Linx System with Atra Flex Installation for Model 424 Automotive Dynamometers

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2 Dynojet Research, Inc. All Rights Reserved. Linx System with Atra Flex Installation for Model 424 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 02 (01/2018)

3 Linx with Atra Flex Installation TABLE OF CONTENTS Introduction Conventions Used In This Manual Tool Requirements Technical Support Linx Belt Drive Specifications Unpacking the Linx Parts Dynojet Logo Panels and Pit Covers Removing the Dynojet Logo Panels Above Ground Removing the Pit Covers In Ground Carrier Bearing and Splined Shaft Installation Inner Mounting Plate and Flange Bearing Installation Installing the Inner Mounting Plate and Flange Bearing Moveable Dyno Installing the Inner Mounting Plate and Flange Bearing Stationary Dyno Drive Pulley Installation Idler Pulley Installation Belt and Tensioner Pulley Assembly Installation Pulley Mounting Plates and Outer Bearings Installation Installing the Idler Pulley Outer Bearing, Bearing Mounting Plate, Linx Detect Sensor, and Lower Pulley Mount Installing the Moveable Dyno Lower Pulley Mount Installing the Lower Pulley Mount Stationary Dyno Outer Carrier Bearing Installation Atra Flex Coupler Installation Installing the Fly Wheel Installing the Flex Hub Installing the Yellow Insert and Drive Ring Upper Pulley Mount Installation Installing the Upper Drive Pulley and Upper Idler Pulley Mounts Installing the Upper Stationary Dyno Pulley Mount Routing the Linx Detect Sensor Cable Brake Signal Relay Installation Tension the Belt i

4 TABLE OF CONTENTS Linx Belt Covers Above Ground Installing the Right Cover Assembly Installing the Left Cover Assembly Installing the Lid and Door Assemblies Linx Belt Covers In Ground Disconnect the Belt Drive from Both Dyno Drums Reconnecting the Belt Drive Appendix A Red Head Anchor Installation Installation A-2 Appendix B D-Lok Bearing Installation Installation B-2 Bearing Lubrication B-2 ii ii

5 Thank you for your interest in Dynojet s Automotive Dynamometers. Dynojet s 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 Power Core software and a Dynojet dynamometer (dyno) will give you the professional results you require. The Linx belt drive system synchronizes the speed of the front and rear drums for testing sensitive all-wheel drive and two-wheel drive vehicles with traction control while the atra flex system reduces vibration and wear on the drive system. This document is designed to help you install the Linx with Atra Flex system on your model 424 automotive dyno. 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 2 Linx Belt Drive Specifications, page 3 Unpacking the Linx Parts, page 4 Dynojet Logo Panels and Pit Covers, page 10 Carrier Bearing and Splined Shaft Installation, page 14 Inner Mounting Plate and Flange Bearing Installation, page 15 Drive Pulley Installation, page 19 Idler Pulley Installation, page 23 Belt and Tensioner Pulley Assembly Installation, page 24 Outer Carrier Bearing Installation, page 31 Atra Flex Coupler Installation, page 32 Upper Pulley Mount Installation, page 35 Routing the Linx Detect Sensor Cable, page 38 Brake Signal Relay Installation, page 40 Tension the Belt, page 42 Linx Belt Covers Above Ground, page 44 Linx Belt Covers In Ground, page 53 Disconnect the Belt Drive from the Dyno Drums, page 57 1

6 Introduction INTRODUCTION Thank you for your interest Dynojet s Automotive Dynamometers. Before installing the Linx with Atra Flex system, 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. example of convention Blue 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. Highlights items you can click on directing you to a location with additional information (electronic version). TOOL 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: ½-inch minimum hole depth: 1 ⅝-inch (41.2 mm) You will need to provide a long hex bit socket to tighten the bearing screws to the torque specifications. Refer to Appendix B for more information on installing the bearings. hex bit socket: ¼-inch minimum bit length: 1 ½-inch or longer 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 and where Dynojet provides state of the art technical support, on-line shopping, and press releases about our latest product lines. Try our remote support assistance or watch one of our informative videos. Stay informed about product releases and new map downloads by signing up for the Dynojet Newsletter. Access the electronic version of this guide along with additional accessory guides, software guides, and the latest technical bulletins at 2

7 Linx Belt Drive Specifications LINX BELT DRIVE SPECIFICATIONS The following specifications specific to the Linx belt drive dyno application will help you set up your dyno area and verify you have met the requirements necessary to operate your dyno safely. For more detailed information about your dyno specifications, refer to the installation guide included with your dyno. description Length of Linx option Width of Linx option of frame and Linx option of frame with eddy current brake and Linx option Maximum Speed Maximum Power specifications cm ( in.) cm (25.00 in.) cm ( in.) cm ( in.) 290 kph (180 mph) 1000 ft.-lb. of differential torque between the axles Figure 1: Above Ground Model 424xLC 2 Dyno with Linx Belt Drive Dimensions Version 2 3

8 Unpacking the Linx Parts UNPACKING THE LINX PARTS Use the following steps to unload your Linx system parts. 1 Using a pry bar, or a large flat screwdriver, and a hammer, carefully remove the top and sides of the crate. At this point, you will want to inspect the exterior of the dyno for any indications of damage. Report any damage immediately. 2 Remove the following parts from the crate and set aside. part description part description stationary pulley mounting plate P/N tensioner assembly P/N moveable pulley mounting plate P/N upper stationary pulley mount P/N stamped 1 idler pulley mounting plate P/N lower stationary pulley mount (3) P/N stamped 2 flange bearing with lock collar (6) P/N inner stationary dyno mounting plate P/N bushing (2) includes three bolts and washers per bushing P/N upper moveable pulley mount P/N stamped 3 grooved pulley (2) P/N lower moveable pulley mount P/N stamped 4 screw, 1/4-20 x 5/8", pan-head, torx, black (8) P/N inner moveable dyno mounting plate P/N

