Obd Dyne Manual

MAINTENANCE AND SERVICE MANUAL MODEL MD-OBD-DYNE SERIES

Revision

Release Date

Initial

A B C D E F G H

09 July 98 KS 15 July 98 KS 21 September 98 KS KS 30 November 98 KS 1 April 99 JH 11 June 1999 JH 25 October, 1999 D DF F 14 March , 2002 DF

M U S T A N G D Y N A M OM ET ER YNE M AINTENANCE AINTENANCE AND S ERVICE ERVICE - 1 -MODEL OBD D YNE

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Information in this document is subject to change without notice. No part of this document may be reproduced or transmitted in any form or by any means, electrical or mechanical, for any purpose, without the express written permission of Mustang Dynamometer. Copyright © 1999 Ganzcorp Investments, Investments, Inc. dba Mustang Dynamometer All rights reserved

M us t an g D yn am om et er 2300 Pinnacle Parkway Twinsburg, Twinsburg, Ohio 44087 USA Telephone: (330) 963-5400 * Fax: (330) 425-3310

ODEL MD-OBD-D YNE YNE M AINTENANCE AINTENANCE AND S ERVICE ERVICE M ODEL

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M US TA N G D Y N A M OM ET ER

NOTICE This manual has been designed and written to provide useful information about Mustang Dynamometer equipment and systems. Every effort has been been ma made de to ma make ke this this ma manu nual al as comp comple lete te as poss possib ible le,, but 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 Dynamometer shall have either liability or responsibility to any person or entity with respect to any loss or damages arising from the information contained in this manual.

AVIS Ce manuel manuel a été conçu et écrit écrit pou pourr fou fourni rnirr de l’info l’informa rmatio tion n utile utile sur l’éq l’équi uipe pemen mentt et les les syst systèm èmes es Mu Must stan ang g Dyna Dynamom momet eter er.. Tout Toutes es les les précau précautio tions ns ont été prises prises pou pourr rendre rendre ce manuel manuel aussi aussi comple complett que possible, mais aucune garantie d’adaptation ni autre n’est implicite. L’information contenue dans ce manuel est fournie « telle quelle ». Ni l’auteur de ce manuel ni la direction ni les propriétaires de Mustang Dynamometer ne seront responsables envers quiconque ni envers quelque entité que ce soit des pertes ou dommages résultants de l’information contenue dans ce manuel.


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WARRANTY LIM LI M I T OF OF LI LI ABI LITY LI TY Mustang warrants that the product(s) that is the subject of this sale is free from defects in material. material. The duration duration of this warranty is one year from date of shipment on all Mustang-relat Mustang-related ed components. Components not manufactured by Mustang will carry the original manufacturer’s warranty, typically 90 days for all electronic-related components. All warranty claims must be processed through Mustang. If a problem problem arises within the applicable warranty warranty period, it is the responsibilit responsibilityy of the purchaser to (a) promptly promptly notify Mustang Mustang in writing writing (b) obtain obtain a RMA Number from Mustang (c) return to Mustang the component(s) that are claimed to be defective (transportation charges must be prepaid by the purchaser). RMA Number must be clearly marked on outside of package(s). With Within in a reaso reasona nabl blee time time after after such such notif notific icat atio ion, n, Musta Mustang ng will will corre correct ct any any defe defect ct(s) (s) in component(s). If Mustang is unable to repair the component after a reasonable number of attempts, attempts, or if Mustang determines at any time the repair is impracticabl impracticable, e, Mustang will provide a repl replac acem emen entt with with like like or simi simila larr comp compon onen ent( t(s) s).. The The purc purcha hase serr is resp respon onsi sibl blee for for all all transportation expenses to and from Mustang and all labor expenses associated with removal and replacement replacement of the component(s) component(s) as well as labor involved involved to repair component(s). component(s). Mustang will bear the expense of parts only. These remedies are the Purchaser’s sole remedies for breach of warranty. The expiration expiration of the warranty period, period, use of the product for purposes other than those for which it is designed, other abuse or misuse, unauthorized attachments, modifications, or disassembly, or mishandling of the product during shipping, shall end all liability of Mustang. In no case shall Mustang be liable for any special, incidental, or consequential damages based upon breach of warranty, breach of contract, negligence, strict tort, or any other legal theory. Such damages include but are not limited to, loss of profits, loss of savings or revenue, loss of use of the product or any associated associated equipment, equipment, cost of capital, cost of any substitute substitute equipment, equipment, facilities or services, downtime, the claims of third parties including customers, and injury to property. Unless modified in writing and signed by officers of both parties, this agreement is understood to be the complete and exclusive agreement between the parties, superseding all prior agreements, oral or written written and all other communications communications between the parties relating to the subject subject matter of the agreement. GANZCORP INVESTMENTS INC. dba MUSTANG DYNAMOMETER


