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Mustang Dynamometer

MD-AWD-150

Page 18

3.4

M

AINTENANCE

S

AFETY

I

SSUES

E

LECTRICAL

S

HOCK

H

AZARD

– Turn off electrical service to the system before performing any

maintenance activity. Turn off the main breaker in your breaker box before working on anything
related to the PAU.

N

O

J

EWELRY

– Before performing any electrical or mechanical trouble-shooting, repair, etc. on

the dyne, it is highly advisable to remove any jewelry that you may be wearing.

D

YNE

C

OVER

P

ANELS

– use extreme caution around drive mechanisms and moving parts when

operating the dyne with any of its cover panels removed from the chassis assembly.

A

VOID

S

TRAINING

Y

OURSELF

– Be careful when lifting dyne cover panels – they are very heavy.

Be very careful when replacing belts, couplings, or bearings – the rolls are very heavy and can
be difficult to handle.

A

IR

P

RESSURE

– Make sure that there is no air pressure in the lines whenever you are working

on the roll locks, frame lock or pneumatic on/off couplings.

W

ATCH

Y

OUR

H

ANDS

– Never put your hands between the rolls brakes and the roll when there is

air hooked up to the system.

NEVER,

NEVER,

NEVER!

– Never pull on the drive belt in order to spin the rolls.

C

HECK

T

IGHTNESS

– Make sure that all bolts on the Dyne are tight and all couplings are properly

secured.

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Содержание MD-AWD-150

Страница 1: ...Mustang Dynamometer MD AWD 150 Page 1 MD AWD 150 SERIES MANUAL REV A ...

Страница 2: ...TICE This manual has been designed and written to provide useful information about Mustang Dynamometer equipment and systems Every effort has been made to make this manual as complete and accurate as possible but no warranty or fitness is implied The information contained in this manual is provided on an as is basis Neither the author of this manual nor the management and owners of Mustang Dynamom...

Страница 3: ...chine is running Only properly trained and responsible personnel should attempt to operate this machine LWARNINGL Removal and disassembly instructions in this manual have been reduced to a minimum for ease of readability Only experienced maintenance personnel should attempt to install and or make repairs to this machine LWARNINGL Keep limbs hair jewelry and clothing away from the moving rolls When...

Страница 4: ...ransportation expenses to and from Mustang and all labor expenses associated with removal and replacement of the component s as well as labor involved to repair component s Mustang will bear the expense of parts only These remedies are the Purchaser s sole remedies for breach of warranty The expiration of the warranty period use of the product for purposes other then those fro which it is designed...

Страница 5: ...SPECTION 19 4 3 TOOLS AND EQUIPMENT NEEDED FOR INSTALLATION 19 4 4 SHOP LAYOUT AND REQUIREMENTS 19 4 4 1 Pit Excavation Belowground Installation Only 19 4 4 2 Electrical 20 4 4 3 Pneumatic air 20 4 4 4 Ventilation 20 4 4 5 Floor Anchors 20 4 4 6 Clearance 20 4 5 ABOVE GROUND INSTALLATION 21 4 5 1 Above Ground Installation Procedure 21 4 6 BELOW GROUND INSTALLATION 27 4 6 1 Below Ground Installatio...

Страница 6: ...150 Page 6 SECTION 7 TROUBLESHOOTING 42 7 1 INTRODUCTION 42 7 2 TROUBLESHOOTING GUIDE 42 SECTION 8 APPENDIX 45 APPENDIX A TORQUE SPECIFICATIONS 45 APPENDIX B RECOMMENDED FLUIDS 48 APPENDIX C ANCHOR POD INSTALLATION NEW FLOORS 49 ...

Страница 7: ...st instruments and diagnostic equipment to the test vehicle s engine to monitor specific engine performance characteristics As the torque from the test vehicle s drive wheels cause the rolls of the Dyne to rotate Mustang s air cooled electrical eddy current Power Absorbing Unit PAU opposes this force by converting the vehicle s kinetic energy into heat A microcomputer based control unit using clos...

