure safety and accuracy in the procedures, perform the procedures as they are described.

Document Part Number: 98200019

Version 2

Last Updated: 01-16-13

This chapter is divided into the following categories:

Introduction, page 2

Hydraulic Movement Requirements, page 3

Unpacking the Hydraulic Parts, page 4

Prepare the Dyno, page 6

Hydraulic Installation, page 6

Replace the Covers, page 25

Hydraulic Upgrade for Model 224-4WD Automotive Dynamometers1

2 2 4 - 4 W D H Y D R A U L I C U P G R A D EIntroduction

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INTRODUCTION

Thank you for your interest Dynojets Automotive Dynamometers. Before installing the hydraulic upgrade, please take a moment to read this guide for proper installation procedures.

CONVENTIONS USED IN THIS 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, e-mail Dynojet at [email protected], or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV 89081.

Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of the art technical support, on-line shopping, 3D visualizations, 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.


2 2 4 - 4 W D H Y D R A U L I C U P G R A D EHydraulic Movement Requirements

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HYDRAULIC MOVEMENT REQUIREMENTS

Take a moment to review the requirements and make sure you can provide what your dyno will need.

For more detailed information about your dyno specifications and requirements, refer to the installation guide included with your dyno.

DRILL AND DRILL BIT REQUIREMENTS

You will need to provide a drill and drill bit capable of drilling holes in concrete. Refer to Appendix A for more information on installing Red Head Anchors.

drill bit size: 1/2-inch

minimum hole depth: 1 5/8-inch (41.2 mm)

ELECTRICAL REQUIREMENTS

The hydraulic motor has the following power requirements:

FLUID REQUIREMENTS

The hydraulic motor has the following fluid requirements:

description specifications

Power Requirements: hydraulic motor 110 VAC, 60 Hz, 20A or 240 VAC, 60 Hz, 10A

description specifications

Fluid Requirements: hydraulic motor AW-68 hydraulic fluid (4 quarts)

Version 2 Hydraulic Upgrade for Model 224-4WD Automotive Dynamometers3

2 2 4 - 4 W D H Y D R A U L I C U P G R A D EUnpacking the Hydraulic Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .UNPACKING THE HYDRAULIC PARTS

Use the following steps to unload your hydraulic movement parts.

1 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the top and sides of the crate. Report any damage immediately.

2 Remove the following parts from the crate and set aside.

part description part description

hose, hydraulic movement (2)P/N 11100000

cylinder mount, floorP/N 61300061

motor mounting bracket, leftP/N 21600020

control assembly bracketP/N 64111004

motor mounting bracket, rightP/N 21600024

cable, hydraulic relay controlP/N 76950130

spacer, 424 hydraulic movement (2)P/N 26100000

cable, hydraulic motor controlP/N 76950131

clevis pin, 3/4 x 4.5" (2)P/N 32900000

cable, hydraulic solenoid controlP/N 76950132

hairpin cotter, 7/16 x 3/4" (2)P/N 32904080

cable, power-hydraulic 4WD movementP/N 76950135


2 2 4 - 4 W D H Y D R A U L I C U P G R A D EUnpacking the Hydraulic Parts

bolt, 3/8-16 x 1.5", flange, hex (2)P/N 36582471

1/4" pipe fittingP/N BR102-038-9

for upgrading older dynos

washer, 3/8", flat, hardened, steel (4)P/N 36923100

bolt, 1/2-13 x 1", hex (8)P/N BR102-058

anchor, redhead, 3/8" (12)P/N 37513200

washer, 5/16", flat (4)P/N DM150-002-007

installation tool, redhead anchorP/N 37518200

bolt, 3/8-16 x 1.25", hex (4)P/N DM150-011-006

hydraulic motorP/N 39500000

bolt, 3/8-16 x 1", hex (4)P/N DM150-019-012

hydraulic ramP/N 39500001

bolt, 5/16-18 x 1", hex (4)P/N DM150-053

cylinder mount, dynoP/N 61300016

part description part description


2 2 4 - 4 W D H Y D R A U L I C U P G R A D EPrepare the Dyno

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PREPARE THE DYNO

To access the 4WD Movement, the pit covers or rear deck will need to be removed. For older dynos that have the air motor controls in a box refer to Appendix B.

