Eddy Current Brake Installation and User Guide For Model 224 Pit Automotive Dynamometers.

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2 Dynojet Research, Inc. All Rights Reserved. Eddy Current Brake Installation and User Guide For Model 224 Pit 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: Version 2 (03/05) RECORD # Dynamometer Number: Eddy Current Brake (Retarder) Number:

3 TABLE OF CONTENTS Chapter 1 Chapter 2 Eddy Current Brake Installation Introduction Conventions Used In This Manual Technical Support Parts List Power Requirements and Installation Installing the Wall Receptacle Testing for Correct Voltages Replacing the Power Plug Hard Wiring to the Building Eddy Current Brake Installation Before Installing the Eddy Current Brake: Verify Optimal Brake Cooling Unpacking the Eddy Current Brake Installing the Bearing Installing the Spline Shaft and Driveline Assembly Installing the Eddy Current Brake Installing the Pit Cover Supports and Theta Controller Securing the Brake to the Dyno Pit Floor Routing the Brake Cables Wiring the Breakout Board Replacing the Theta Controller Fuses Torque Module Installation Load Cell Installation Parts List Installing the Load Cell Torque Module Installation Accessing the Dyno Electronics Installing the Torque Module Routing the Load Cell Cable Installing the End Deck and Deck Assemblies Load Cell Calibration i

4 TABLE OF CONTENTS Chapter 3 Basic Dynamometer Operation Loading the Car Connecting The RPM Pickup RPM Pickup Descriptions Connecting the Secondary Inductive Pickup Connecting The Primary Inductive Pickup Pre-run Inspection Before Starting the Engine Engine Warm Up After Engine Warm Up Making a Test Run Appendix A Red Head Anchor Installation Installation A-2 Appendix B Power Requirements Excluding North America Power Requirements and Installation B-2 Installing the Wall Receptacle B-3 Testing for Correct Voltages B-4 Replacing the Power Plug B-5 Hard Wiring to the Building B-5 Appendix C Installing the Adapter and Bearing Early Model Dynamometers Installing the Adapter and Bearing Early Model Dynos C-2 Index Index-i ii

5 C HAPTER 1 EDDY CURRENT BRAKE INSTALLATION This document provides instructions for installing the eddy current brake (retarder) to the Dynojet model 224 pit automotive dynamometer (dyno). This document also provides instructions for installing and calibrating the load cell and basic dynamometer operation. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: Version 2 Last Updated: This chapter is divided into the following categories: Introduction, page 1-2 Power Requirements and Installation, page 1-5 Eddy Current Brake Installation, page

6 CHAPTER 1 Introduction INTRODUCTION Before installing your eddy current brake, please take a moment to read this guide for installation instructions and other important information. This guide is designed to be a reference tool in your everyday work and includes the following chapters and information: EDDY CURRENT BRAKE INSTALLATION This chapter describes the procedures for installing the eddy current brake. TORQUE MODULE INSTALLATION This chapter describes the procedures for installing the torque module and load cell along with load cell calibration. BASIC DYNO OPERATION This chapter describes basic dyno operating procedures. RED HEAD INSTALLATION This appendix describes the procedures for installing the Red Head anchors. POWER REQUIREMENTS EXCLUDING NORTH AMERICA This appendix describes the power requirements and installation instructions for all locations excluding North America. INSTALLING THE ADAPTER AND BEARING EARLY MODEL DYNOS This appendix describes the procedures for installing the adapter and bearing needed for early model dynos. 1-2

7 EDDY CURRENT BRAKE INSTALLATION Introduction CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. Example of Convention Bold RECORD # 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. The Record # icon reminds you to record your dynamometer and/or eddy current brake (retarder) number on the inside cover of this manual. 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. TECHNICAL SUPPORT For assistance, please contact Dynojet Technical Support at , or write to Dynojet at 2191 Mendenhall Drive, North Las Vegas, NV Visit us on the World Wide Web at where Dynojet provides state of the art technical support, on-line shopping, 3D visualizations, and press releases about our latest product line. Version 2 1-3

8 CHAPTER 1 Introduction PARTS LIST The following table lists all of the parts included in the Eddy Current Brake (P/N ) Installation kit. Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support. part number description quantity Pit Cover Support Hood Scoop Hood Scoop, Z-Bracket (cable routing channel) Foot Bearing-Flange, 1.75, 2-Bolt O-Ring, 7/16 x 11/16, # Weight, 25 lb Screw, 1/4-20 x 1/2, Bh-Flange Screw, 1/4-20 x 3/4, Bh-Flange Screw-Set, 3/8-16 x 1/2, W/Tlok Bolt, 3/8-16 x 1, Bh, Allen Nut, 1/2-13, Nylock-Hex Nut, 5/8-11 UNC, Hex Bolt, 1/2-13 x 1.25, Flange-Hex Washer, 5/16, Hardened, Flat, Stl Anchor, Redhead, 3/ Installation Tool, Redhead Anchor Woodruff Key, 1/2 x 2.75, Temp Sensor, C Max End Deck Assembly Deck Assembly Calibration Arm Assembly Splined Shaft Assembly Driveline Assembly, 7C, 224 Retarder Theta-2 Controller - 240V -20A PCB, Torque Cell Rev Switch, Loaded or Torque Module Sub-Assembly or Torque Module High Resolution Sub-Assembly Torque Cell Assembly, Cable, Input, 224 Torque Rev Sw Cable, Output, 224 Torque Rev Sw 1 DM Nut, 1/4 16 DM Bolt, 3/8-16 x 1, Hex

