2004-2008 Dynojet Research, Inc. All Rights Reserved. Maintenance Guide For Model 224, Model 224 with 4WD, Model 424x, and Model 248 Automotive Dynamometers. This manual is copyrighted by Dynojet Research, Inc., hereafter referred to as Dynojet, and all rights are reserved. This manual 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 89031, USA. Printed in USA. Part Number: 98119101 Version 3 (03/2008)
TABLE OF CONTENTS Auto Dyno Maintenance Introduction................................................... 2 Conventions Used In This Manual................................ 2 Technical Support............................................ 2 Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems....... 3 Things to Check.............................................. 3 Maintaining the Model 224 AOH Drum Brake Shoe Clearance........... 4 Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System. 6 Things to Check.............................................. 6 Verifying the SAAR Brake Pressure................................ 7 Maintaining the SAAR Brake Shoe Clearance........................ 8 Changing the SAAR Brake Shoes................................ 10 4WD Attachment for Model 224 Dynos........................... 16 Things to Check............................................. 16 Filling the Air Motor Lubricator................................. 17 Adjusting the Air Motor Lubricator............................... 18 Inspecting the Rail Brake Clearance.............................. 19 Model 424x All-Wheel Drive Dynos.............................. 20 Things to Check............................................. 20 Filling the Air Motor Lubricator................................. 21 Adjusting the Air Motor Lubricator............................... 22 Verifying the SAAR Brake Pressure............................... 23 Maintaining the SAAR Brake Shoe Clearance....................... 24 Changing the SAAR Brake Shoes................................ 25 Checking the Air Can Sleeve Retraction........................... 26 Model 248 Dynos............................................. 27 Things to Check............................................. 27 Checking the 248 Drum Brake Shoe Clearance..................... 28 i
This document provides instructions for performing maintenance on the model 224 dynamometer (dyno), the model 224 dyno with the four wheel drive (4WD) attachment, the model 224-2 dyno, the model 424x dyno, and the model 248 dyno. To ensure safety and accuracy in the procedures, perform the procedures as they are described. Document Part Number: 98119101 Version 3 Last Updated: 03-19-08 1
Introduction INTRODUCTION................................... You may have a model 224 dyno configured with one drum for testing two-wheel drive vehicles, or with two drums for testing four-wheel drive vehicles. Model 224 dynos also may use either the Air Over Hydraulic (AOH) brake or the Spring Applied Air Release brake (SAAR). Model 424x dynos all use the SAAR brake and have two dyno drums for testing four-wheel drive cars. Or you may have a model 248 dyno. Make sure to perform all of the maintenance procedures for your dyno configuration. CONVENTIONS USED IN THIS MANUAL The conventions used in this manual are designed to protect both the user and the equipment. 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. 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 89031. Visit us on the World Wide Web at www.dynojet.com where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product line. 2
Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems MODEL 224 DYNOS WITH AIR OVER HYDRAULIC (AOH) BRAKE SYSTEMS................................... This section covers maintenance items for model 224 dynos with a single drum and AOH braking. AD203 Figure 1: Model 224 with Air Over Hydraulic (AOH) Brakes THINGS TO CHECK Check all air fittings for leaks monthly. Correct any leaks found. Once per month verify that the drum brake pressure gauge reads 55 to 65psi (380-450kPa). Adjust the regulator if the pressure is out of specification. Once per month check the drum brake shoe clearance. Refer to page 4 for more information. Dyno Bearing Grease: Under steady use, over 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every 2 months. Under occasional use, less than 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every six months. Recommended Grease: grease specification description thickener Lithium 12 Hydroxy Stearate oil Petroleum thickness NLGI 2 operating temperature -20 F to 200 F, intermittent to 250 F (Fahrenheit) operating temperature -29 C to 93 C, intermittent to 121 C (Celsius) EP additive yes examples Mobil Mobilith AW-2 Version 3 3
Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems MAINTAINING THE MODEL 224 AOH DRUM BRAKE SHOE CLEARANCE The 224 AOH drum brake shoe clearance must be checked once per month. If you have upgraded your 224 dyno to use the Spring Applied Air Release (SAAR) braking system, refer to Maintaining the SAAR Brake Shoe Clearance on page 8. 1 Remove the air from the system. 1a Shut off or disconnect the air supply to the dyno, and follow lock out procedure. 1b Press the red button on the pendant to activate the drum brakes; the button will be lit. 1c Using the red button on the pendant, cycle the drum brakes on and off several times until all of the air is released from the system. 2 Remove the covers as necessary to provide safe working access to the dyno. 3 Measure the gap between the brake shoe and the drum surface. This gap should be.125 inch -.375 inch (3mm - 10mm). 4 If the brake shoe clearance is out of specification, perform the following steps: 4a Remove the two 3/8-inch bolts and washers that secure the brake slave cylinder to the dyno frame. AD204 remove bolts and washers remove bolts and washers Figure 2: 224 Dyno AOH Brake Remove the Bolts from Brake Slave Cylinder 4
Model 224 Dynos with Air Over HyDraulic (AOH) Brake Systems 4b 4c 4d 4e Pull the slave cylinder away from the dyno being careful not to kink the brake line. Screw the brake piston rod in to increase brake shoe clearance or out to decrease brake shoe clearance. Refer to Figure 3. Attach the slave cylinder using the bolts and washers removed earlier. Recheck the brake shoe clearance. No part of the brake shoe should touch the drum. Note: If you cannot adjust the brakes to specification, you will need new brake shoes. Contact Dynojet. 5 Turn on or reconnect the air supply and verify the drum brakes operate before replacing the covers and using the dyno. AD205 screw brake piston rod in or out to adjust brake clearance carefully pull slave cylinder away to expose the brake piston rod Figure 3: 224 Dyno AOH Brake Pull the Cylinder Away Version 3 5
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System MODEL 224 DYNOS WITH SPRING APPLIED AIR RELEASE (SAAR) BRAKE SYSTEM................................... This section covers maintenance items for model 224 dynos with the SAAR brake. THINGS TO CHECK Check all air fittings for leaks monthly. Correct any leaks found. Once per month verify the drum brake pressure gauge reads 100psi (690kPa). Adjust the regulator if the pressure is out of specification. Refer to Verifying the SAAR Brake Pressure on page 7 for more information. Check the drum brake shoe clearance. Refer to Maintaining the SAAR Brake Shoe Clearance on page 8 for more information. Dyno Bearing Grease: Under steady use, over 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every 2 months. Under occasional use, less than 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every six months. Recommended Grease: grease specification description thickener Lithium 12 Hydroxy Stearate oil Petroleum thickness NLGI 2 operating temperature -20 F to 200 F, intermittent to 250 F (Fahrenheit) operating temperature -29 C to 93 C, intermittent to 121 C (Celsius) EP additive yes examples Mobil Mobilith AW-2 6
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System VERIFYING THE SAAR BRAKE PRESSURE 1 Verify the SAAR brake pressure gauge reads 100psi (690kPa). 2 Using the knob, adjust the regulator until the correct pressure is achieved. brake pressure regulator AB096 use knob to adjust regulator until correct pressure is achieved 0 AB095 Figure 4: 224 Dyno Verify the SAAR Brake Pressure and Adjust Using the Regulator brake pressure gauge should read 100psi (690kPA) Version 3 7
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System MAINTAINING THE SAAR BRAKE SHOE CLEARANCE 1 Verify the area is clear and the dyno can be operated safely. 2 Power up the dyno electronics. 3 Using the pendant, turn the brake to the off position. This will release the SAAR brake by moving the brake shoe away from the drum. Keep hands and fingers clear when operating dyno. 4 Measure the gap between the brake shoe and the drum surface. This gap should be between.125 inch -.375 inch (3mm - 10mm). Note: For clarity, the dyno frame is shown transparently to reveal the drum. Note: The mounting bracket shown is used with the SAAR upgrade. Factory installed SAAR brakes use a slightly different bracket. brake shoe drum measure gap AB094 Figure 5: 224 SAAR Brake Measure the Gap Between the Brake Shoe and Drum 8
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 5 If the brake shoe clearance is out of specification, loosen the upper nut on the air can rod. 6 Adjust the lower nut until the brake shoes are.25 inch (6mm) away from the dyno drum. 7 Tighten the upper nut on the air can rod down onto the brake actuating tube to sandwich the tube between the two nuts. 8 Torque the lower nut to 110 foot-pounds. If you cannot adjust the brakes to specification, you will need new brake shoes. Contact Dynojet. air can rod upper nut brake actuating tube BR032 lower nut Figure 6: 224 SAAR Brake Adjust the Brake Shoe Clearance Version 3 9