9 Unpacking the Linx Parts part description part description bolt, 3/8-16 x 1.5", flangehex (2) P/N nut, 9/16-12, hex (24) P/N Linx belt covers, above ground P/N above ground installation only see parts list below tension arm assembly P/N bolt, 9/16-12 x 2", hex (12) P/N Linx brake relay kit P/N washer, 3/8", hardened, flat (86 above ground) P/N additional for in ground as P/N DM Linx belt covers, in ground P/N in ground installation only see parts list below washer, 9/16", flat (24) P/N Linx detect sensor kit P/N see parts list below anchor, red head, 3/8" (10 above ground, 6 in ground) P/N atra flex kit P/N see parts list below installation tool, red head anchor P/N nut, 3/8-16, hex (2) P/N DM v-belt 10/5V3800 P/N bolt, 3/8-16 x 1.25", hex (4) included as extras P/N DM Version 2 5

10 Unpacking the Linx Parts part description part description idler pulley assembly bolt, 3/8-16 x 1", hex (85) P/N DM The following parts are included in the Linx Detect Sensor Kit P/N : zip tie, 4" (18) P/N pickup collar, Linx detect sensor P/N adhesive mounting pad (15) P/N screw, 8-32 x 3/8", pan-head, phil (5) P/N mounting bracket, Linx detect sensor P/N zip tie, 6" (2) P/N tab, Linx detect sensor P/N Linx detect sensor P/N mounting plate, Linx detect sensor P/N cable, Linx detect sensor P/N The following parts are included in the Atra Flex Kit P/N : outer carrier bearing, bore (2) P/N atra flex coupler (2) P/N see parts list below outer carrier bearing, flange (4) P/N splined shaft (2) P/N

11 Unpacking the Linx Parts part description part description bearing, flange (2) P/N bolt, 1/2-13 x 1", hex (8) P/N BR bolt, 1/2-13 x 1.5", flangehex (4) P/N bolt, 3/8-16 x 1", hex (16) P/N DM outer shaft assembly (2) P/N The following parts are included in the Atra Flex Coupler P/N : flex hub, atra flex P/N yellow insert, atra flex P/N fly wheel, atra flex P/N screw, 1/2-20 x 2.25", socket head (6) P/N drive ring, atra flex P/N The following parts are included in the Linx Belt Covers, Above Ground P/N : door magnet, 2 x 1" (4) P/N belt cover right support P/N letter O P/N brace (4) P/N Version 2 7

12 Unpacking the Linx Parts part description part description end panel (2) P/N nut, 1/4-20, nylock (66) P/N lid assembly (2) P/N screw, 1/4-20 x 5/8", pan-head, torx, black (37) P/N center leg (2) P/N left door assembly P/N right leg P/N right door assembly P/N belt cover center support P/N washer, 1/4", flat (33) P/N DM The following parts are included in the Linx Belt Covers, In Ground P/N : pit cover mount P/N washer, 3/8", hardened, flat (6) P/N calibration access cover (2) P/N anchor, red head, 3/8" (6) P/N belt cover center support P/N pit cover assembly (2) P/N P 8

13 Unpacking the Linx Parts part description part description feet (6) P/N bolt, 3/8-16 x 1", hex (6) P/N DM screw, 1/4-20 x 5/8", pan-head, torx, black (16) P/N nut, crush, 1/4-20 (5) P/N DM bolt, 3/8-16 x 1/2",2 buttonhead flange allen, (8) P/N Version 2 9

14 Dynojet Logo Panels and Pit Covers DYNOJET LOGO PANELS AND PIT COVERS The Linx option can only be installed on one side of the dyno, refer to Figure 1. When the Linx option is being installed on an existing above ground dyno, the Dynojet logo panels must be removed. When the Linx option is being installed on an existing in ground dyno, the pit covers must be removed. If your Dynojet logo panels or pit covers are already removed, continue with Carrier Bearing and Splined Shaft Installation on page 14. REMOVING THE DYNOJET LOGO PANELS ABOVE GROUND Repeat the following steps for each logo panel. 1 Remove the five 1/4-20 x 5/8-inch pan-head torx screws securing the logo panel to the mounting brackets. Set these screws aside. 2 Remove the logo panel and set aside. logo panel XD001 Figure 2: Remove the Dynojet Logo Panel 10

15 Dynojet Logo Panels and Pit Covers 3 Remove the two 7/16-14 x 1-inch hex bolts, two 7/16-inch flat washers, and two 7/16-14 nuts securing the lower mounting bracket to the dyno. Set the hardware aside. 4 Remove the lower mounting bracket and set aside. 5 Remove the two 3/8-16 x 3/4-inch hex bolts and two 3/8-inch flat washers securing each mounting bracket to the dyno. Set the hardware aside. 6 Remove each mounting bracket and set aside. XD002 XD003 lower mounting bracket mounting bracket Figure 3: Remove the Logo Panel Mounting Brackets Version 2 11

16 Dynojet Logo Panels and Pit Covers 7 Remove the two 3/8-16 x 1.5-inch flange hex bolts, washers, and nuts securing the rear deck brace to the mounting bracket. Set the hardware aside. 8 Remove two 3/8-16 x 1.5-inch flange hex bolts securing the rear deck brace mounting bracket to the dyno. Set the hardware aside. 9 Remove the rear deck brace mounting bracket and set aside. XD004 rear deck brace XD005 rear deck brace mounting bracket Figure 4: Remove the Rear Deck Brace Mounting Bracket 12