9 EDDY CURRENT BRAKE INSTALLATION Power Requirements and Installation POWER REQUIREMENTS AND INSTALLATION The following power requirements and instructions are for North America, Japan, and locations using 60 Hz power. All other locations should refer to the instructions found in Appendix B. The eddy current brake requires a dedicated 240VAC single phase power outlet rated for 30A for proper operation. Failure to follow these instructions could result in personal injury or damage to the brake. Connecting the brake to the incorrect voltage will void the brake warranty. Contact Dynojet with any questions. The eddy current brake requires a dedicated wall receptacle which must be wired for operation and is included with the brake or may be shipped in advanced in a separate package. The brake is equipped with a twenty-five foot power cord with a twist lock plug pre-wired on the end. The dedicated wall receptacle is a twist lock four wire grounded 30A NEMA L14-30 type and must be wired in accordance with local building codes and requirements. If the facility does not have 120/240 volt single phase power, and it does have 120/208 volt three phase Y power, then it is acceptable to connect the four wire receptacle with two of the three phase lines, the neutral and the ground. With this arrangement, there will only be 208 volts between line 1 and line 2 instead of 240 volts. This acceptable, but performance of the eddy current brake will be reduced. In no case shall all three phase lines be connected to the receptacle! Installation may require a licensed electrician and must conform to UL and NEC safety standards. Note: If you are installing your brake in North American or Japan and the brake is not equipped with twist lock four wire grounded plug, contact Dynojet before attempting to connect the brake. Local and national electrical codes require a grounded receptacle box. This circuit should have a dedicated 30A double pole circuit breaker. The brake should be the only device connected to this circuit. INSTALLING THE WALL RECEPTACLE The wall receptacle is included with your brake and is shipped in a separate box or may be shipped in advance in a separate package. The wall receptacle is a single phase 240 volt 30A dedicated circuit with a neutral connection and a ground. The neutral connection is required to split the 240 volt into two 120 volt connections internal to the dyno. The cable carrying the power to this receptacle should be ten gauge or larger. Check with local building codes for the correct size. 1 Connect one of the 240V legs to the X terminal (gold colored screw). 2 Connect the other 240V leg to the Y terminal (gold colored screw). 3 Connect the neutral conductor to the W or WH terminal (silver screw). 4 Connect the ground conductor to the green grounding screw. Version 2 1-5

10 CHAPTER 1 Power Requirements and Installation TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the eddy current brake is connected to the outlet. If the voltage readings do not match the following table, DO NOT connect the brake. You must have a licensed electrician correct the power connection. Connecting the brake to the incorrect voltage can result in damage to the brake and will void the brake warranty. Contact Dynojet with any questions. Using a voltmeter that is capable of measuring AC voltage, measure between the points listed below and verify that the correct voltages are present. probe 1 probe 2 desired voltage measurement V to 260V* V to 130V V to 130V 1 3 <5V 3 box <5V *If using two of the three phase lines of a 120/208 V 3 phase Y system, then expect to see 187V to 225V Figure 1-1: Dedicated Power Receptacle 1-6

11 EDDY CURRENT BRAKE INSTALLATION Power Requirements and Installation REPLACING THE POWER PLUG Use the following instructions to replace the four wire plug and socket. The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of four conductors. The power cord that attaches to the brake has four conductors internally and their colors are brown, blue, black, and green/yellow. 1 Connect 240VAC single phase power between the brown and the blue wire connection points. 2 Connect the green/yellow wire to the ground connection point. 3 Wrap the black wire with the white tape to denote that it is a neutral connection and connect it to the neutral connection point. 4 Refer to the previous table for testing and probe the new connections as follows: blue wire as location #2 brown wire as location #4 black wire as location #1 green/yellow wire as location #3. HARD WIRING TO THE BUILDING Use the following instructions to wire the dyno directly to the building. The brake must connect to a two pole disconnect switch to allow the removal of all power to the dyno for servicing. This box may contain fusing, circuit breakers, or the circuit protection may be upstream in the building power system. The circuit must be protected to 30A with slow blow fuses or time delayed circuit breakers. The power cord that attaches to the dyno has four conductors internally and their colors are brown, blue, black, and green/yellow. 1 Remove the brake power plug and connect 240VAC single phase between the brown and the blue wires through the disconnect switch. 2 Connect the green/yellow wire to the ground connection. 3 Wrap the black wire with white tape to denote that it is a neutral connection and connect it to the neutral connection. 4 Refer to the previous table for testing and probe the new connections as follows: blue wire as location #2 brown wire as location #4 black wire as location #1 green/yellow wire as location #3 Version 2 1-7

12 CHAPTER 1 Eddy Current Brake Installation EDDY CURRENT BRAKE INSTALLATION This section will walk you through removing the eddy current brake from the crate, installing the eddy current brake on model 224 pit automotive dynos, installing the Theta Controller, and routing cables. You will need to provide equipment capable of lifting the eddy current brake off the crate and into position in your dyno room. You will also need a pair of straps. Dynojet recommends using single loop style straps. To prevent possible injury, turn off the dyno electronics and unplug the dyno. BEFORE INSTALLING THE EDDY CURRENT BRAKE: VERIFY OPTIMAL BRAKE COOLING Placing the eddy current brake on the left or right side of the dyno will determine the direction that it turns. For optimal eddy current brake cooling, the brake should turn in the direction of the arrows on the rotors. When running mostly rear wheel drive cars, orient the dyno and brake so the brake is turning in the direction of the arrows when a rear wheel drive car is on the dyno (as shown in Figure 1-2). Note: The dyno will function correctly for front wheel drive cars, but cooling of the rotors will not be optimal. The rear wheel drive example below shows the brake turning in the direction of the arrows on the rotors. In this example, the load cell is in compression. direction of rotation arrow on rotor load cell Figure 1-2: Optimal Brake Cooling 1-8

13 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation UNPACKING THE EDDY CURRENT BRAKE 1 Remove the top and sides of the crate. 2 Remove any hardware and parts boxes and set aside. 3 Remove the uprights and cross members off the crate. crate top uprights and cross members remove boxes Figure 1-3: Remove the Crate Top Version 2 1-9