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System CHANGING THE SAAR BRAKE SHOES 1 Apply air to the brake system. Air pressure to the brake system must be maintained while changing the SAAR brake shoes. 2 Release the brakes. 2a Turn on the dyno electronics. 2b Verify the brake button on the pendant is not lit. 3 Remove the nut from the bottom air can rod and set aside. air can rod nut Figure 7: 224 SAAR Brake Remove the Nut from the Bottom Air Can Rod 10
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 4 Slowly lower the pressure using the regulator. The air can rod will retract from the tube. Note: Verify the rod does not bind on the tube. regulator air can rod tube Figure 8: 224 SAAR Brake Retract the Air Can Rod from the Tube Version 3 11
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 5 Slide the tube out and set aside. tube Figure 9: 224 SAAR Brake Slide the Tube Out 6 Using the access holes in the dyno frame, remove the cotter key from each brake. 7 Remove the pin from each brake. Note: For clarity, the drum is not shown. pin top view drum not shown for clarity cotter key Figure 10: 224 SAAR Brake Remove the Cotter Key and Pin 12
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 8 Remove each brake arm assembly. brake arm assembly Figure 11: 224 SAAR Brake Remove the Brake Arm Assembly 9 Remove the cotter key from the brake arm assembly. 10 Remove the pin. 11 Remove the retainer and shoe. 12 Install the new brake shoe and replace the retainer. Note: Verify the brake shoe is secure. 13 Replace the pin and cotter key. brake shoe retainer cotter key pin brake shoe retainer cotter key pin Figure 12: 224 SAAR Brake Replace the Brake Shoe Version 3 13
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 14 Replace each brake arm assembly using the pin and cotter key removed earlier. Refer to Figure 10. 15 Slide the tube in. 16 Slowly raise the pressure using the regulator. The air can rod will go through the tube. Note: Verify the rod does not bind on the tube. regulator air can rod tube Figure 13: 224 SAAR Brake Replace the Air Can Rod Through the Tube 14
Model 224 Dynos with Spring Applied Air Release (SAAR) Brake System 17 Replace the nut, removed earlier, on the bottom air can rod. 18 Adjust the brake shoe clearance as necessary. Refer to Maintaining the SAAR Brake Shoe Clearance on page 8 for more information. 19 Press the red button on the pendant to activate the drum brakes; the button will be lit. air can rod nut Figure 14: 224 SAAR Brake Replace the Nut on the Bottom Air Can Rod Version 3 15
4WD Attachment for Model 224 Dynos 4WD ATTACHMENT FOR MODEL 224 DYNOS................................... This section covers maintenance items for model 224 dynos with the 4WD attachment. THINGS TO CHECK Check customer supplied air filter/dryer daily, empty and clean as necessary. Inspect the 4WD dyno movement rails for debris once per month. Clear any debris from the rails. Check all air fittings for leaks monthly. Correct any leaks found. Once per month maintain the brake pressure and brake shoe clearance. For AOH brakes refer to page 3. If you have upgraded to the SAAR brake, see page 6. Adjust the lubrication provided by the air motor lubricator. Refer to Adjusting the Air Motor Lubricator on page 18 for more information. Check the air motor lubricator once per month and fill as necessary. Refer to Filling the Air Motor Lubricator on page 17 for more information. Dyno Bearing Grease: Under steady use, over 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every 2 months. Under occasional use, less than 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every six months. Recommended Grease: grease specification description thickener Lithium 12 Hydroxy Stearate oil Petroleum thickness NLGI 2 operating temperature -20 F to 200 F, intermittent to 250 F (Fahrenheit) operating temperature -29 C to 93 C, intermittent to 121 C (Celsius) EP additive yes examples Mobil Mobilith AW-2 16
4WD Attachment for Model 224 Dynos FILLING THE AIR MOTOR LUBRICATOR Check the air motor lubricator once per month and fill as necessary. 1 Disconnect the air before removing the lubricator bowl. 2 Shut off or disconnect the air supply to the dyno, and follow lock out procedure. 3 Press and hold the dyno in or out movement switch until you cannot hear any air going through the movement motor. 4 Before running the Gast Air Motor, remove the lubricator bowl and fill the bowl with oil. Note: Use a non-detergent SAE #10 automotive engine oil (Gast Part #AD220). BR043 remove bowl and fill to line with oil Figure 15: 224 4WD Attachment Check Air Motor Lubricator Version 3 17