17 Dynojet Logo Panels and Pit Covers REMOVING THE PIT COVERS IN GROUND If present, remove the pit covers, runner extension, and support leg. 1 If present, remove the pit covers. 2 Remove the two 1/4-20 torx screws securing the runner extension to the runner assembly. Replace the torx screws. 3 Remove the two bolts, flat washers, and nuts securing the runner extension to the support leg and remove the runner extension. 4 Replace the two torx screws removed from the runner assembly. 5 Remove the bolt and washer securing the support leg to the floor. 6 Remove the bolt and washer securing the support leg to the track and remove the support leg. Replace the bolt and washer. Note: For clarity, the 4WD dyno and bridge are not shown. runner extension runner assembly runner extension support leg support leg track AD547 Figure 5: Remove the Runner Extension and Support Leg Version 2 13

18 Carrier Bearing and Splined Shaft Installation CARRIER BEARING AND SPLINED SHAFT INSTALLATION Use the following instructions to install the carrier bearing and splined shaft to both the stationary and moveable dynos. You will need the following parts: Bearing, Flange (2) Bolt, 1/2-13 x 1.5", Flange-Hex (4) Splined Shaft (2) 1 Loosely install the inner carrier bearing using two 1/2-13 x 1.5-inch flange bolts. 2 Apply a small amount of grease to the first two inches of the splined shaft. 3 Push the splined shaft into the dyno until it stops (bottoms). Pull the shaft assembly back slightly, approximately 1/8-inch. Verify the sleeve on the shaft is lined up with the set screw in the bearing. 4 Lift lightly on the shaft finding the mid point of the vertical travel. 5 While applying just enough upward pressure to support the shaft, tighten the two 1/2-inch bolts. 6 Torque the bearing set screws to ft.-lbs. Verify the set screw is lined up on the shaft sleeve. Do not tighten the set screw on the splines or sleeve edge. bearing shaft sleeve splined shaft Figure 6: Install the Carrier Bearing and Splined Shaft 14

19 Inner Mounting Plate and Flange Bearing Installation INNER MOUNTING PLATE AND FLANGE BEARING INSTALLATION Use the following instructions to install the inner mounting plate and flange bearing to both the stationary and moveable dynos. You will need the following parts: Flange Bearing with Lock Collar (2) Bolt, 3/8-16 x 1.5", Flange-Hex (2) Nut, 9/16-12, Hex (8) Washer, 3/8", Flat (18) Washer, 9/16", Flat (8) Inner Mounting Plate, Stationary Dyno Inner Mounting Plate, Moveable Dyno DM Nut, 3/8-16, Hex (2) DM Bolt, 3/8-16 x 1", Hex (16) INSTALLING THE INNER MOUNTING PLATE AND FLANGE BEARING MOVEABLE DYNO 1 Place the flange bearing on the threaded studs on the inner plate. 2 Loosely secure the flange bearing to the inner plate using four 9/16-inch washers and four 9/16-inch nuts. 3 Secure the inner mounting plate to the moveable dyno using eight 3/8 x 1-inch bolts and eight 3/8-inch flat washers. Note: For above ground installations, use only six 3/8 x 1-inch bolts and six 3/8-inch flat washers. 4 Verify the flange bearing on the inner mounting plate is centered on the shaft. Loosen the bearing nuts and center the bearing if necessary. inner mounting plate flange bearing for in ground installations only Figure 7: Secure the Inner Mounting Plate and Flange Bearing to the Moveable Dyno Version 2 15

20 Inner Mounting Plate and Flange Bearing Installation 5 Using the access holes, secure the bottom of the inner mounting plate to the moveable dyno using two 3/8-16 x 1.5-inch flange bolts, two 3/8-inch flat washers, and two 3/8-inch nuts. access hole Figure 8: Secure the Bottom of the Inner Mounting Plate to the Moveable Dyno 16

21 Inner Mounting Plate and Flange Bearing Installation The following steps are for the above ground dyno only. 6 Secure the rear deck brace mounting bracket to the inner mounting plate and dyno using the two 3/8-16 x 1.5-inch flange-hex bolts removed earlier. 7 Secure the rear deck brace to the mounting bracket using the two 3/8-16 x 1.5-inch flange-hex bolts, washers, and nuts removed earlier. rear deck brace mounting bracket rear deck brace Figure 9: Secure the Rear Deck Brace and Mounting Bracket Version 2 17

22 Inner Mounting Plate and Flange Bearing Installation INSTALLING THE INNER MOUNTING PLATE AND FLANGE BEARING STATIONARY DYNO 1 Place the flange bearing on the threaded studs on the inner plate. 2 Loosely secure the flange bearing to the inner plate using four 9/16-inch washers and four 9/16-inch nuts. 3 Secure the inner mounting plate to the stationary dyno using eight 3/8 x 1-inch bolts and eight 3/8-inch flat washers. 4 Verify the bearing on the inner mounting plate is centered on the shaft. Loosen the bearing nuts and center the bearing if necessary. inner mounting plate flange bearing Figure 10: Secure the Inner Mounting Plate and Flange Bearing to the Stationary Dyno 18

23 Drive Pulley Installation DRIVE PULLEY INSTALLATION Use the following instructions to install the drive pulleys for both the moveable and stationary dynos. You will need the following parts: Stationary Dyno Pulley Bearing Mounting Plate Moveable Dyno Pulley Bearing Mounting Plate Flange Bearing with Lock Collar Bushing (2) includes three bolts and lock washers each Grooved Pulley (2) Nut, 9/16-12, Hex (8) Bolt, 9/16-12 x 2", Hex (8) Washer, 9/16", Flat (8) Outer Shaft (2) 1 Secure the flange bearing to the pulley bearing mounting plate using four 9/16-12 x 2-inch bolts, four 9/16-inch flat washers, and four 9/16-inch nuts. 2 Slide the pulley bearing mounting plate assembly over the outer shaft. 3 Using the installation instructions in Appendix B, loosely secure the bearing cap screw. pulley bearing mounting plate flange bearing outer shaft Figure 11: Install the Pulley Bearing Mounting Plate Version 2 19