14 CHAPTER 1 Eddy Current Brake Installation 4 Remove the two screws securing each pit cover support. Set the screws and covers aside. RECORD # Be sure you record the dynamometer and/or eddy current brake number on the inside cover of this manual. pit cover support pit cover support EB096 brake number Figure 1-4: Remove the Pit Cover Supports INSTALLING THE BEARING The eddy current brake can be installed on either side of your dyno, the installation instructions are the same. 1 Install the bearing using two 1/2-13 x 1.25-inch flanged bolts. Leave the bolts loose. Note: If you are retrofitting an early model dyno which does not have the bearing mounting holes, refer to the instructions in Appendix C. bearing mounting holes bearing Figure 1-5: Install the Bearing 1-10

15 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation INSTALLING THE SPLINE SHAFT AND DRIVELINE ASSEMBLY 1 Insert the spline shaft through the bearing and into the spline hub of drum. Note: Make sure the short spline end faces out. 2 Push the spline shaft as far as it will go. 3 Torque the bearing mounting bolts to 57 ft.-lbs. 4 Torque the two set screws on the bearing to 25 ft.-lbs. bearing mounting bolts spline shaft bearing set screws Figure 1-6: Install the Spline Shaft 5 Remove the four bolts securing the u-joint to the keyed driveline yoke. Set these bolts aside; they will be used to secure the eddy current brake to the driveline assembly. 6 Separate the keyed yoke from the driveline assembly. You may need to use a screwdriver or pry bar to separate the u-joint from the yoke. 7 Place the driveline assembly on the spline shaft. remove four bolts, two on either side driveline assembly Figure 1-7: Install the Driveline Assembly Version

16 CHAPTER 1 Eddy Current Brake Installation INSTALLING THE EDDY CURRENT BRAKE 1 Remove the four lag bolts securing the brake to the crate 2 Place the keyed yoke onto the eddy current brake shaft. shaft yoke bolt shaft Figure 1-8: Remove the Bolts Securing the Brake to the Crate and Install the Yoke 1-12

17 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation 3 Place one nylon loop strap around the brake shaft with the yoke. Keep the strap close to the bearing. 4 Place one nylon loop strap around the other side of the brake shaft. Keep the strap close to the bearing. Dynojet recommends using single loop style straps. 5 Place the nylon loop straps around the forklift forks. 6 Slide the forklift forks together until the straps angle inward. This will prevent the straps from slipping off the brake shaft. 7 Using the forklift, lift the eddy current brake from the crate and place the brake in the pit next to the dyno. straps yoke shaft Figure 1-9: Remove the Brake from the Crate Version

18 CHAPTER 1 Eddy Current Brake Installation 8 Line up the eddy current brake yoke with the driveline assembly. 9 Slide the brake frame towards the dyno frame until they touch. Make sure the brake yoke is aligned with the driveline. 10 Secure the yoke to the driveline assembly using the four bolts removed earlier. Torque the bolts to 70 ft.-lbs. 11 Secure the brake frame to the dyno using eight 3/8 x 1-inch bolts and eight 5/16-inch hardened flat washers. Not all of the bolts and washers are visible from this view. 12 Torque the brake yoke set screws to 25 ft.-lbs. bolts and washers (not all visible) bolts and washers (not all visible) brake yoke Figure 1-10: Secure the Brake Frame to the Dyno 1-14

19 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation INSTALLING THE PIT COVER SUPPORTS AND THETA CONTROLLER 1 Loosely secure the pit cover supports to the frame using two 1/4-20 x 3/4-inch button-head flange screws for each support. Note: Do not tighten the screws. 2 Verify the pit cover supports are flush with the top of the pit floor before you tighten the screws. 2a Place a straight edge across the pit cover supports. 2b With the pit cover supports tight against the straight edge, tighten the screws. Note: You can use c-clamps to attach the upright to the straight edges to make this quicker. Tighten the c-clamps until the pit cover supports are flush with the pit floor. 2c Remove the straight edge. pit cover supports Figure 1-11: Install the Pit Cover Supports Version

20 CHAPTER 1 Eddy Current Brake Installation 3 Install the Theta Controller using four 8-32 x 3/8-inch screws. 4 Install the cable routing channel using two screws. cable routing channels theta controller Figure 1-12: Install the Theta Controller and Cable Routing Channel 1-16

21 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation SECURING THE BRAKE TO THE DYNO PIT FLOOR 1 Install one foot on either side of the brake, as shown in Figure 1-13, using one 1/2-13 x 1.25-inch flange bolt and one 1/2-13-inch nylock nut (not visible). 2 Install the Red Head Anchors. Refer to Appendix A for Red Head Anchor installation instructions. foot install red head anchor Figure 1-13: Secure the Brake to the Pit Floor Version

22 CHAPTER 1 Eddy Current Brake Installation ROUTING THE BRAKE CABLES Refer to Figure 1-14 on page 1-18 for cable routing location information. 1 Route the temperature sensor cable from the eddy current brake over to the Breakout board. For more information on wiring the Breakout board refer to page Route the speed pick-up cable from the Breakout board over to the pick-up card. 3 Route the 25-pin cable from the Breakout board along the inside of the panel using the cable routing channel, through one of the PVC conduits in the pit, and to the dyno electronics. 4 Route the brake power cable from the eddy current brake through the pit cover support and over to the Theta Controller (underneath). 5 Route the input power cable from the Theta Controller through pit cover support, through the PVC conduit in the pit (not used by any other cables), and to your power source. 6 Route the control cable from the Theta Controller to the Breakout board. speed pick-up cable breakout board 25-pin cable control cable temperature sensor cable brake power cable input power cable theta controller Figure 1-14: Routing the Brake Cables 1-18