IN GROUND DYNOREMOVING THE PIT COVERS

For in ground dynos, you will need to remove the pit covers first. Use the following instructions to remove the pit covers.

1 Remove the two 3/8-16 x 3-inch bolts securing the left and right pit covers tot he pit cover spacer and dyno frame. Set these bolts aside.

2 Remove the five 3/8-16 x 1/2-inch bolts securing the left and right pit covers to the middle pit cover and set aside.

3 Remove the two 3/8-16 x 1/2-inch bolts securing the left and right pit covers to the end of the middle pit cover and set aside.

4 Remove the left and right pit covers.

Figure 1: Remove the Left and Right Pit Covers

AD389

secure to pit cover spacer with 3/8-16 x 3-inch bolt

left and right pit covers

secure ends with3/8-16 x 1/2-inch bolt

secure to middlepit cover with

3/8-16 x 1/2-inch bolt

middle pit cover



5 Remove the 3/8-16 x 3-inch bolt securing the middle pit cover to the pit cover

spacer and set aside.

6 Remove the middle pit cover and set aside.

Figure 2: Remove the Middle Pit Cover

AD388

middle pit cover

pit cover spacer



ABOVE GROUND DYNOREMOVING THE REAR DECK PANELS

For above ground dynos, you will need to remove the rear deck panels first. Use the following instructions to remove the rear deck panels.

1 Remove the four 3/8-16 x 3-inch flange hex bolts, four 3/8-inch flat washers, and four 3/8-inch nylock nuts securing the rear tube to the outer panels and deck supports and set aside.

2 Remove the rear tube and set aside.

Figure 3: Remove the Rear Tube

AD182

rear tube



3 Remove the center bolt securing the center panel to the drum guard and set

aside.4 Remove the six 1/4-20 x 5/8-inch screws and crush nuts securing the center panel

to the supports and set aside.5 Remove the six 1/4-20 x 5/8-inch screws and crush nuts securing the center panel

and outer panels to the supports and set aside.6 Remove the center panel and set aside.

Figure 4: Remove the Center Panel

AD181

center panel

support outer panel

center bolt



7 Remove the outside panels.

7a Remove the 3/8-16 x 1.5-inch flange hex bolt, 3/8-inch washer, and 3/8-inch nylock nut securing the inside of the panel to the inner brace and set aside.

7b Remove the two 3/8-16 x 1.5-inch flange hex bolts, two 3/8-inch washers, and two 3/8-inch nylock nuts securing the three tie downs to the panel and to the deck braces and set aside. Remove the tie downs and set aside.

7c Remove the three 3/8-16 x 1.5-inch button-head flange bolts securing the panel to the dyno frame and set aside. Remove the panel and set aside.

Figure 5: Remove the Outside Panels

AD366

panel

tie-down

inside boltstep 7a

outer brace

inner brace

reserved boltstep 7c

step 7c step 7c



REMOVING THE CHAIN

1 Remove the 1/2-13 nuts securing the chain to each end of the rail tie assembly.2 Remove the chain from the top of the drive sprocket and the idler sprockets. Set

the chain aside.

Figure 6: Remove the Chain

AD051

chain

drive sprocket

idler sprocket

rail tie assembly

nut

chain

rail tie assembly

nut

chain



3 Remove the two bolts securing the idler sprockets to the cradle assembly.

4 Remove the idler sprockets and spacers.

Figure 7: Remove the Idler Sprockets and Spacers

AD050

idler sprocket

bolt

spacer

cradle assembly



REMOVING THE AIR MOTOR, BRACKET, AND HOSES

For older dynos that have the air motor controls in a box refer to Appendix B.

1 Remove the four screws securing the 4WD Movement board and set aside. Leave the board hanging by the wires.

2 Disconnect the four solenoid wires marked In and Out from the 4WD Movement board.

3 Remove the two screws securing each cable track to the bracket.4 Disconnect the two hoses as shown in Figure 8.5 Remove the four bolts securing the bracket.6 Remove the four bolts securing the air motor.7 Remove the air motor, bracket, and hoses from the dyno.