Страница 8: ...inciples of dynamometer operation are discussed Section 3 Safety First A number of very important safety tips are presented in this section Be sure to study this section carefully Section 4 Installation A step by step procedure is given in this section to help ensure that your dyne is installed properly Section 5 Operational Checkout A sequence of operational checks is provided in this section to ...

Страница 9: ...llowed v DANGER This is an example of an electrical DANGER message An electrical DANGER message alerts a person that as a result of electrical shock severe bodily injury or loss of life could occur if procedures are not followed l WARNING This is an example of a WARNING message A WARNING message alerts a person to potential bodily injury if procedures are not followed CAUTION This is an example of...

Страница 10: ...ho will be performing maintenance and service on your Dynamometer have read this manual in its entirety and understand all of the information presented 1 5 IF YOU NEED HELP Much effort has been extended to make this manual easy to work with as well as complete and accurate However if there is something that you do not understand or something that you have a question about please feel free to conta...

Страница 11: ...ration When learning to operate and or maintain your new Dynamometer we strongly suggest that you take a few moments to familiarize yourself with the information presented in this section of the manual Doing so will greatly help you to understand the information that is presented in other sections of this manual 2 2 MAJOR SYSTEM COMPONENTS The Major components of a MD AWD 150 Series Dynamometer Sy...

Страница 12: ...reen cast iron pillow block housing for exceptional strength Bearings can float to minimize misalignment of shafts 3 Rolls The dyne is equipped with a Drive Roll set and an Idler Roll set All rolls are dynamically balanced for speeds up to 150 MPH The surfaces of the rolls are grooved to provide maximum traction and good tracking 4 Coupling High power couplings are used to accurately transmit spee...

Страница 13: ...elow See fig 2 2 Fig 2 2 Key Fig 2 2 1 Power Absorber Unit PAU Eddy current Power Absorbing Units P A U s provide infinitely variable loading without the use of water or hydraulics The PAU can operate while rotating in either direction Its rugged construction enables it to be operated under extremely demanding conditions The PAU is wired for 96 VDC operation 2 PAU Load Cell The strain gauge load c...

Страница 14: ...the dyne s driveline It is prevented from freely rotating by the installation of the load cell The load is measured by the load cell and is transmitted to the control system via an electrical signal The PAU absorbs this load by energizing stationary electric field coils with a direct current These coils establish magnetic fields through which the iron rotors of the PAU are rotated This rotation ge...

Страница 15: ...lert you to situations that are potentially dangerous to you or damaging to your machine Please pay attention to these advisories and follow the directions given in them The safety messages presented below are categorized as follows General Safety Issues Operational Safety Issues Maintenance Safety Issues The GENERAL SAFETY ISSUES apply whenever you are working with the dyne for any reason The OPE...

Страница 16: ...or performing maintenance on your dyne Always observe typical common sense test area precautions BEWARE OF PROJECTILES Tires that are rotating at high rates of speed can throw off stones and other projectiles Wear approved safety glasses when in the vicinity of the vehicle being tested PROTECT YOUR EARS Dynamometer noise can damage your hearing Always wear approved ear protection when working near...

Страница 17: ...r proper inflation Inspect the tires for any signs of damage and remove any large embedded objects from the tread RESTRAIN VEHICLE MOVEMENT During dynamometer operation it is common for the test vehicle to move laterally on the rolls Also unrestrained vehicles can launch off the dyne causing death or serious injury To prevent personal injury and or damage to the test vehicle it is imperative that ...

Страница 18: ...erating the dyne with any of its cover panels removed from the chassis assembly AVOID STRAINING YOURSELF Be careful when lifting dyne cover panels they are very heavy Be very careful when replacing belts couplings or bearings the rolls are very heavy and can be difficult to handle AIR PRESSURE Make sure that there is no air pressure in the lines whenever you are working on the roll locks frame loc...