24 Drive Pulley Installation 4 Slide the grooved pulley onto the outer shaft with the narrow end of the tapered bore towards the bearing plate. 5 Slide the taper lock bushing onto the outer shaft and into the taper of the pulley. 6 Place the bushing into the grooved pulley. Note: Insert the bushing into the larger diameter end of the pulley tapered hole. 7 Loosely secure the bushing in the pulley using the three included bolts and lock washers. taper lock bushing section view of bushing and grooved pulley to show correct alignment with the tapered hole grooved pulley tapered bushing pulley outer shaft pulley plate Figure 12: Install the Pulley and Bushing 20

25 Drive Pulley Installation 8 With the pulley and shaft assembly on the floor, have another person slide the pulley until it is approximately cm ( in.) from the end of the shaft. Slowly tighten the bolts until the pulley starts to move to the end of the shaft. 9 Tighten all three bolts by working around the bushing until none of the bolts will turn at a torque wrench setting of 70 ft.-lb. Note: It is very important all three bolts on the bushing are tightened to a torque wrench setting of 70 ft.-lb. Work around all three bolts a second time to verify. The pulley should have moved to approximately 8.38 cm (3.30 in.) from the end of the shaft. 10 Verify the pulley is 8.38 cm (3.30 in.) from the end of the shaft. Note: The measurement of 8.38 cm (3.30 in.) is not critical; however, this measurement should be the same on both the moveable and stationary dynos cm ( in.) before tightening bolts 8.38 cm (3.3 in.) after tightening bolts Figure 13: Verify the Pulley Distance Version 2 21

26 Drive Pulley Installation 11 Slide the pulley shaft assembly onto the splined shaft and into the inner bearing until the outer face of the pulley is approximately 17-inches from the inner mounting plate. 12 Using the installation instructions in Appendix B, secure the cap screw on the inner bearing. pulley shaft assembly Figure 14: Install the Pulley Shaft Assembly 22

27 Idler Pulley Installation IDLER PULLEY INSTALLATION You will need the following parts: Flange Bearing with Lock Collar Nut, 9/16-12, Hex (4) Washer, 9/16", Flat (4) Idler Pulley Assembly 1 Place the flange bearing on the threaded studs on the inner plate. 2 Secure the flange bearing to the inner plate using four 9/16-inch flat washers and four 9/16-inch nuts. 3 Holding the idler assembly horizontal, slide the assembly into the bearing until its outer edge is approximately 11-1/8-inches from the face of the inner plate. 4 Using the installation instructions in Appendix B, secure the lock collar. Note: Refer to Appendix B for bearing installation instructions. Carefully allow the idler pulley assembly to hang in the bearing. flange bearing idler pulley assembly Figure 15: Install the Idler Pulley Version 2 23

28 Belt and Tensioner Pulley Assembly Installation BELT AND TENSIONER PULLEY ASSEMBLY INSTALLATION You will need the following parts: Washer, 3/8", Flat (8) Anchor, Red Head, 3/8" (8) Red Head Anchor Installation Tool Belt Tensioner Assembly DM Bolt, 3/8-16 x 1", Hex (8) Use the following instructions along with Figure 16 on page Route the belt around the pulleys as shown in Figure 16 on page Place the belt around the tensioner pulley and place the tensioner assembly in the position shown in Figure 16 on page 25. Standard Wheelbase place the tensioner assembly 10.2 cm (4.0 in.) from the outside of the rail. Extended Wheelbase Option place the tensioner assembly 12.7 cm (5.0 in.) inside of the end of the rail. Note: Verify the welded on nuts on the tensioner assembly are towards the back and the tensioner pulley is slid all the way to the end of the assembly towards the stationary dyno. 3 Verify the belt is aligned and seated in the grooves on each pulley. 4 Verify the bearings are the same distance from each mounting angle. 5 Using a long straight edge, verify the tensioner pulley and the movable dyno pulley are aligned. 6 With the tensioner assembly in this position, drill the eight holes needed to secure the tensioner assembly to the floor. 7 Install eight Red Head anchors. Refer to Appendix A for installation instructions. 8 Secure the tensioner assembly to the floor using eight 3/8-16 x 1-inch bolts and eight 3/8-inch flat washers. Note: If a Red Head is drilled too deep, use one of the four 3/8 x 1.25-inch bolts included. Two extra Red Heads are also included. 9 Apply some grease to the two ACME threads. 24

29 Belt and Tensioner Pulley Assembly Installation tensioner pulley towards stationary dyno apply grease to ACME threads welded nuts towards back Figure 16: Install the Belt and Tensioner Pulley Assembly Version 2 25

30 Pulley Mounting Plates and Outer Bearings Installation PULLEY MOUNTING PLATES AND OUTER BEARINGS INSTALLATION The inner pulley mounting plates and the pulley mounts are stamped with numbers to help match the parts and guide you in the installation process. You will need the following parts: Idler Pulley Bearing Mounting Plate Linx Detect Sensor Mounting Bracket Linx Detect Sensor Tab Linx Detect Sensor Mounting Plate Linx Detect Sensor Pickup Collar Flange Bearing with Lock Collar Screw, 8-32 x 3/8", Pan-Head, Phil (5) Nut, 9/16-12, Hex (4) Bolt, 9/16-12 x 2", Hex (4) Washer, 1/4", Lock (4) Washer, 3/8", Flat (64) Washer, 9/16", Flat (4) Zip Tie, 6" (2) Pulley Mount, Upper, Stationary Dyno Pulley Mount, Lower, Stationary Dyno (3) used for stationary dyno pulley, lower moveable dyno pulley, upper idler pulley Pulley Mount, Upper, Idler Pulley Pulley Mount, Lower, Moveable Dyno Linx Detect Sensor Linx Detect Sensor Cable DM Bolt, 3/8-16 x 1", Hex (64) 26