Figure 8: Removing the Air Motor, Bracket, and Hoses

AD411

bracket

air motor

disconnect hose

remove 4WD movement board screws

disconnect hose

cable track


2 2 4 - 4 W D H Y D R A U L I C U P G R A D EHydraulic Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .HYDRAULIC INSTALLATION

This section includes instructions for installing the hydraulic motor, hydraulic movement parts, and control assembly mounting bracket along with wiring and testing the hydraulic movement.

INSTALLING THE MOTOR MOUNTING BRACKETS AND MOTOR

You will need the following parts:

11100000 Hose, Hydraulic Movement (2) 21600020 Motor Mounting Bracket, Left 21600024 Motor Mounting Bracket, Right BR105-058 Bolt, 1/2-13 x 1", Hex (4) 39500000 Hydraulic Motor DM150-002-007 Washer, 5/16", Flat (4) DM150-053 Bolt, 5/16-08 x 1", Hex (4)

1 Secure the left and right motor mounting bracket to the dyno using four 1/2-13 x 1-inch hex bolts.

Figure 9: Secure the Motor Mounting Brackets

AD412motor mounting brackets



2 Secure the hydraulic motor to the mounting brackets using four 5/16 x 1-inch

bolts and four 5/16-inch flat washers.

Verify the motor faces as shown for the above ground or in ground dynos.

Figure 10: Install the Motor

3 Attach the two hydraulic hoses to the motor as shown.

Figure 11: Attach the Hoses to the Motor

AD413

motorabove ground

motorin ground

AD425

hoses



INSTALLING THE HYDRAULIC MOVEMENT

Use the following instructions to install the hydraulic movement.


26100000 Spacer,424 Hydraulic Movement (2) 32900000 Clevis Pin, 3/4 x 4.5" (2) 32904080 Hairpin Cotter, 7/16 x 3/4" (2) 36582471 Bolt, 3/8-16 x 1.5", Flange-Hex (2) 36923100 Washer, 3/8", Flat, Hardened, Steel (4) 37513200 Anchor, Redhead, 3/8" (2) 37518200 Installation Tool, Redhead 39500001 Hydraulic Ram 61300016 Cylinder Mount, Dyno 61300061 Cylinder Mount, Floor DM150-011-006 Bolt, 3/8-16 x 1.25", Hex (4) DM150-019-012 Bolt, 3/8-16 x 1", Hex (4)

1 Place the hydraulic ram under the dyno as shown in Figure 12.2 Route the hose from the hydraulic motor under the dyno and attach the hose to

the ram as shown Figure 12.3 Secure the dyno cylinder mount to the dyno using two 3/8-16 x 1.5-inch bolts.

Figure 12: Secure the Dyno Cylinder Mount to the Dyno

AD414

dyno cylinder mount

ram

hose



4 Secure the hydraulic ram to the dyno cylinder mount using one clevis pin and

hairpin cotter.

Figure 13: Secure the Hydraulic Ram to the Dyno Cylinder Mount

5 Attach the second hose from the hydraulic motor to the ram as shown in Figure 14. Route the hose so it is off the floor.

6 Temporarily hold the floor cylinder mount to the hydraulic ram using two spacers and one clevis pin.

Figure 14: Hold the Floor Cylinder Mount to the Ram

AD415

clevis pin

hairpin cotter

dyno cylinder mount

hydraulic ram

AD471

clevis pin

spacers

floor cylinder mount

hydraulic ramhose



7 Using the floor cylinder mount as a template, mark each hole needed to secure the mount to the floor.

8 Remove the clevis pin, spacers, and floor cylinder mount.9 Move the hydraulic ram out of the way.10 Drill the holes marked in step #7.11 Install the Red Head anchors. Refer to Appendix A for installation instructions.12 Secure the floor cylinder mount to the floor using four 3/8-16 x 1-inch hex bolts

and four 3/8-inch flat washers.Note: Four 3/8-16 x 1.25-inch hex bolts were included if you find the anchors are too deep for the 3/8-16 x 1-inch hex bolts.

13 Secure the hydraulic ram to the floor cylinder mount using the clevis pin and two spacers removed in step #8 and one hairpin cotter.