23 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation WIRING THE BREAKOUT BOARD Refer to Figure 1-15 on page 1-20 for Breakout board location information. 1 Attach the temperature sensor cable to the Breakout board. The temperature sensor cable has five wires which connect to the wiring block labeled TEMP. This cable was routed to the Breakout board on page Green wire connects to G1 White wire connects to W1 Black wire connects to B1 Red wire connects to R1 Ground (shield) wire connects to S1 2 Attach the control cable to the Breakout board. The control cable has five wires which connect to the wiring block labeled LOAD CONTROL. This cable was routed to the Breakout board on page Black wire connects to V- Red wire connects to V+ White wire connects to O+ Green wire connects to O- Ground (shield) wire connects to SH 3 Attach the speed pick-up cable to the Breakout board. The control cable has four wires which connect to the wiring block labeled DRUM 1. This cable was routed to the Breakout board on page Red wire connects to R1 Black wire connects to B1 White wire connects to W1 Ground (shield) wire connects to S1 Version

24 CHAPTER 1 Eddy Current Brake Installation 4 Verify jumpers J1 and J2 are set for the eddy current brake as shown in Figure The air brake will be activated when the dyno electronics power is turned off or when the red button on the pendant is lit. The eddy current brake is used for load control. temp jumpers J1 and J2 load control speed pick-up Figure 1-15: Wiring the Breakout Board 1-20

25 EDDY CURRENT BRAKE INSTALLATION Eddy Current Brake Installation REPLACING THE THETA CONTROLLER FUSES Hazardous voltage. To avoid risk of electrical shock, disconnect the battery and unplug the dyno. 1 Remove the nine button-head screws securing the deck assembly and set aside. 2 Remove the deck assembly and set aside. 3 Gently push the fuse holder slightly inward and rotate counterclockwise. Remove the fuse holder. 4 Replace the fuse with a fuse type listed below. For continued protection against risk of fire, replace only with a fuse of the same type and having the same electrical rating. Buss P/N BAF-25, 25A Fuse Fast Blow, Dynojet P/N Replace the deck assembly using the nine button-head screws removed earlier. Refer to Figure 2-10 on page Version

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27 C HAPTER 2 TORQUE MODULE INSTALLATION The Torque Module, when added to Dynojet's market leading inertia dynamometer, results in a complete vehicle performance test. This chapter provides instructions for installing and using the Torque Module with WinPEP 7. To ensure safety and accuracy in the procedures, perform the procedures as they are described. This chapter is divided into the following categories: Load Cell Installation, page 2-2 Torque Module Installation, page 2-4 Load Cell Calibration, page

28 CHAPTER 2 Load Cell Installation LOAD CELL INSTALLATION This section describes how to install the load cell. PARTS LIST The following table lists all of the parts included in the Torque Module Installation kit (P/N ). Check your kit against the parts listed to make sure you have received all of the parts. If any part is missing, contact Dynojet Technical Support. part number description quantity Weight, 25 lb Calibration Arm Assembly or Torque Module Sub-Assembly or Torque Module High Resolution Sub-Assembly Torque Cell Assembly, Cable, Input, 224 Torque Rev Sw Cable, Output, 224 Torque Rev Sw 1 1 INSTALLING THE LOAD CELL 1 Verify the main dyno power is disconnected. 2 Remove the two bolts and nuts securing the existing bar on the eddy current brake and remove the bar. Set the bolts and nuts aside. 3 Verify the eyelets on the load cell are spaced the same as the bar removed earlier. Adjust the load cell spacing by loosening the lock nut and turning the eyelet. bar eyelet lock nut distance must be the same Figure 2-1: Verify Load Cell Spacing 2-2

29 TORQUE MODULE INSTALLATION Load Cell Installation 4 Secure the load cell to the mounting bracket using the two bolts and nuts removed earlier. 5 Route the load cell cable through the PVC conduit in the pit (not used by the input power cable). Make sure the load cell cable is clear of any power cable or hot or rotating objects. load cell cable dyno install the load cell (the brake is not shown for clarity) Figure 2-2: Install the Load Cell Version 2 2-3

30 CHAPTER 2 Torque Module Installation TORQUE MODULE INSTALLATION This section describes how to access the dyno electronics, install the Torque Module, route the load cell cable, and install the side and top brake covers. ACCESSING THE DYNO ELECTRONICS You will need to access your dyno electronics in order to add the torque module. Use the following steps to access the dyno electronics. 1 Remove the eight screws securing the cover and lift the cover off. 2 Add the torque module to the top of the dyno electronics. Refer to Installing the Torque Module on page Leave the dyno electronics enclosure out. You will need to route the load cell cable to the Torque Module later. dyno electronics Figure 2-3: Inside the Electronics Enclosure 2-4

31 TORQUE MODULE INSTALLATION Torque Module Installation INSTALLING THE TORQUE MODULE 1 Verify the main dyno power is disconnected. 2 Turn off the main power switch on the CPU Module on the dyno electronics and unplug the power cord. 3 Remove the dust cover from the existing top module. dust cover power cord input power switch Figure 2-4: Remove Dust Cover 4 Loosen the top right screw on the back of the existing top module. 5 Plug the Torque Module into the existing top module. Place the dust cover, removed in step 3, on the Torque Module. 6 Secure the grounding strap on the back of the Torque Module to the existing top module. grounding strap Figure 2-5: Secure Grounding Strap Version 2 2-5

32 CHAPTER 2 Torque Module Installation torque module 7 Secure the Torque Module to the dyno electronics with the plastic tie straps (one on each side). Note: Do not attach the load cell cable at this time. tie strap green LED light load cell cable and port do not attach at this time Figure 2-6: Attach Torque Module 2-6