31 Pulley Mounting Plates and Outer Bearings Installation INSTALLING THE IDLER PULLEY OUTER BEARING, BEARING MOUNTING PLATE, LINX DETECT SENSOR, AND LOWER PULLEY MOUNT 1 Secure the Linx detect sensor to the mounting plate using two #8-32 screws. 2 Loosely secure the Linx detect sensor and mounting plate assembly to the mounting bracket using two #8-32 screws. Leave these screws loose to align the sensor with the tab 3 Attach the Linx detect sensor cable to the sensor. Linx detect sensor attach cable mounting plate mounting bracket Figure 17: Install the Linx Detect Sensor and Mounting Plate to the Mounting Bracket 4 Secure the Linx detect sensor mounting bracket and the outer idler bearing to the idler bearing mounting plate using four 9/16-12 x 2-inch bolts, four 9/16-inch flat washers, and four 9/16-inch nuts. Slide this assembly onto the idler shaft. sensor mounting bracket idler bearing plate outer idler bearing Figure 18: Install the Sensor Mounting Bracket, Outer Idler Pulley Bearing, and Bearing Mounting Plate Version 2 27

32 Pulley Mounting Plates and Outer Bearings Installation 5 Secure the Linx detect sensor tab to the pickup collar using one #8-32 screw. Note: Verify the tab is positioned perpendicular to the pickup collar as shown in Figure Slide the pickup collar onto the idler shaft. The tab will sit in the sensor window. 7 Tighten the pickup collar cap screw. idler shaft pickup collar cap screw position tab perpendicular to the pickup collar sensor tab pickup collar Figure 19: Install the Sensor Tab and Pickup Collar 8 Place a lower stationary dyno pulley mount (P/N , stamped 2) under the idler pulley and loosely secure the mount to the inner plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers (one of the holes in the pulley mount is not used). 9 Loosely secure the pulley mount to the idler bearing mounting plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers. 10 Before tightening these bolts, align the idler with the moveable dyno pulley. With a straight edge on the idler pulley there should be an even gap of about 1/8-inch to the moveable dyno pulley. 11 Tighten all the bolts. idler bearing plate pulley mount P/N stamped 2 Figure 20: Install the Pulley Mount Under the Idler Pulley 28

33 Pulley Mounting Plates and Outer Bearings Installation 12 With the mounting bracket screws loose, slide the mounting plate and sensor until the Linx detect sensor tab is centered in the sensor window. 13 Tighten the screws securing the mounting plate and sensor assembly to the mounting bracket. pickup collar tab sensor window sensor mounting plate mounting bracket tighten screws Figure 21: Align the Linx Detect Sensor Tab INSTALLING THE MOVEABLE DYNO LOWER PULLEY MOUNT 1 Place the lower moveable dyno pulley mount (P/N , stamped 4) under the moveable dyno pulley and loosely secure the mount to the inner plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers. 2 Loosely secure the pulley mount to the moveable dyno pulley bearing plate using three 3/8-16 x 1-inch bolts and three 3/8-inch flat washers. pulley mount P/N stamped 4 Figure 22: Install the Pulley Mount Under the Moveable Dyno Pulley Version 2 29

34 Pulley Mounting Plates and Outer Bearings Installation INSTALLING THE LOWER PULLEY MOUNT STATIONARY DYNO 1 Place a lower stationary dyno pulley mount (P/N , stamped 2) under the stationary dyno pulley and loosely secure the mount to the inner plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers (one of the holes on the pulley mount is not used). 2 Loosely secure the pulley mount to the stationary dyno pulley bearing plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers. stationary dyno pulley bearing plate pulley mount P/N stamped 2 Figure 23: Secure the Pulley Mount Under the Stationary Dyno Pulley 30

35 Outer Carrier Bearing Installation OUTER CARRIER BEARING INSTALLATION Use the following instructions to install the outer carrier bearing for both the moveable and stationary dynos. You will need the following parts: Bearing Bore (2) Bearing Flange (4) BR Bolt, 1/2-13 x 1, Hex (8) 1 Assemble the bearing flanges and bearing bore as shown in Figure Loosely secure the bearing flanges and bearing bore using four 1/2-13 x 1-inch hex bolts. 3 Lock the outer carrier bearing lock collar by turning the collar with a punch and tightening the set screw. Verify the bearing is lined up on the shaft sleeve. Do not tighten the set screw on the splines or sleeve edge. bearing flange bearing bore bearing flange Figure 24: Install the Outer Carrier Bearing Version 2 31

36 Atra Flex Coupler Installation ATRA FLEX COUPLER INSTALLATION Use the following instructions to install the Atra Flex coupler on both the moveable and stationary dynos. You will need the following parts: Flex Hub (2) Fly Wheel (2) Drive Ring (2) Yellow Insert (2) Screw, 1/2-20 x 2.25", Socket Head (12) DM Bolt, 3/8-16 x 1", Hex (16) INSTALLING THE FLY WHEEL 1 Secure the fly wheel to the pulley shaft flange using eight 3/8-16 x 1-inch hex bolts. 2 Torque the bolts to 23 ft.-lbs. fly wheel Figure 25: Install the Fly Wheel 32