Figure 15: Secure the Floor Cylinder Mount to the Floor

AD472

secure the hydraulic ram to the floor cylinder mount

use the floor cylinder mount to mark holes

install the anchors and secure the floor cylinder mount to the floor



INSTALLING THE CONTROL ASSEMBLY MOUNTING BRACKET


64111004 Control Assembly Mounting Bracket BR102-058 Bolt, 1/2-13 x 1", Hex (4)

1 Secure the control assembly mounting bracket to the dyno using four 1/2-13 x 1-inch hex bolts.

Figure 16: Secure the Control Assembly Mounting Bracket to the Dyno

2 Secure each cable track to the control assembly mounting bracket using the four screws removed earlier.

Figure 17: Secure the Cable Track to the Control Assembly Mounting Bracket

AD473

control assembly mounting bracket

AD474

cable track




3 Replace the air hose as shown below.

Figure 18: Replace the Air Hose

WIRING

Refer to Figure 21 on page 22 for the hydraulic movement wiring diagram.

You will need the following cables:

76950130 Cable, Hydraulic Relay Control 76950131 Cable, Hydraulic Motor Control 76950132 Cable, Hydraulic Solenoid Control 76950135 Cable, Power-Hydraulic 4WD Movement

1 Remove the four nuts securing the relay cover and set aside.2 Remove the relay cover and set aside.

Figure 19: Remove the Relay Cover

AD475

secure hose to air canister

AD476

relay cover



3 Attach the cable P/N 76950130 to the 4WD Movement board.

This cable has two wires which connect to the wiring block labeled RAIL.

Note: Verify the solenoid wires remain connected.

4 Attach the other end of cable P/N 76950130 to the Relay.

This cable has two wires which connect to #3 and #4 on the Relay.

5 Attach the cable P/N 76950132 to the 4WD Movement board.

This cable has four wires which connect to the wiring block labeled IN and OUT. Refer to Figure 21 on page 22.

6 Attach the cable P/N 76950132 to the hydraulic motor solenoid.

This cable has four wires which connect to the hydraulic solenoid as shown in Figure 21. The red and black wires connect to one side of the solenoid while the green and white wires connect to the other side of the solenoid.

7 Attach the cable P/N 76950131 to the Relay and terminal strip below the Relay.

This cable has three wires. The brown wire connects to #2 on the Relay. The green and blue wires connect to the terminal strip below the Relay as shown.

8 Remove the two screws securing the wiring cover to the hydraulic motor and set aside. Remove the wiring cover and set aside.

9 Attach the cable P/N 76950131 to the hydraulic motor. Wire the hydraulic motor for 110V or 220V as shown in Figure 21.Note: The wiring cover also contains wiring instructions.

10 Replace the hydraulic motor wiring cover using the screws removed earlier.11 Attach the cable P/N 76950135 to the terminal strip. This cable has three wires

which connect to the terminal strip as shown in Figure 21.12 Replace the relay cover using the four nuts removed earlier.13 Secure the 4WD Movement board to the control assembly mounting bracket

using the four screws and nuts removed earlier.

Figure 20: Secure the 4WD Movement Board

AD477


4WD movement board



Figure 21: Hydraulic Movement Wiring Diagram

dru

m b

rake

fro

m B

.O.B

.

BR

N

T2

T4

T8

BR

N

BLU

E

T1

T3

T5

110V

T2

T3

T5

BLU

E

T4

T8

T1

220V

hyd

rau

licm

oto

r

P/N

769

5013

1

gro

un

d

BLK

P/N

769

5013

5G

RN

WH

T

P/N

769

5013

6

GR

N

BLU

BR

N1

3 2

4re

lay

LOAD

IN

rail

brak

e so

len

oid

P/N

769

5013

0

RE

DB

LKG

RN

WH

T

P/N

769

5013

2R

ED

BLK

GR

NW

HT

in s

ole

no

id, h

ydra

ulic

rea

r, A

po

rt

ou

t so

len

oid

, hyd

rau

lic fr

on

t, B

por

t

hyd

rau

licso

len

oid

BLK

YEL

WH

TB

LKR

ED

BLK

WH

T

BLK

YEL

po

wer

su

pp

ly

mo

vem

ent

swit

ch

rail

brak

ep

ress

ure

sw

itch

4WD

mo

vem

ent

boar

d

AD

507

wir

ing

cove

r GRN



FILLING THE HYDRAULIC MOTOR WITH HYDRAULIC FLUID

1 Remove the cap on the hydraulic motor.2 Add four quarts of AW-68 hydraulic fluid.3 Replace the cap.

Figure 22: Fill the Hydraulic Motor with Oil

AD478

remove the cap on the hydraulic motor



TESTING THE HYDRAULIC MOTOR AND DYNO MOVEMENT

Verify any person(s) are clear of the dyno as it will move. Never allow any person(s) to stand behind the dyno or vehicle when it is being operated. Only the operator should be near the dyno or the vehicle during the test.