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DANGER Keep limbs, hair, jewelry and clothing away from the moving rolls. When operating a vehicle on the machine, remain inside vehicle until the rolls have stopped. Cover the rolls when the equipment is not in use. DANGER Garder les membres, les cheveux, les bijoux et les vêtem vêtemen ents ts éloig éloignés nés des des roul rouleau eauxx en mouv mouvem emen ent. t. Lors de l’utilisation d’un véhicule sur l’équipement, rester à l’intérieur du véhicule jusqu’à ce que les roul roulea eaux ux se soie soient nt arrê arrêté tés. s. Co Couv uvri rirr les les roul roulea eaux ux lorsque l’équipement ne sert pas. DANGER Do not operate or perform any maintenance on your equipment until you have carefully read this manual in its entirety making sure that you understand all of the material presented in each section. DANGER Ne pas utiliser ser l’équipement ent ni eff effectu ctuer son entretien avant d’avoir lu attentivement ce manuel en entier et d’avoir compris tout le matériel présenté dans chaque section.


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CAUTION Unsafe operating practices can lead to potentially dangerous situations when your machine is running.

Only properly trained and responsible personnel should attempt to operate this machine. ATTENTION Des pratiques d’utilisation non sûres peuvent conduire à des situations potentiellement dangereuses lors du fonctionnement de l’équipement.

Seul le personnel responsable et correctement instruit doit entreprendre d’utiliser cet équipement. CAUTION 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. ATTENTION Les instructions de dépose et de démontage données dans ce manuel ont été réduites au minimum pour en faciliter la lecture.

Seul du personnel d’entretien expérimenté doit entreprendre d’installer ou de faire des réparations sur cet équipement. SECTION M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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INTRODUCTION C ONTENTS

1.1 DESCRIPTION ...................................................................................................1-3 1.2 GENERAL SAFETY ISSUES..................................................................................1-4 1.3 OPERATIONAL SAFETY ISSUES ...........................................................................1-4 1.4 MAINTENANCE SAFETY ISSUES ...........................................................................1-6 1.5 ENVIRONMENTAL DATA .....................................................................................1-7 1.6 INSTALLATION DATA .........................................................................................1-7 1.7 NAMEPLATE DATA ............................................................................................1-7 1.8 IF YOU NEED HELP ...........................................................................................1-7

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1.1 DESCRIPTION This manual contains maintenance and service information for Model MD-OBD Series Chassis Dynamometers. Table 1.1 lists part numbers and descriptions of the dynamometers. Most maintenance and service procedures are similar for all model dynamometers. Specific procedures for some model numbers are given.

Table 1.1

ESP/Mustang Dynamometer ASM-97 Series Dynamometers

MD Model Number

Description

MD-OBD

Low profile

Model MD-OBD Series Chassis Dynamometers are designed for Acceleration Simulation Mode (ASM) emissions testing and meet or exceed all State design and performance criteria. Major system components include the dynamometer, and the control system. Major dynamometer components include the frame, rolls, inertia weight, and Power Absorber Unit (PAU). Refer to Figure 3.1 for an illustration of the major components of the MD-OBD Series Dynamometers.