37 Atra Flex Coupler Installation INSTALLING THE FLEX HUB 1 Loosen the four 1/2 x 1-inch bearing bolts to allow the bearing to move slightly. 2 Slide the flex hub onto the splined shaft leaving a small gap to the outer carrier bearing. The flex hub face should be nearly flush with the splined shaft face. 3 Loosely secure the flex hub using two set screws. 4 Set up a dial indicator on the outer diameter of the flex hub. Rotate the outer pulley shaft watching for the high and low readings on the indicator. 5 Adjust the position of the outer carrier bearing until there is inches or less between the high and low readings. 6 Loosen the set screws and remove the flex hub. 7 Tighten the 1/2 x 1-inch bearing bolts. Note: The flex hub must be removed to access the bearing bolts. 8 Slide the flex hub onto the splined shaft leaving a small gap to the outer carrier bearing. 9 Tighten the flex hub set screws. dial indicator flex hub flex hub Figure 26: Install the Flex Hub Version 2 33

38 Atra Flex Coupler Installation INSTALLING THE YELLOW INSERT AND DRIVE RING 1 Spread the yellow insert and slide the insert over the flex hub. 2 Slide the drive ring over the yellow insert and secure to the outer shaft using six 1/2-20 x 2.25-inch socket head screws. 3 Torque the screws to ft.-lbs. yellow insert drive ring Figure 27: Install the Yellow Insert and Drive Ring 34

39 Upper Pulley Mount Installation UPPER PULLEY MOUNT INSTALLATION Use the following instructions to install the upper pulley mounts on both the stationary and moveable dynos. The upper pulley mounts are stamped with numbers to help match the parts and guide you in the installation process. INSTALLING THE UPPER DRIVE PULLEY AND UPPER IDLER PULLEY MOUNTS 1 Place a lower stationary dyno pulley mount (P/N , stamped 2) over the moveable dyno pulley and loosely secure the mount to the inner plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers (one of the holes in the pulley mount is not used). 2 Loosely secure the pulley mount to the moveable dyno pulley bearing plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers. pulley mount P/N stamped 2 Figure 28: Install the Pulley Mount Over the Moveable Dyno Pulley Version 2 35

40 Upper Pulley Mount Installation 3 Place the upper moveable dyno pulley mount (P/N , stamped 3) over the idler pulley and loosely secure the mount to the inner plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers. 4 Loosely secure the pulley mount to the idler pulley bearing plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers. 5 Loosely secure the pulley mount to the movable dyno pulley bearing plate using two 3/8-16 x 1-inch bolts and two 3/8-inch flat washers. 6 While applying upward pressure to support the shaft and pulley, tighten all the bolts. 7 Using the installation instructions in Appendix B, secure the cap screws on both bearings. pulley mount P/N stamped 3 apply upward pressure Figure 29: Install the Pulley Mount Over the Idler Pulley 36

41 Upper Pulley Mount Installation INSTALLING THE UPPER STATIONARY DYNO PULLEY MOUNT 1 Place the upper stationary dyno pulley mount (P/N , stamped 1) over the stationary dyno pulley and loosely secure the mount to the inner plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers (one of the holes on the pulley mount is not used). 2 Loosely secure the pulley mount to the stationary dyno pulley bearing plate using five 3/8-16 x 1-inch bolts and five 3/8-inch flat washers. 3 While applying upward pressure to support the shaft and pulley, tighten all the bolts. 4 Using the installation instructions in Appendix B, secure the cap screws. pulley mount P/N stamped 1 Figure 30: Install the Pulley Mount Over the Stationary Dyno Pulley Version 2 37

42 Routing the Linx Detect Sensor Cable ROUTING THE LINX DETECT SENSOR CABLE Use the following instructions along with Figure 31 on page 38 to route the Linx detect sensor cable to the DynoWare RT module. You will need the following parts: zip tie, 4" (18) adhesive mounting pads (15) 1 Route the Linx detect sensor cable up and over the moveable dyno pulley, along the back of the dyno, and over to the cable track. 2 Using the supplied adhesive mounting pads and cable ties, secure the Linx detect sensor cable to the pulley mounts and dyno. Note: You may wish to secure any additional cables with the Linx detect sensor cable for a clean installation. adhesive mounting pad and cable tie cable track Linx detect sensor cable moveable dyno pulley Linx detect sensor cable Figure 31: Routing the Linx Detect Sensor Cable 38

43 Routing the Linx Detect Sensor Cable 3 Remove the two screws and washers securing the cable track containing the signal cables to the front rail tie assembly. Pull the cable track out from under the dyno. Note: Do not place the Linx detect sensor cable in the track with the power cables. Keep the power cables in a separate track from the signal cables. 4 Using a screwdriver, open the crossbar on each link. 5 Place the Linx detect sensor cable in the cable track and close the crossbar on each link. crossbar cable track link use screwdriver to open Figure 32: Cable Track Link Crossbar 6 Place the cable track back under the dyno and secure the cable track to the front rail tie assembly using the screws and washers removed earlier. 7 Route the Linx detect sensor cable to the back of the DynoWare RT module and connect the cable to Linx 1 as shown in Figure 31 on page 38. Version 2 39