33 TORQUE MODULE INSTALLATION Torque Module Installation ROUTING THE LOAD CELL CABLE 1 Route the load cell cable from the load cell, through the PVC conduit in the pit (not used by input power cable), and over to the dyno electronics. Make sure the load cell cable is clear of any power cables or hot or rotating objects. 2 Route the load cell cable through the cable clamp on the back of the dyno electronics enclosure. 2a Loosen the two screws and lift the clamp up to slide the load cell cable through. 2b Secure the clamp with the two screws. 3 Attach the 9-pin connector on the load cell cable to the front of the Torque Module and tighten down the screws. 4 Attach the power cord to the dyno electronics and turn the power switch on. cable clamp torque module load cell cable Figure 2-7: Route the Load Cell Cable to the Torque Module Version 2 2-7

34 CHAPTER 2 Torque Module Installation torque module 5 The green LED light on the Torque Module should now be on. 6 Replace the dyno electronics cover. tie strap green LED light load cell cable and port do not attach at this time Figure 2-8: Attach Torque Module and Load Cell Cable 2-8

35 TORQUE MODULE INSTALLATION Torque Module Installation INSTALLING THE END DECK AND DECK ASSEMBLIES 1 If not already installed, secure the hood scoops to the covers using four button-head screws and nuts per hood scoop. 2 Install the end deck assembly using five 3/8-16 x 1-inch button-head flange screws. hood scoops end deck assembly Figure 2-9: Install the End Deck Assembly Version 2 2-9

36 CHAPTER 2 Torque Module Installation 3 Install the deck assembly using nine 3/8-16 x 1-inch button-head flange screws. deck assembly hood scoop Figure 2-10: Install the Deck Assembly 2-10

37 TORQUE MODULE INSTALLATION Load Cell Calibration LOAD CELL CALIBRATION This section provides instructions for using the Torque Module with WinPEP 7. The Torque Module must be calibrated prior to use. Follow the directions on the screen exactly. Failure to perform the directions accurately will result in improper torque values. 1 Verify you are in the MakeRun screen. 2 Verify you are connected to the dyno electronics. Note: For more information on connecting to the dyno electronics, refer to the WinPEP 7 User Guide (on your WinPEP CD or at or the WinPEP 7 Online Help. 3 Select Tools MakeRun Options Torque Cell Calibration. Note: Before proceeding, be sure the eddy current brake is free and clear of any obstructions. There should not be anything resting on the eddy current brake or the dynamometer drum during this procedure. 4 Click Next to perform the Zero Calibration. The Calibration window will appear. The hardware is now zeroing out the torque cell. If the unit does not calibrate, recheck the setup and retry. Figure 2-11: Zero Calibration Window Version

38 CHAPTER 2 Load Cell Calibration Once the Zero Calibration is complete, the Calibration Mass window will appear. 5 Enter the Torque Module calibration value. Refer to Figure Note: You must perform this step the first time you calibrate the load cell. Or If you are only performing a Zero Calibration, click Finish. Figure 2-12: Calibration Mass Window Enter the calibration number stamped near the bolt pattern at the end of the calibration arm. 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 pattern closest to the end of the arm unless space constraints in your dyno room do not allow you to. bolt pattern near the center of the calibration arm bolt pattern closest to the end of the calibration arm Figure 2-13: Calibration Arm Number 2-12

39 TORQUE MODULE INSTALLATION Load Cell Calibration 6 Click Next to continue. The Span Calibration window will appear. 7 Install the calibration arm and weights. Refer to step 8 and Figure 2-15 on page Figure 2-14: Span Calibration Window Version

40 CHAPTER 2 Load Cell Calibration 8 Install the calibration arm and weights using the bolts at the end of the calibration arm. Note: If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm. Refer to Figure 2-16 on page a Secure the calibration arm to the eddy current brake by tightening the bolt using the handle. 8b Gently place the weights on the calibration arm. Note: Verify the calibration arm is not contacting the cover. The calibration weights are very heavy. The weights must be set on the arm gently or you will damage the load cell. secure arm to brake by tightening handle weight support pin weights Figure 2-15: Install Calibration Arm and Weights Using the Bolt Pattern Closest to the End 2-14

41 TORQUE MODULE INSTALLATION Load Cell Calibration If you do not have enough room to use the bolt pattern closest to the end of the calibration arm, use the bolt pattern in the center of the arm as shown in Figure secure arm to brake by tightening handle weight support pin weights Figure 2-16: Install Calibration Arm and Weights Using the Bolt Pattern in the Center Version

42 CHAPTER 2 Load Cell Calibration While installing the calibration weights, you should notice the Torque Gauge on the DynoTrac Window moving from 0 to about 500 foot-pounds. Note: The Torque Gauge may or may not be in this range. If the torque cell has been previously calibrated incorrectly or has not been calibrated for a while, the gauge may show values out of this range until calibration is complete. If you use the bolt pattern in the center of the calibration arm, the gauge will show values around foot-pounds. Note: Let the torque gauge needle stabilize before clicking Next. 9 From the Span Calibration window (Figure 2-14), click Next to continue. At this point, the value on the gauge should match the value on the calibration arm. 10 Remove the calibration arm and weights and click Finish. Figure 2-17: Calibration Is Complete Window 2-16

43 C HAPTER 3 BASIC DYNAMOMETER OPERATION The Dynojet dynamometer (dyno) gives state of the art technology, durability, and accuracy that you need. Dynojet s advanced engineering delivers the precise horsepower measurements a technician needs to make quick and accurate evaluations of engine performance and drive train problems. This chapter will walk you through loading and preparing your dynamometer and includes instructions for basic dyno operation. For more detailed instructions, refer to the WinPEP 7 User Guide. This manual can be found on your WinPEP CD or at This chapter is divided into the following categories: Loading the Car, page 3-2 Connecting the RPM Pickup, page 3-5 Pre-Run Inspection, page 3-8 Making a Run, page