1 Attach the cable P/N 76950135 to a wall outlet appropriate for how the hydraulic motor is wired.

2 Press and hold the "out" button on the dyno movement pendant. You should hear air venting, and the rail clamps releasing.

3 Keep holding the "out" button down until you see the dyno begin to move.4 Repeat this procedure holding the "in" button.

Note: If the dyno moves opposite of the direction expected, switch the red/black and green/white wires on the hydraulic motor solenoid.

Note: If the hydraulic motor runs and the rail clamps release, but the dyno does not move, verify the hydraulic motor wiring (the motor may be running in the wrong direction). Refer to Figure 21 on page 22.

5 Adjust the force the dyno hits the stops by removing the bypass cover and turning the bypass counter clockwise to lower the force or clockwise to increase the force.

6 Remove the cap on the hydraulic motor and check the level of the oil. Add additional oil if needed. Refer to Filling the Hydraulic Motor with Hydraulic Fluid on page 23 for more information.

Figure 23: Hydraulic Motor Bypass Cover

AD479

bypass cover


2 2 4 - 4 W D H Y D R A U L I C U P G R A D EReplace the Covers

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REPLACE THE COVERS

Once the hydraulic movement has been successfully tested, replace the pit covers or rear deck panels.

REPLACING THE PIT COVERS

Use the following instructions to replace the 4WD dyno pit covers.

1 Place the pit cover spacer on the dyno frame with the holes aligned.2 Secure the middle pit cover to the pit cover spacer using one 3/8-16 x 3-inch bolt.

Figure 24: Replace the Middle Pit Cover

AD388

middle pit cover

pit cover spacer



3 Secure the left and right pit covers to the pit cover spacer and dyno frame using two 3/8-16 x 3-inch bolts each.

4 Secure the left and right pit covers to the middle pit cover using five 3/8-16 x 1/2-inch bolts each.

5 Secure the end of the middle pit cover to the end of the left and right pit covers using two 3/8-16 x 1/2-inch bolts each.

Figure 25: Replace the Left and Right Pit Covers

AD389

secure to pit cover spacer with 3/8-16 x 3-inch bolt

left and right pit covers

secure ends with3/8-16 x 1/2-inch bolt

secure to middlepit cover with

3/8-16 x 1/2-inch bolt

middle pit cover



REPLACING THE REAR DECK PANELS

1 Install the outside panels.1a Secure the panel to the dyno frame using three 3/8-16 x 1.5-inch button-

head flange bolts.1b Secure the three tie downs to the panel and to the deck braces using two

3/8-16 x 1.5-inch flange hex bolts, two 3/8-inch washers, and two 3/8-inch nylock nuts each.

Verify the panel is sandwiched between the tie-downs and the brace.1c Secure the inside of the panel to the inner brace using one 3/8-16 x 1.5-inch

flange hex bolt, one 3/8-inch washer, and one 3/8-inch nylock nut.

Figure 26: Install the Outside Panels

AD480

panel

tie-down

inside boltstep 1c

outer brace

inner brace

reserved boltstep 1a

step 1a step 1a



2 Secure the supports to the outer panels using three 1/4-20 x 5/8-inch screws and crush nuts each.

3 Secure the center panel to each support using three 1/4-20 x 5/8-inch screws and crush nuts each.

4 Secure center panel to dyno with the bolt removed earlier.

Figure 27: Install the Center Panel

AD181

center panel

support outer panel

center bolt



5 Install the rear tube to the outer panels and deck supports using four

3/8-16 x 3-inch flange hex bolts, four 3/8-inch flat washers, and four 3/8-inch nylock nuts.