44 Brake Signal Relay Installation BRAKE SIGNAL RELAY INSTALLATION Use the following instructions along with Figure 33 on page 41 if you are upgrading an existing dyno. If you are installing a new dyno, skip these instructions and continue with Tension the Belt on page Disconnect the 4WD power supply. 2 Turn off the power to the dyno electronics. 3 Remove the two brake signal wires from the terminal labeled BRK IN on the 4WD board. 4 Cut off the ferrules and strip the wires. 5 Attach the butt connector from the relay 85 to the green brake signal wire. 6 Attach the butt connector from the relay 86 to the white brake signal wire. 7 Remove the black and white power wires from the terminal labeled GND and +12 on the 4WD board. 8 Cut off the ferrules and strip the wires. 9 Attach the butt connector from the white jumper wire to the white power wire. 10 Insert one of the ferrules from the white jumper wire to the BRK IN terminal and secure. 11 Insert the other ferrule from the white jumper wire to the +12 terminal and secure. 12 Attach the butt connector from the relay 30 to the black power wire. 13 Insert the ferrule from the relay 30 wire to the GND terminal and secure. 14 Attach the yellow wire from the relay 87a to the open BRK IN terminal. 15 Secure the relay to the 4WD board using an existing nut. 16 Reconnect the 4WD power supply. 17 Turn on the power to the dyno electronics. 18 Wheelbase adjustment may now be performed only with the dyno brakes released. 40

45 Brake Signal Relay Installation secure relay to 4WD board using existing nut Figure 33: Install the Brake Signal Relay Version 2 41

46 Tension the Belt TENSION THE BELT You will need the following part: Tension Arm Assembly Use the following instructions along with Figure 34 on page Verify the drum brakes are released. The dyno wheel base should only be adjusted with the brakes released or the Linx belt drive system disengaged. 2 Set the dyno to a wheelbase adjustment of 101-inches. 3 Measure 50.5-inches from the center of one of the drums. Mark this point on the bridge tube closest to the belt. 4 Loosen the ACME lock nuts on the tensioner. Note: Before tensioning the belt, the brakes must be released and the drums free to turn. Note: Verify the belt is aligned and seated in the grooves on each pulley. 5 Turn the ACME screws on the tensioner to tension the belt. Alternate sides to keep the pulley aligned with the belt. 6 Once the belt has some tension, place the tension arm centered on the mark. Verify the angle is completely seated on the underside of the tube. 7 Place two weights on the tension arm with the outer weight flush with the end of the arm. If the weights want to slip off of the bar, tension the belt more before putting the weights on. Note: Use the weights included in the Eddy Current Brake calibration set. 8 With the weights placed on the bar, tension the belt until the tension bar is horizontal. 9 Place a straight edge on the side of the tensioner pulley so it runs parallel to the belt. Verify the distance between the straight edge and the edge of the belt is even. Adjust this distance by turning one of the ACME screws if necessary. 10 Tighten the lock nuts. 11 Remove the weights and the tension arm. 12 Recheck the belt tension after the first several dyno runs and occasionally after that. 42

47 Tension the Belt mark in. from center of drum angle on underside of bridge tube weights tension arm lock nuts ACME screws Figure 34: Tension the Belt Version 2 43

48 Linx Belt Covers Above Ground LINX BELT COVERS ABOVE GROUND You will need the following parts: Door Magnet (4) Letter O End Panel (2) Lid Assembly (2) Center Leg (2) Right Leg Belt Cover Center Support Belt Cover Right Support Brace (4) Nut, 1/4-20, Nylock (66) Screw, 1/4-20 x 5/8", Pan-Head, Torx (37) Left Door Assembly Right Door Assembly DM Washer, 1/4", Flat (33) INSTALLING THE RIGHT COVER ASSEMBLY Use the following instructions to assemble and install the right Linx cover assembly. 1 Place two braces on the floor. 2 Secure the end panel to the braces using two 1/4-20 nuts. 3 Secure the right leg to the braces as shown using four 1/4-20 nuts. 4 Secure the center leg to the braces as shown using two 1/4-20 nuts. right leg end panel center leg brace Figure 35: Install the Legs and End Panel Right Cover Assembly 44

49 Linx Belt Covers Above Ground 5 Secure the belt cover center support to the right cover assembly using three 1/4-20 x 5/8-inch torx screws, three 1/4-inch flat washers, and three 1/4-20 nuts. 6 Secure the belt cover right support to the right cover assembly using one 1/4-20 x 5/8-inch torx screw, one 1/4-inch flat washer, and one 1/4-20 nut. right support center support Figure 36: Install the Right and Center Supports Version 2 45

50 Linx Belt Covers Above Ground 7 Remove the 1/4-20 x 5/8-inch torx screw from the outer most tube of the dyno bridge as shown in Figure Remove the screw from the drum guard on the stationary dyno as shown in Figure Turn the cover assembly over and move towards the dyno. 10 Place the cover assembly so the center support is on the outer tube with the hole lined up as shown and the right support is on the stationary dyno with the hole lined up as shown. 11 Secure the right cover assembly to the outer bridge tube and the stationary dyno drum guard using the two screws removed earlier. right support secured to drum guard center support secured to bridge Figure 37: Install the Right Cover Assembly to the Dyno 46

51 Linx Belt Covers Above Ground INSTALLING THE LEFT COVER ASSEMBLY Use the following instructions to assemble and install the left Linx cover assembly. 1 Place two braces on the floor. 2 Secure the end panel to the braces using two 1/4-20 nuts. 3 Secure the center leg to the braces as shown using four 1/4-20 nuts. end panel center leg brace Figure 38: Install the Legs and End Panel Left Cover Assembly Version 2 47

52 Linx Belt Covers Above Ground 4 Turn the cover assembly over and move towards the dyno. 5 Secure the left cover assembly to the center support leg using two 1/4-20 nuts and the existing nut and washer. Note: The center support leg is shown in a cutaway view to better show the installation. 6 Square up the end panel with the braces and tighten the bolts. secure to inside of leg center support leg existing nut and washer secure to leg Figure 39: Install the Left Cover Assembly 48