Страница 19: ... 8 masonry bit and a 4 foot bubble level You will also need a forklift with a capacity of at least 12 000 lbs a minimum of 2 18 chains with hooks and a come along or hoist Shim stock for leveling the dyne also may be required 4 4 SHOP LAYOUT AND REQUIREMENTS This section includes minimum requirements necessary to install the dynamometer and ensure safe operation After determining which method of i...

Страница 20: ...eds be installed in the main supply line 4 4 4 Ventilation Your shop should be equipped with an effective ventilation system to direct tailpipe emissions to the outside air Exhaust vents should be able to connect to all types of vehicles front wheel drive rear wheel drive dual exhaust etc 4 4 5 Floor Anchors It is common for vehicles to move laterally on the rolls during dynamometer operation To p...

Страница 21: ... the above ground method of installing is less expensive the shop requires little renovation the dyne can be moved however the dyne takes up a large portion of floor space in your shop 4 5 1 Above Ground Installation Procedure In this section we ll go thru step by step of the above ground installation The first few steps apply to both types of installation Remove the dyne s cover plates do this by...

Страница 22: ...s shown in Fig 4 2a and Fig 4 2b Lift the dynamometer evenly and then place it in the location of the shop where you wish it to remain Keep in mind clearance requirements as discussed in 4 4 6 and the fact that there is only 30 feet of cabling shipped with the dynamometer ...

Страница 23: ...afely lift the dynamometer All pictures are shown with optional clutch and optional extra roll set and the second PAU Your dynamometers configuration may differ however the lifting points will remain the same Before placing the dynamometer in your shop it might be helpful for a reference to snap a chalk line on the floor Using Fig 4 1 as a reference ramps facing shop door and the AWD or larger sec...

Страница 24: ...the dynamometer frame near the anchor locations Using a hammer drill drill holes and clear all debris from the holes With the nut of the Thunderstuds flush with the top of the stud tap the Thunderstuds into the holes until the nut and washer is flush with the dynamometer s anchor feet Expand the anchors by tightening the nut Connect all electrical and air connections Next step is to connect the be...

Страница 25: ...aring adjustment blocks this will insure proper alignment and belt tension if you only loosen the two indicated with the red arrows Fig 4 7 Remove the sprocket shaft and place the belt around it Then replace the sprocket shaft keeping the shims in the same position Replace bearing hardware and tighten finger tight Tighten the bearing block adjustment bolts so that the bearing slides over and makes...

Страница 26: ...wing the steps in the preventive maintenance section of this manual 6 6 Re install the dynamometer s plates Torque the button head bolts to 35 ft lbs You will still need access to the PAU for calibration these steps will be explained in the Power Dyne software manual located on the software disc sent with your machine ...

Страница 27: ... CAREFUL These plates are very heavy and awkward to balance Remove the PAU cover Remove the lag bolts that hold the 4 X 4 wood pieces to the feet of the dyne Then after the above is completed you need to Check dynamometer pit and verify dimensions Also make sure the conduits are in the proper locations Clear the pit of all debris There should be 3 conduits on the bottom of your pit floor one for t...

Страница 28: ...and will not be crushed Before placing the dynamometer in your shop place the larger section in first Then place the spacers round tubes on the floor with one end tight up against the AWD section for a guide then place the smaller half in place leaving about an inch gap from the spacers Then with a come along pull the dyne halves together while holding the spacers in place Use the same procedures ...

Страница 29: ...Mustang Dynamometer MD AWD 150 Page 29 INSTALLATION ILLUSTRATIONS 4 7 CONTROL INSTALLATION ...

Страница 30: ...e bolts from the upper and lower load cell brackets Attach the load cell on the lower bracket first Upon completion attach the load cell to the upper bracket Tighten both bolts to 50 ft lbs Torque the eyelet bolt jam nuts to 200 in lbs DO NOT OVER TIGHTEN NOTE Position the load cell so the wire is on the side opposite the Power Absorbing Unit 2 Route cabling and air line Leave enough slack in the ...

Страница 31: ...nd refer to figure below 8 Install main air supply line to the tubing near the conduit run to the dyne This air supply must have an in line air dryer and must be regulated between 80 120 psi 9 On the bottom of the PowerDyne control box there is the lift solenoid The Red screw indicated by the arrow in picture to the right can be pushed in and turned 90o to raise the lifts in case of a power failur...