44 CHAPTER 3 Loading the Car LOADING THE CAR Use the following steps to load a car on the dyno. 1 Verify the dyno electronics power is on and connected to your computer. 2 Make sure you are in the MakeRun screen. 3 Set the dyno brake on by pressing the red button on the hand held pendant. 4 For four or all wheel drive vehicles, measure the wheel base on the vehicle and adjust the 224-4WD dyno to the dimension before driving the vehicle on the dyno. 5 Drive the vehicle onto the dyno and align the vehicle straight with the dyno. 6 Stop the vehicle when the drive axle(s) is centered on the drum(s). rear or front wheel drive vehicles center drive axle on dyno drum four or all wheel drive vehicles center drive axle on both dyno drums adjust wheel base of 224-4wd dyno Figure 3-1: Center the Drive Axle(s) on the Drum(s) 7 When the vehicle is positioned properly on the dyno, shut the engine off. If the vehicle has an automatic transmission, place it in park. If the vehicle has a manual transmission, place it in gear. 8 Set the vehicle s emergency brake. 9 Secure the non-drive wheels using the provided tire chocks. Do not use tire chocks for four wheel drive vehicles. 3-2

45 BASIC DYNAMOMETER OPERATION Loading the Car 10 Attach the tie-down straps. Rear Wheel Drive Attach two tie-down straps from secure anchor points to the rear of the vehicle. Attach additional tie-down straps from the rear of the vehicle as shown in Figure 3-2. Attach two tie-down straps from secure anchor points to the front of the vehicle. Front Wheel Drive Attach two tie-down straps from secure anchor points to the rear of the vehicle. Attach two tie-down straps from secure anchor points to the front of the vehicle. Attach additional tie-down straps across the front of the vehicle to form a crisscross. Four Wheel (All Wheel) Drive Attach two tie-down straps from secure anchor points to the rear of the vehicle. If the vehicle is equipped with a rear steering system, attach additional tie-down straps across the rear of the vehicle to form a crisscross. Attach two tie-down straps from secure anchor points to the front of the vehicle. Attach additional tie-down straps across the front of the vehicle to form a crisscross. rear wheel drive front wheel drive four wheel drive Figure 3-2: Attach Tie-down Straps Version 2 3-3

46 CHAPTER 3 Loading the Car 11 Tighten the tie-down straps evenly making sure that the drive wheels remain centered on the drum. The tie-down straps should always be connected to the vehicle s solid axle or the suspension control arms. Factory tie-down hooks connected to the vehicle s frame may be used on the end opposite the drive wheels (for example: the front end of a rear driven vehicle). 12 Release the brake on the vehicle and the dyno. 13 Start the vehicle and put the transmission into first gear or drive. 14 Press the accelerator pedal so the drums begin turning slowly. While the drums are slowly turning, get a feel for the stability of the vehicle. Stop the drum with the dyno brakes. 15 Check all the straps and ensure the vehicle is tracking straight on the dyno. 3-4

47 BASIC DYNAMOMETER OPERATION Connecting The RPM Pickup CONNECTING THE RPM PICKUP Your Dynojet dynamometer includes a primary wire inductive pickup and two secondary wire inductive pickups. These small clothespin like inductive pickups are used to sense RPM. An RPM pickup is required if you want to view torque graphs. Generally you will use one secondary wire inductive pickup on a spark plug wire. Vehicles with wasted spark ignition systems may require two secondary inductive pickups. On a wasted spark ignition, typically one coil will be connected to two spark plug wires. Attach one secondary pickup to each of these wires. If the pickups are connected to two plug wires that do not fire at the same time, an erratic RPM readout may occur. The primary wire inductive pickup senses RPM pulses from the coil. Although this pickup location generally works better, it is harder to find the correct location to connect the RPM pickup. Note: If a pickup is not being used, disconnect it from the dyno electronics to prevent any stray pick up of signals. The optional Optical Sensor is useful on diesel powered vehicles, MSD ignitions, and other high RFI ignition systems. For more detailed information on the Optical Sensor, refer to the Optical RPM Sensor Installation Guide (P/N ). Inductive pickups are very fragile. The ferrite core can easily be damaged and is not covered under warranty. Dropping, snapping, vibration, and heat can all damage the ferrite core. The DynoWare EX+ RPM module contains the electronics that sense the RPM pulses. An auto-gain circuit looks at only the peak voltage of the vehicle s spark, ignoring the lower voltages to help reduce electronic noise problems. Wasted spark ignition systems will produce a lower voltage level on the exhaust stroke than the compression stroke. By definition of the auto-gain circuit, lower voltage spark levels will be ignored, missing every other spark the vehicle would produce. RPM PICKUP DESCRIPTIONS RPM pickup Secondaries (Non- wasted spark system) Secondaries (Wasted spark ignition system) Primary pickup Optional Optical RPM Sensor description Use one secondary pickup. Unplug the other pickup from the RPM module and set the degrees between plug fires to 720 in WinPEP. Use two secondary pickups. Attach one pickup on each spark plug wire on the same coil and set the degrees between plug fires to 360 in WinPEP. Attach the primary wire pickup to the primary side of the coil. Set the degrees between plug fires by taking 720/number of cylinders. For example, the number of degrees between plug fires on a V-8 engine with a single coil is 720/8=90 degrees. Attach the sensor wire to the RPM module, also be sure to plug in the small power lead into the CPU module. The other end of the wire attaches to the Optical Sensor. Set the degrees between plug fires to 360 in WinPEP. Refer to the Optical RPM Sensor Installation Guide (P/N ). Version 2 3-5

48 CHAPTER 3 Connecting The RPM Pickup CONNECTING THE SECONDARY INDUCTIVE PICKUP The secondary inductive pickup cannot be in contact with, or it s connecting wire be crossing, other engine electrical wires or stray RF interference may result. 1 Clip the secondary inductive pickup around one spark plug wire. 2 Route the inductive pickup cable clear of devices that produce electronic noise (spark plug wires, coil wire, coil etc.). 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 the dyno for the electronics to function properly. connect secondary inductive pickup on a single spark plug wire automobile distributor Figure 3-3: Secondary Inductive Pickup Figure 3-4: Separate Spark Plug Wire 3-6