Figure 28: Install the Rear Tube

AD182

rear tube


A P P E N D I X

ARED HEAD ANCHOR INSTALLATION

This appendix contains instructions for installing the Red Head Multi-SetII Anchors. The anchors will be used to secure the dyno to concrete. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Be sure to read and understand the warnings included in this appendix.

WARNINGS

Always wear safety glasses and other necessary protective devices or apparel when installing or working with anchors.

ITW Ramset/Red Head Multi-Set II Anchors are designed to operate properly only when installed with ITW Ramset/Red Head brand Setting Tools.

The use of a 24 to 40 ounce hammer is recommended for expanding Multi-Set II anchors.

The use of carbide drill bits manufactured with ANSI B94. 12-77 drill bit diameter requirements is recommended for installation of this anchor.

Not recommended for use in lightweight masonry material such as block or brick.

Use of core drills is not recommended to drill holes for use with this anchor.

Not recommended for use in new concrete which has not had sufficient time to cure.

Anchor spacing and edge distance requirements (anchor installation locations) are the responsibility of the engineer of record.

CONTACT INFORMATION FOR ITW RAMSET/RED HEADContact ITW Ramset/Red Head at 1-630-350-0370, or 1300 North Michael Drive, Wood Dale, IL 60191.

Hydraulic Upgrade for Model 224-4WD Automotive DynamometersA-1

A P P E N D I X AInstallation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INSTALLATION

Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number.

Use the following instructions to install the Red Head anchors.

1 Drill the hole in the concrete the same outside diameter as the anchor being used to any depth exceeding minimum embedment.

Figure A-1: Red Head AnchorDrill the Hole

2 Insert the anchor.

Figure A-2: Red Head AnchorInsert the Anchor

catalog number drill bit size minimum hole depthsetting tool catalog number

Carbon SteelRM-38/RL-38 (9.5 mm)

1/2-inch 1 5/8-inch (41.2 mm) RT-138

anchor

Hydraulic Upgrade for Model 224-4WD Automotive DynamometersA-2

R E D H E A D A N C H O R I N S T A L L A T I O NInstallation

3 Using a hammer, drive the anchor flush with the surface of the concrete, or below

the surface if the hole depth exceeds minimum embedment.

Figure A-3: Red Head AnchorDrive the Anchor Flush

4 Using a hammer, expand the anchor with the setting tool. The anchor is properly expanded when the shoulder of the setting tool is flush with the top of the anchor.Note: Use only Ramset/Red Head setting tools to insure proper installtion.

Figure A-4: Red Head AnchorExpand the Anchor

setting tool

Version 2 Hydraulic Upgrade for Model 224-4WD Automotive DynamometersA-3

A P P E N D I X

BCONTROL BOX REMOVAL

This appendix contains the instructions for removing the control box from model 224-4WD automotive dynamometers (dynos). To ensure safety and accuracy in the procedures, perform the procedures as they are described.

This Appendix is divided into the following categories:

Remove the Control Box, on page B-2

Hydraulic Upgrade for Model 224-4WD Automotive DynamometersB-1

A P P E N D I X BRemove the Control Box

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .REMOVE THE CONTROL BOX

Use the following instructions to remove the control box from your dyno.

You will need the following part:

BR102-038-9 1/4" Pipe Fitting1 Disconnect the two blue hoses from location 2.

Note: Cutting may be required.

2 Compare the wires in the box to the wiring schematic included in this Appendix and label them accordingly.

3 Disconnect all the wires from the Breakout board and the 4WD Movement board4 Remove the four screws holding the panel in the box.5 Pull the panel out enough to access the nuts on the rear of it. Remove the two

boards and the four bolts holding the solenoids.6 Unscrew the plastic line (at A) from the solenoid. Unscrew the brake solenoid (4)

from the t-fitting (1). Set the solenoid aside.7 Unscrew the t-fittings (2) from the t-fitting (1).8 Unscrew the plastic line (5) from the top of the air can (6). This plastic line should

be the same one disconnected in step #6.9 Remove the box, remaining air lines, and the air motor from the dyno.

Figure B-1: Control Box Removal

Hydraulic Upgrade for Model 224-4WD Automotive DynamometersB-2

C O N T R O L B O X R E M O V A LRemove the Control Box

10 Place the control assembly mounting bracket on the dyno as shown inFigure B-2.11 Using the bracket as a template, mark and drill the four holes needed to mount

the bracket. Thread these holes 1/2-13-inch tap.