Страница 32: ...ed in the Appendix This procedure is very critical as some components my have loosened during shipping 4 Verify all cable and airline connections are properly fastened secure and tightened 5 Rotate dynamometer rolls by hand or foot a car should not be on at this time and verify they spin freely The rolls will be somewhat difficult to spin due to the large mass that rotates 6 Check to see that ther...

Страница 33: ...ND PERSONNEL ARE CLEAR OF THE DYNAMOMETER 4 Activate the roll lock by clicking on LIFT then up at the top of the PowerDyne screen The rolls should be locked 5 Select a Rear Wheel Drive vehicle for this initial start up procedure Check the vehicles oil level radiator coolant level and automatic transmission fluid level if applicable 6 Ensure the vehicle tires are at their proper road pressure 7 Be ...

Страница 34: ...L WARNING THE COMPUTER SHOULD STILL BE IN THE MAIN MENU SCREEN 17 Be sure all personnel and equipment are clear of the rotating dynamometer and that no personnel stand in front or directly behind the test vehicle 18 Unlock rolls by clicking lift then down on the top of the PowerDyne display 19 Start the engine and apply brake and or clutch place the vehicle in drive gear or low gear 20 Slowly rele...

Страница 35: ... be now locked 29 Release and remove all straps and move the wheel chocks from the vehicle 30 Be sure the exhaust ventilation system is clear Remove the vehicle from dynamometer 31 Verify and check the torque of all the bolts and set screws to the specifications located in the Appendix 32 If You Have Any Questions Please do not hesitate to call our corporate headquarters at 330 963 5400 or toll fr...

Страница 36: ...tion of expansion and non expansion types of ball and high capacity double row spherical roller bearings A Expansion Non Expansion Bearings During the operation of your dynamometer temperature changes may cause a linear expansion or contraction of the various components in the system In a two pillow block arrangement for example on a given roll at least one non expansion type of bearing is used as...

Страница 37: ...duty application relubricate monthly with Shell Alvania 2 grease or standard Lithium base grease 2 until excess grease is visible at the bearing seals Wipe off excess grease 6 2 2 Gear Toothed Couplings Gear toothed couplings are used in the drive line of your dynamometer between major sub assemblies ex Rolls PAUs for the purposes of transmitting torque and enabling the sub assemblies to be easily...

Страница 38: ...ng in premature mesh failure unless periodic lubrication cycles are maintained 6 2 3 Pneumatic Clutch Couplings The pneumatic clutch will disengage the long roll so that the dynamometer can test motorcycles If your dynamometer is equipped with this feature you will need to grease the cam follower bearings once a week Using a hand held grease gun pump grease into the zerk as shown below marked with...

Страница 39: ...ocated 180º away from each other and 90º away from the pole shoe being checked Measure the gap with a feeler gauge 2 Measure the air gap between the same rotor and the same pole shoe but with the rotor moved towards the pole shoe by two pry bars ex screw drivers inserted in the air gap on the other side of the power absorber Do not rotate the rotor when making the above two checks Place a chalk ma...

Страница 40: ...Mustang Dynamometer MD AWD 150 Page 40 ...

Страница 41: ...K BEARINGS X 1 SET SCREW TORQUE COUPLINGS X 2 SET SCREW TORQUE SPROCKETS X 2 SET SCREW TORQUE PILLOW BLOCK BEARINGS X 2 CLEANING CORROSION PREVENTION UN PAINTED METAL PARTS X NOTES 1 AFTER FIRST 8 HOURS OF OPERATION AND THEN MONTHLY THEREAFTER 2 AFTER FIRST 8 HOURS OF OPERATION THEN AFTER THE FIRST WEEK THEN MONTHLY THEREAFTER THIS PREVENTATIVE MAINTENANCE TIME TABLE IS BASED UPON AN AVERAGE OF 40...