4WD Attachment for Model 224 Dynos ADJUSTING THE AIR MOTOR LUBRICATOR Use the following steps to adjust the amount of oil provided by the air motor lubricator. 1 Turn the top knob on the air motor lubricator clockwise until it shuts off the flow of oil. 2 Back off the knob one turn counter-clockwise to start the flow of oil. 3 Adjust the knob as needed between one turn and fully on (turning counterclockwise) as needed for the particular environment in your dyno room. turn knob clockwise to shut off oil, back off one turn counterclockwise to start the flow of oil AD206 Figure 16: 224 4WD Attachment Adjust the Air Motor Lubricator 18
4WD Attachment for Model 224 Dynos INSPECTING THE RAIL BRAKE CLEARANCE Inspect the rail brake clearance once per month. 1 Shut off or disconnect the air supply to dyno, and follow your company s lock out procedure. 2 Press the red button on the pendant to activate the drum brakes; the button will be lit. 3 Press and hold the dyno movement switch in either the in or out position until you cannot hear any air going through the movement motor. 4 Using the red button on the pendant, cycle the drum brakes on and off several times until no air is heard. 5 Remove the covers as necessary to provide safe working access to the dyno. 6 Using a ruler, measure the free play movement of each rail brake. The free play should not exceed 3/16 inch (5mm). 7 If the rail brake free play is out of specification, adjust by loosening the jam nut and turning the adjusting bolt until free play is within specification. Tighten the jam nut while holding the adjusting bolt. Figure 17: 224 4WD Attachment Inspect the Rail Brake Clearance Version 3 19
Model 424x All-Wheel Drive Dynos MODEL 424X ALL-WHEEL DRIVE DYNOS................................... This section covers maintenance items for model 424x dynos. THINGS TO CHECK Check all air fittings for leaks monthly. Correct any leaks found. Check the air motor lubricator once per month and fill as necessary. Refer to Filling the Air Motor Lubricator on page 21 for more information. Once per month verify that the SAAR brake pressure gauge reads 100psi (690kPa). Adjust the regulator if the pressure is out of specification. Refer to Verifying the SAAR Brake Pressure on page 23 for more information. Check the drum brake clearance. Refer to Maintaining the SAAR Brake Shoe Clearance on page 24 for more information. Check the air can sleeve retraction. Refer to Checking the Air Can Sleeve Retraction on page 26 for more information. Check customer supplied air filter/dryer daily, empty and clean as necessary. Inspect the 4WD dyno movement rails for debris once per month. Clear any debris from the rails. Dyno Bearing Grease: Under steady use, over 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every 2 months. Under occasional use, less than 25 runs per day, each bearing should receive.65oz (19 ml) of a recommended grease every six months. Recommended Grease: grease specification description thickener Lithium 12 Hydroxy Stearate oil Petroleum thickness NLGI 2 operating temperature -20 F to 200 F, intermittent to 250 F (Fahrenheit) operating temperature -29 C to 93 C, intermittent to 121 C (Celsius) EP additive yes examples Mobil Mobilith AW-2 20
Model 424x All-Wheel Drive Dynos FILLING THE AIR MOTOR LUBRICATOR Check the air motor lubricator once per month and fill as necessary. 1 Disconnect the air before removing the lubricator bowl. 2 Shut off or disconnect the air supply to the dyno, and follow lock out procedure. 3 Press and hold the dyno in or out movement switch until you cannot hear any air going through the movement motor. 4 Before running the Gast Air Motor, remove the lubricator bowl and fill the bowl with oil. Note: Use a non-detergent SAE #10 automotive engine oil (Gast Part #AD220). remove bowl and fill to line with oil Figure 18: 424x Dyno Filling the Air Motor Lubricator AD0195 Version 3 21
Model 424x All-Wheel Drive Dynos ADJUSTING THE AIR MOTOR LUBRICATOR Use the following steps to adjust the amount of oil provided by the air motor lubricator. 1 Turn the top knob on the air motor lubricator clockwise until it shuts off the flow of oil. 2 Back off the knob one turn counter-clockwise to start the flow of oil. 3 Adjust the knob as needed between one turn and fully on (turning counterclockwise) as needed for the particular environment in your dyno room. turn knob to adjust amount of oil delivered Figure 19: 424x Dyno Adjusting the Air Motor Lubricator AD0195 22
Model 424x All-Wheel Drive Dynos VERIFYING THE SAAR BRAKE PRESSURE 1 Verify the SAAR brake pressure gauge reads 100psi (690kPa). 2 Using the knob, adjust the regulator until the correct pressure is achieved. brake pressure regulator AB096 use knob to adjust regulator until correct pressure is achieved 0 AB095 Figure 20: 424x Dyno Check the SAAR Brake Pressure and Adjust the Regulator brake pressure gauge should read 100psi (690kPA) Version 3 23