Figure B-2: Mark and Drill Holes

12 Secure the control assembly mounting bracket to the dyno using four 1/2-13 x 1-inch hex bolts.

Figure B-3: Secure the Control Assembly Mounting Bracket to the Dyno

13 If present remove the threaded fitting (3) from the solenoid (4).14 Thread the 1/4-inch pipe fitting into the air can (6). Thread port A of the solenoid

onto the fitting on the air can (6).15 Thread the two t-fittings (2) into the solenoid (4) at port B. Reconnect the two

blue hoses.16 Re-wire the Breakout board and the 4WD Movement board as previously labeled.

Refer to the wiring schematic included in this Appendix.Note: The air motor solenoid wires will not be reconnected.

17 Continue with the Hydraulic Installation on page 14.

AD481control assembly mounting bracket

AD482


Version 2 Hydraulic Upgrade for Model 224-4WD Automotive DynamometersB-3

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Version 1 March 09, 2011 Copyright 2004-2011 Dynojet Research, Inc. All Rights Reserved. 03/2011SA

4WD DYNAMOMETER AIR AND WIRING SCHEMATICHYDRAULIC

INDEX

4WD movement board 1-13wiring 1-21

Bbypass 1-24

Cchain

drive sprocket 1-11removing 1-11

control assembly mounting bracket 1-19control box B-2conventions 1-2

Ddocument part number 1-1drill and drill bit 1-3drive sprocket 1-11dyno cylinder mount 1-16, 1-17

Eelectrical requirements 1-3

Ffluid requirements 1-3

Hhydraulic fluid

filling 1-23type 1-3

hydraulic hose 1-17hydraulic hoses 1-15hydraulic motor

installing 1-15wiring 1-21

hydraulic motor solenoid, wiring 1-21hydraulic movement

dyno cylinder mount 1-16, 1-17filling with fluid 1-23

hydraulic hose 1-17hydraulic ram 1-16, 1-17spacers 1-17stationary cylinder mount 1-17wiring diagram 1-22

Mmotor mounting brackets 1-14

Ppit covers

removing 1-6replacing 1-25

prepare the dynoremoving the air motor 1-13removing the chain 1-11removing the pit covers 1-6removing the rear deck panels 1-8

Rram 1-16, 1-17rear deck

center panel 1-9, 1-28outside panels 1-10, 1-27rear tube 1-8, 1-29removing the panels 1-8replacing the panels 1-27

red head anchorcontact information A-1installation A-2setting tool A-3warnings A-1

relaycover 1-20wiring 1-21

requirementsdrill and drill bit 1-3electrical 1-3fluid 1-3

Hydraulic Upgrade for Model 224-4WD Automotive DynamometersIndex-i

I N D E X

Ssetting tool A-3

Ttechnical support 1-2terminal strip, wiring 1-21testing 1-24

Uunpacking hydraulic parts 1-4

Wwiring

4WD movement board 1-21hydraulic motor 1-21hydraulic motor solenoid 1-21relay 1-21terminal strip 1-21

wiring diagram 1-22

Hydraulic Upgrade for Model 224-4WD Automotive DynamometersIndex-ii
CoverCopyrightTable of Contents224-4WD Hydraulic UpgradeIntroductionConventions Used In This ManualTechnical SupportHydraulic Movement RequirementsDrill and Drill Bit RequirementsElectrical RequirementsFluid RequirementsUnpacking the Hydraulic PartsPrepare the DynoIn Ground DynoRemoving the Pit CoversAbove Ground DynoRemoving the Rear Deck PanelsRemoving the ChainRemoving the Air Motor, Bracket, and HosesHydraulic InstallationInstalling the Motor Mounting Brackets and MotorInstalling the Hydraulic MovementInstalling the Control Assembly Mounting BracketWiringFilling the Hydraulic Motor with Hydraulic FluidTesting the Hydraulic Motor and Dyno MovementReplace the CoversReplacing the Pit CoversReplacing the Rear Deck PanelsA - Red Head Anchor InstallationInstallationB - Control Box RemovalRemove the Control BoxAir and Wiring SchematicIndex

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