53 Linx Belt Covers Above Ground INSTALLING THE LID AND DOOR ASSEMBLIES 1 Secure each lid assembly to the cover assembly using sixteen 1/4-20 x 5/8-inch torx screws, fourteen 1/4-inch flat washer, and fourteen 1/4-20 nuts. Figure 40: Install the Lid Assemblies Version 2 49

54 Linx Belt Covers Above Ground 2 Install the left and right door assemblies using eight 1/4-20 nuts each. right door assembly left door assembly Figure 41: Install the Left and Right Door Assemblies 50

55 Linx Belt Covers Above Ground 3 Carefully remove the tape backing from the door magnets. Note: The door magnets are fragile until installed. Use care when handling the magnets. 4 Evenly space the door magnets and secure to the braces as shown in Figure 42. Exact placement is not critical. Be sure to press the magnet to ensure a good hold. 5 Close the doors against the magnets. door magnet Figure 42: Install the Door Magnets Version 2 51

56 Linx Belt Covers Above Ground 6 Install the letter O to the cover assembly using two 1/4-20 nuts. letter O Figure 43: Install the Letter O 52

57 Linx Belt Covers In Ground LINX BELT COVERS IN GROUND You will need the following parts: Pit Cover Mount Calibration Access Cover (2) Belt Cover, Center Support Feet, Pit Cover (6) Screw, 1/4-20 x 5/8", Pan-Head, Torx (16) Bolt, 3/8-16 x 1/2" Button-Head Flange, Allen (8) Washer, 3/8", Flat (6) Anchor, Red Head, 3/8" (6) P Pit Retarder Cover Assembly (2) DM Bolt, 3/8-16 x 1", Hex (6) DM Nut-Crush, 1/4-20 (4) 1 Secure the center support to the pit cover mount using four 1/4-20 x 5/8-inch torx screws and four 1/4-20 nuts. Note: When the dyno is equipped with the wheelbase extension kit (P/N ), use the center support (P/N ) included in the kit. center support pit cover mount center support pit cover mount center support included with wheelbase extension kit Figure 44: Install the Center Support to the Pit Cover Mount Version 2 53

58 Linx Belt Covers In Ground 2 Remove the 1/4-20 x 5/8-inch torx screw from the outer most tube of the dyno bridge. 3 Secure the center support assembly to the outer bridge tube using the screw removed earlier. center support assembly Figure 45: Install the Center Support to the Dyno 54

59 Linx Belt Covers In Ground 4 Place the pit cover assemblies on the floor in the position shown. 5 Secure the covers to the center support using two 3/8-16 x 1/2-inch button-head flange bolts. Figure 46: Secure the Pit Cover Assemblies to the Center Support Version 2 55

60 Linx Belt Covers In Ground 6 Secure the six angle feet to the pit cover assemblies in the positions shown using one 3/8-16 x 1/2-inch button-head flange bolt each. 7 Using the feet as a template, drill each hole needed to secure the feet to the floor. 8 Install the six Red Head anchors. Refer to Appendix A for installation instructions. 9 Secure each foot to the floor using one 3/8-16 x 1-inch hex bolt and one 3/8-inch washer. 10 Secure one access cover to each pit cover assembly using six 1/4-20 x 5/8-inch torx screws each. access cover Figure 47: Install the Pit Cover Feet and Access Covers 56

61 Disconnect the Belt Drive from Both Dyno Drums DISCONNECT THE BELT DRIVE FROM BOTH DYNO DRUMS The belt drive can be disengaged by removing the drive ring and the yellow insert from both the stationary and moveable dyno. It is best to have the dyno brakes released and no vehicle on the dyno when removing the drive rings. 1 Open the linx cover doors. For in ground dynos, remove the six 1/4-20 x 5/8-inch torx screws securing each access cover and set aside. Remove each access cover and set aside. 2 Verify the dyno brakes are released. Note: There should not be a vehicle on the dyno. 3 Remove the six socket head screws securing the drive ring and set aside. 4 Remove the drive ring and yellow insert and set aside. Always disengage the belt drive at BOTH dynos. yellow insert drive ring Figure 48: Disconnect the Belt Drive from both Dyno Drums Version 2 57

62 Disconnect the Belt Drive from Both Dyno Drums RECONNECTING THE BELT DRIVE Reconnect the belt drive on both the stationary and moveable dynos. 1 Spread the yellow insert and slide the insert over the flex hub. 2 Slide the drive ring over the yellow insert and secure to the outer shaft using six 1/2-20 x 2.25-inch socket head screws. 3 Torque the screws to ft.-lbs. Engage the belt drive at BOTH dynos. yellow insert drive ring Figure 49: Connect the Belt Drive on both Dyno Drums 58

63 APPENDIX 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

64 APPENDIX A Installation INSTALLATION Use the table below to determine the catalog number, drill bit size, minimum hole depth, and setting tool catalog number. catalog number Carbon Steel RM-38/RL-38 (9.5 mm) minimum hole setting tool drill bit size depth catalog number 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

65 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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67 APPENDIX B D-LOK BEARING INSTALLATION This appendix contains instructions for installing the Dodge D-Lok Mounted Ball Bearings. 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 Components attached to and within the dynamometer operate with potentially lethal voltages. To provide the greatest assurance of safety, the AC power cord(s) must be disconnected from the power source before servicing the dyno. Always wear protective clothing, ear protection, and eye protection (goggles, safety glasses) when using and servicing the dynamometer. Do not repair or replace any part of the dynamometer or attempt any servicing unless specifically recommended in published user-repair instructions that you understand and have the skills to carry out. CONTACT INFORMATION FOR BALDOR DODGE Contact Baldor at , or PO Box 2400, Fort Smith, AR Contact Dodge at , or 6040 Ponders Court, Greenville, SC B-1