Страница 42: ... you have exhausted all possibilities please feel free to contact a Mustang Service Engineer 7 2 TROUBLESHOOTING GUIDE Troubleshooting Guide Roll Set Problem Possible Cause Correction Vibration and or noise Structural frame of dyne is not secured to the floor Check anchor bolts on dyne frame and tighten to proper specifications Dyne is not level to the floor Level dyne and be sure shims are in pla...

Страница 43: ... replace defective components Roll speed other then zero is being displayed Troubleshoot speed sensor and wiring Low air pressure Adjust dry regulated air pressure furnished to dyne to a maximum of 120 psi Defective or improperly wired air pressure switch Verify correct wiring and test opening and closing of pressure switch contacts Defective cable or connector Inspect all electrical wiring and re...

Страница 44: ...ble connectors are properly seated Verify that all connections inside the junction box are secure Bad load cell connection Check and if necessary repair all load cell connections No Speed Readout Bad electrical connection Check all electrical connections in the system Incorrect magnetic pickup to gear air gap Verify that the air gap is set to 0 020 Magnetic pickup failure Replace magnetic pickup ...

Страница 45: ... lbs 11 3 Nm 1 4 28 110 in lbs 12 4 Nm 7 16 5 16 18 200 in lbs 22 6 Nm 5 16 24 215 in lbs 24 3 Nm 1 2 3 8 16 30 ft lbs 40 7 Nm 3 8 24 30 ft lbs 40 7 Nm 9 16 7 16 14 45 ft lbs 61 Nm 7 16 20 50 ft lbs 67 8 Nm 5 8 1 2 13 70 ft lbs 94 9 Nm 1 2 20 75 ft lbs 101 6 Nm 3 4 9 16 12 100 ft lbs 135 5 Nm 9 16 18 110 ft lbs 149 1 Nm 13 16 5 8 11 135 ft lbs 182 9 Nm 5 8 18 150 ft lbs 203 3 Nm 15 16 3 4 10 240 f...

Страница 46: ... lbs 352 3 Nm M16 2 90 ft lbs 122 Nm 7 8 14 350 ft lbs 474 3 Nm M20 2 5 175 ft lbs 237 1 Nm 1 14 335 ft lbs 453 9 Nm M22 2 5 235 ft lbs 318 4 Nm TORQUE SPECIFICATIONS BEARING SET SCREWS ANSI B 18 3 1986 BS 4168 1981 SET SCREW SIZE TORQUE HEX KEY SIZE 10 32 30 in lbs 3 4 Nm 3 32 1 4 28 75 in lbs 8 5 Nm 1 8 5 16 24 140 in lbs 15 8 Nm 5 32 3 8 24 250 in lbs 28 2 Nm 3 16 1 2 20 50 ft lbs 67 8 Nm 1 4 5...

Страница 47: ...40 Nm K 70 CHI 470 ft lbs 640 Nm Flange to Rotor Bolts K 40 to K 160 150 ft lbs 205 Nm K 200 to K 480 200 ft lbs 275 Nm Flange Bolts Size 1410 Flange 85 ft lbs 120 Nm Size 1600 Flange 50 ft lbs 70 Nm Pole Plate Bolts K 40 to K 160 50 ft lbs 270 Nm K 200 to K 480 85 ft lbs 120 Nm Seal Plate Bolts 85 in lbs 9 Nm Terminal Block Nuts M5 20 in lbs 1 95 Nm M6 30 in lbs 3 43 Nm ...

Страница 48: ...nst rust and corrosion smooth and tacky green in color OIL 20010653 Mobil SHC 634 Used in all gear boxes CORROSION PREVENTION 20014736 Sprayon 710 PDRP Used on all bright metal parts A heavy duty water displacing film that provides great protection in salt water and high humidity atmosphere does not contain silicon will penetrate and lubricate non accessible areas Easily removed with petroleum sol...

Страница 49: ...Mustang Dynamometer MD AWD 150 Page 49 APPENDIX C ANCHOR POD INSTALLATION NEW FLOORS fl ...

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