49 BASIC DYNAMOMETER OPERATION Connecting The RPM Pickup CONNECTING THE PRIMARY INDUCTIVE PICKUP The primary inductive pickup cannot be in contact with, or it s connecting wire be crossing, other engine electrical wires or stray RF interference may result. 1 Clip the primary inductive pickup around the primary side of the coil. 2 Route the primary wire cable clear of devices that produce electronic noise. Note: You must ground the vehicle to the dyno for the electronics to function properly. coil connect primary inductive pickup on the negative side of the coil Figure 3-5: Primary Inductive Pickup Version 2 3-7

50 CHAPTER 3 Pre-run Inspection PRE-RUN INSPECTION Perform a vehicle inspection before making a run. Check the radiator coolant and oil levels. Check the fuel source. Rotate the drum(s) and check for rocks caught in the tire tread that could fly out. Check the tire pressure and tire speed rating. Improperly inflated tires or exceeding the maximum speed rating can result in premature wear or severe tire damage. Make sure the tire has no major deficiencies (cracks in sidewalls, tread life, etc.). Visually inspect the vehicle. Make sure it is in safe running order. Make sure ear protection and safety glasses are used when the dyno is being operated. Check the tie-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 dynamometer s 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 running your vehicle on the dyno. 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. BEFORE STARTING THE ENGINE Connect an exhaust hose or hoses (if dual exhaust) on the vehicle, make sure the hose fits over the tail pipe, is not plugged or kinked and the hose is vented correctly out of the dyno room. Engine exhaust contains poisonous carbon monoxide gas. Breathing id could cause death. Operate machine in well ventilated area. 3-8

51 BASIC DYNAMOMETER OPERATION Pre-run Inspection ENGINE WARM UP Warm the vehicle s engine and drivetrain before beginning testing. Consistent engine temperatures will assure your runs are repeatable. AFTER ENGINE WARM UP Always leave the vehicle in 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 excessive exhaust smoke should be resolved before continuing. Version 2 3-9

52 CHAPTER 3 Making a Test Run MAKING A TEST RUN Dyno runs provide safe, reliable road testing right in the shop. The dyno allows you to measure, record, and diagnose performance problems quickly. The dyno combined with WinPEP 7 produces consistent, easily interpretable power graphs. Use the following instructions to ensure repeatable and accurate measurements. 1 Verify the vehicle is secured properly. 2 Place the vehicle in a low gear and release the dyno brake using the hand held pendant. 3 Slowly accelerate the vehicle to 20 m.p.h. 4 Test the tachometer operation. 4a Rev the engine. The gauges on the computer screen should be moving. If the tachometer is moving but not registering the correct RPM values, the number of degrees of revolution of the crank shaft (the plug fires number) is incorrect. 4b Stop the vehicle, return to the MakeRun Configuration dialog box, and enter the correct value for the plug firing order. 5 Press the red brake button to apply 100% braking and slow down the vehicle. Using the vehicle s own brakes to slow or stop the drum at speeds over 30 m.p.h. can severely over heat the brake parts. Dynojet dynamometers with the mechanical brake, air brake, or eddy current brake accessory can be used to slow the vehicle and drum to a full stop at any speed. The vehicle s brakes should be used in an emergency stop situation only. 6 Shut the engine off and put the vehicle in gear (manual transmission) or park (automatic transmission). 7 Set the vehicle s parking brake and leave the dyno brake on. 8 Perform a final inspection. Verify the drive tire s alignment on the dyno drums. Make any adjustments to the tie-down straps as needed. Perform any other safety checks that you deem appropriate to your particular situation. You are now ready to make a high speed run on the dyno. Refer to your WinPEP 7 User Guide for more detailed instructions. 3-10

53 A PPENDIX A RED HEAD ANCHOR INSTALLATION This appendix contains instructions for installing the Red Head Multi-Set II 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 B 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 HEAD Contact ITW Ramset/Red Head at , or 1300 North Michael Drive, Wood Dale, IL A-1

54 APPENDIXA Installation INSTALLATION Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number. catalog number drill bit size minimum hole depth setting tool catalog number Carbon Steel RM-38/RL-38 (9.5 mm) 1/2-inch 1 5/8-inch (41.2 mm) RT-138 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. 2 Insert the anchor. Figure A-1: Red Head Anchor Drill the Hole anchor Figure A-2: Red Head Anchor Insert the Anchor A-2

55 RED HEAD ANCHOR INSTALLATION Installation 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 Anchor Drive 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. setting tool Figure A-4: Red Head Anchor Expand the Anchor Version 2 A-3

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57 A PPENDIX B POWER REQUIREMENTS EXCLUDING NORTH AMERICA This appendix contains the power requirements and instructions for all locations excluding North America brake installations. Refer to page 1-5 for power requirements and instructions for North America and Japan. To ensure safety and accuracy in the procedures, perform the procedures as they are described. B-1

58 APPENDIXB Power Requirements and Installation POWER REQUIREMENTS AND INSTALLATION The eddy current brake (excluding North America and Japan) requires a dedicated wall receptacle which must be wired for operation and is included with the brake or may be shipped in advanced in a separate package. The eddy current brake requires a dedicated 240VAC single phase power outlet rated for 30A for proper operation. Failure to follow these instructions could result in personal injury or damage to the brake. Connecting the brake to the incorrect voltage will void the brake warranty. Contact Dynojet with any questions. The dedicated wall receptacle is a three-pin IEC grounded 30A type and must be wired in accordance with local building codes and requirements. Installation may require a licensed electrician to conform to applicable safety standards. If you are installing your brake in a location other than North America or Japan and the brake is not equipped with a three pin IEC grounded plug, contact Dynojet before attempting to connect the brake. Local and national electrical codes will require that the box containing the receptacle is grounded. This circuit should have a dedicated 30A double pole circuit breaker. The brake should be the only device connected to this circuit. B-2