Model 424x All-Wheel Drive Dynos MAINTAINING THE SAAR BRAKE SHOE CLEARANCE 1 Verify the area is clear and the dyno can be operated safely. 2 Power up the dyno electronics. 3 Using the pendant, turn the brake to the off position. This will release the SAAR brake by moving the brake shoe away from the drum. Keep hands and fingers clear when operating dyno. 4 Measure the gap between the brake shoe and the drum surface. This gap should be between.125 inch -.375 inch (3mm - 10mm). Note: For clarity, the dyno frame is shown transparently to reveal the drum. Note: The mounting bracket shown is used with the SAAR upgrade. Factory installed SAAR brakes use a slightly different bracket. brake shoe drum measure gap AB094 Figure 21: 424x SAAR Brake Measure the Gap Between the Brake Shoe and Drum 24
Model 424x All-Wheel Drive Dynos 5 If the brake shoe clearance is out of specification, loosen the upper nut on the air can rod. 6 Adjust the lower nut until the brake shoes are.25 inch (6mm) away from the dyno drum. 7 Tighten the upper nut on the air can rod down onto the brake actuating tube to sandwich the tube between the two nuts. 8 Torque the lower nut to 110 foot-pounds. If you cannot adjust the brakes to specification, you will need new brake shoes. Contact Dynojet. air can rod upper nut brake actuating tube BR032 lower nut Figure 22: 424x SAAR Brake Adjust the Brake Shoe Clearance CHANGING THE SAAR BRAKE SHOES Refer to Changing the SAAR Brake Shoes on page 10 for detailed instructions. Version 3 25
Model 424x All-Wheel Drive Dynos CHECKING THE AIR CAN SLEEVE RETRACTION The SAAR brake s air can sleeve must be positioned correctly for safe operation. If the air can sleeve is not in the correct location, use a wrench and loosen the nut as far as you can. The sleeve will drop down as shown in Figure 23. Check all four air cans. Note: Verify that the brakes are operating properly before replacing the covers and using the dyno. correct placement of nut and sleeve incorrect placement of nut and sleeve sleeve sleeve nut nut AD0194 Figure 23: 424x Dyno Air Can Sleeve 26
Model 248 Dynos MODEL 248 DYNOS................................... This section covers maintenance items for model 248 dynos. THINGS TO CHECK Check all air fittings for leaks monthly. Correct any leaks found. Once per month verify the drum brake pressure gauge is reading 55 to 65psi (450kPa). Adjust the regulator if the pressure is out of specification. Maintain the brake shoe clearance. Refer to Checking the 248 Drum Brake Shoe Clearance on page 28 for more information. Dyno Bearing Grease: Under steady use, over 25 runs per day, each bearing should receive 1.5oz (44.36 ml) of a recommended grease every 2 months. Under occasional use, less than 25 runs per day, each bearing should receive 1.5oz (44.36 ml) of a recommended grease every six months. Recommended Grease: grease specification description thickener Lithium Complex oil Petroleum thickness NLGI 2 operating temperature -20 F to 200 F, intermittent to 250 F (Fahrenheit) operating temperature -29 C to 93 C, intermittent to 121 C (Celsius) examples Mobil Mobilith AW-2 Version 3 27
Model 248 Dynos CHECKING THE 248 DRUM BRAKE SHOE CLEARANCE The 248 drum brake shoe clearance needs to be checked once per month. Use the following steps. 1 Remove the air from the system. 1a Shut off or disconnect the air supply to the dyno, and follow lock out procedure. 1b Press the red button on the pendant to activate the drum brakes; the button will be lit. 1c Press and hold the dyno in or out movement switch until you cannot hear any air going through the movement motor. Note: If there is no 4WD dyno, skip this step. 1d Using the red button on the pendant, cycle the drum brakes on and off several times until no air is heard. 2 Remove the covers as necessary to provide safe working access to the dyno. 3 Measure the gap between the brake shoe and the drum surface. This gap should be.125 inch -.50 inch (3mm - 13mm). 28
Model 248 Dynos 4 If the brake shoe clearance is out of specification perform the following steps: 4a 4b 4c 4d 4e 4f 4g 4h Remove the cotter key from the clevis pin and remove clevis pin. Remove the two 5/8-inch nuts and washers securing the air can to the brake bracket. Loosen the jam nut. Pull the air can up so that the clevis can be turned. Screwing the clevis down the air can rod will decrease brake shoe clearance. With the clevis adjusted, secure the jam nut. Place the air can on brake bracket and secure with nuts and washers removed earlier. Secure clevis with pin and cotter key. Adjust the brake shoe support so that the brake shoe clearance is even over the length of the shoe. Loosen the jam nut and turn the brake shoe support. With the brake shoe support adjusted, tighten the jam nut. If you cannot adjust the brakes to specification, you will need new brake shoes. Contact Dynojet. 5 Turn on or reconnect the air supply and check that the drum brakes operate before replacing the covers and using the dyno. Figure 24: 248 Dyno Remove Cotter Key Version 3 29