59 POWER REQUIREMENTS EXCLUDING NORTH AMERICA Power Requirements and Installation INSTALLING THE WALL RECEPTACLE The wall receptacle is a single 240 volt 30A dedicated circuit with a ground. The cable carrying the power to this receptacle should be 4.0 mm 2 (ten gauge) or larger. Check with local building codes for the correct size. 1 Connect one of the 240V legs to the N terminal (white). 2 Connect the other 240V leg to the L terminal (no color). 3 Connect the ground conductor to the green terminal. L terminal N terminal (white) ground terminal (green) Figure B-1: Wiring the Wall Receptacle Version 2 B-3

60 APPENDIXB Power Requirements and Installation TESTING FOR CORRECT VOLTAGES You must test the receptacle for proper voltages before the dyno is connected to the outlet. Using a voltmeter that is capable of measuring AC voltage, measure between the points listed below and verify that the correct voltages are present. probe 1 probe 2 desired voltage measurement V to 250V 2 box <5V Figure B-2: Testing the Wall Receptacle B-4

61 POWER REQUIREMENTS EXCLUDING NORTH AMERICA Power Requirements and Installation REPLACING THE POWER PLUG Use the following instructions to replace the plug and socket. The plug and socket configuration must be rated for at least 240VAC 30A and have a minimum of three conductors. The power cord that attaches to the dyno has four conductors internally and their colors are brown, blue, black, and green/yellow. 1 Connect 240VAC single phase power between the brown and the blue wire connection points. 2 Connect the green/yellow wire to the ground connection point. 3 Cut off the black wire. 4 Refer to the previous table for testing and probe the new connections as follows: blue wire as location #1 brown wire as location #3 green/yellow wire as location #2 HARD WIRING TO THE BUILDING Use the following instructions to wire the brake directly to the building. The brake must connect to a two pole disconnect switch to allow the removal of all power to the brake for servicing. This box may contain fusing, circuit breakers, or the circuit protection may be upstream in the building power system. The circuit must be protected to 30A with slow blow fuses or time delayed circuit breakers. The power cord that attaches to the brake has four conductors internally and their colors are brown, blue, black, and green/yellow. 1 Remove the brake power plug and connect 240VAC single phase between the brown and the blue wires through the disconnect switch. 2 Connect the green/yellow wire to the ground connection. 3 Cut off the black wire. 4 Refer to the previous table for testing and probe the new connections as follows: blue wire as location #1 brown wire as location #3 green/yellow wire as location #2 Version 2 B-5

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63 A PPENDIX C INSTALLING THE ADAPTER AND BEARING EARLY MODEL DYNAMOMETERS This appendix contains instructions for installing the adapter and bearing on early model dynamometers (dynos); this includes dynos with serial numbers between and To ensure safety and accuracy in the procedures, perform the procedures as they are described. C-1

64 APPENDIXC Installing the Adapter and Bearing Early Model Dynos INSTALLING THE ADAPTER AND BEARING EARLY MODEL DYNOS Dynos missing the bearing mounting holes, shown in Figure 1-5 on page 1-10, will need to use the adapter (P/N ) to install the bearing. This includes dynos with serial numbers between and Orient the bearing to the adapter as shown in Figure C-1. The arrow on the adapter plate must point up. 2 Secure the bearing to the adapter plate using two 1/2-13 x 1.25-inch flange bolts and two 1/2-13-inch nuts. Leave the bolts loose. Note: The bolts are included with the eddy current brake while the nuts are included with the adapter kit. bearing adapter plate arrow Figure C-1: Early Model Dynos Install Bearing to Adapter 3 Secure the adapter plate to the dyno using six 1/2-13 x 3/4-inch bolts. bolt adapter plate Figure C-2: Early Model Dynos Install Adapter Plate C-2

65 INSTALLING THE ADAPTER AND BEARING EARLY MODEL DYNAMOMETERS Installing the Adapter and Bearing Early Model Dynos 4 Using the template included in this appendix, drill four additional holes into the dyno frame as shown. Note: If you needed to use the adapter plate, you will need to drill brake mounting holes in the dyno frame. 4a 4b Line the template up with the existing hole on the dyno. Drill two 3/8-16-inch UNC holes on each side of the dyno. template template drill holes drill holes existing hole existing hole Figure C-3: Early Model Dynos Using the Template Version 2 C-3

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67 Template Placement Early Model Dynos ADD 3/8-16 UNC HOLES EXISTING HOLES DYNO FRAME END ADD 3/8-16 UNC HOLES 5 3/4" 5 3/4" EXISTING HOLES 1 5/8" Template Early Model Dynos Template Early Model Dynos UP ø 5/16" EXISTING HOLE 5 3/4" 5 3/4"

68 INDEX 25-pin cable, routing 1-18 A accessing dyno electronics 2-4 adapter plate C-2 B bearing 1-10 retrofit C-2 brake power cable 1-18 breakout board control cable 1-19 jumpers 1-20 speed pick-up cable 1-19 temperature sensor cable 1-19 wiring 1-19 C cable clamp 2-7 cable routing channels 1-16 calibration arm 2-12 number 2-12 weights 2-14 control cable routing 1-18 wiring 1-19 conventions 1-3 CPU module power 2-5 D deck assembly 2-10 document part number 1-1 dyno electronics accessing 2-4 cable clamp 2-7 E eddy current brake installation optimal cooling 1-8 parts list 1-4 securing to floor 1-17 theta controller fuses 1-21 unpacking 1-9 wiring breakout board 1-19 end deck assembly 2-9 I input power cable 1-18 installation requirements power 1-5, B-2 K keyed yoke 1-11, 1-12 L load cell calibration calibration arm 2-12 calibration number 2-12 calibration weights 2-14 installing routing the cable 2-7 torque gauge 2-16 loading the car M making a test run 3-10 O optical RPM sensor 3-5 optimal brake cooling 1-8 Index-i