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1.2 GENERAL SAFETY ISSUES CONSIGNES GÉNÉRALES DE SÉCURITÉ Be Knowledgeable ... Do not attempt to operate, maintain or service your Mustang Chassis Dynamometer System until you have familiarized yourself with the equipment by reading the instructions in this manual. Être instruit ... Ne pas essayer d’utiliser, d’entretenir ni de réparer le système dynamométrique de châssis (banc d’essai) Mustang avant de s’être familiarisé avec l’équipement en lisant les instructions de ce manuel. Act Responsibly ... Exercise caution and discretion when operating or performing maintenance on the dynamometer. Always observe typical, common sense test area precautions. Agir demanière responsable ... Exercer prudence et bon jugement lors de l’utilisation ou de l’entretien de ce dynamomètre. Toujours observer les précautions de bon sens de zone d’essai. Beware of Projectiles ... Tires that are rotating can throw off stones and other projectiles. Wear approved safety glasses when in the vicinity of the vehicle being tested. Attention aux projectiles ... Les pneus en rotation peuvent projeter des pierres et autres projectiles. Porter des lunettes de sécurité approuvées à proximité du véhicule en cours d’essai. Protect Your Ears ... Always wear approved ear protection when working near the dynamometer. Protéger lesoreilles ... Toujours porter une protection approuvée pour les oreilles lors du travail près du dynamomètre. Beware of Being Grabbed ... Keep limbs, hair, jewelry, and clothing away from the moving dynamometer components. Attention denepasêtre happé ... Garder les membres, les cheveux, les bijoux et les vêtements éloignés des composants en mouvement du dynamomètre. Pay Attention ... Maintain acute awareness when the dynamometer rolls are in motion. Faire attention ... Faire très attention lorsque les rouleaux du dynamomètre sont en rotation.

1.3 OPERATIONAL SAFETY ISSUES CONSIGNES DE SÉCURITÉ DE FONCTIONNEMENT Your dynamometer comes standard with “Drop-In” style Restraints. One is for the left wheel and the other for the right wheel. The “Drop-In” style restraints are for ASM 50/15 and ASM 25/25 testing ONLY . The maximum speed for the “Drop-In” style restraints are 25 MPH. Prior to performing an ASM 50/15 or ASM 25/25 test, ensure the “Drop-IN” style restraints are properly positioned and rubber wheel chocks are placed in the appropriate places of the nondrive axle. For ALL other types of testing, use chains, straps, Ratchet binders or strap ratchet binders of suitable size with floor anchors and wheel chocks to safely perform testing. Be careful not overtension the chains or straps. All of these safety devices should be used when testing a vehicle. The above items are not supplied by Mustang Dynamometer. We recommend a minimum of 3/8” diameter chain with 3/8” Ratchet binders. For front wheel drive vehicles, two chains and binders should be used to restrain the front axle and a minimum of one chain/binder for the rear axle. For rear wheel drive vehicles, 2 chains/binders should be used to secure the rear axle. Wheel chocks should be used on the non-drive axle for all testing types.


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OPERATIONAL SAFETY ISSUES (CONTINUED) Vent Engine Exhaust ... Provide adequate room ventilation. High concentrations of engine exhaust can be deadly. Do not operate your dynamometer without proper ventilation. The ventilation system should provide four (4) air changes an hour in the shop and six (6) air changes an hour for the pit. Dégazer leséchappementsdu moteur ... Fournir une aération adéquate de la pièce. Une concentration élevée de gaz d’échappement du moteur peut être mortelle. Ne pas faire fonctionner le dynamomètre sans ventilation appropriée. Le système de ventilation doit fournir quatre (4) renouvellements d’air par heure dans l’atelier et six (6) renouvellements d’air par heure pour la fosse. M onitor Carbon M onoxide ... Make sure you have installed a carbon monoxide monitor in the dynamometer bay. Contrôler le niveau d’oxyde decarbone ... S’assurer d’avoir installé un contrôleur d’oxyde de carbone dans la baie du dynamomètre. Guarding ... Provide floor markings and protective guard railings for customer/operator protection. NEVER operate the dynamometer with any cover panels removed unless specifically directed to do so elsewhere in this manual. Barrièresde protections ... Prévoir un marquage au sol et des rails de protection des clients et des opérateurs. NE JAMAIS faire fonctionner le dynamomètre avec des panneaux de protection déposés sauf instructions contraires spécifiques ailleurs dans ce manuel. Keep Clear of Rolls ... Stay away from the rolls when in operation. Rester éloignédesrouleaux ... Rester éloigné des rouleaux pendant le fonctionnement. Check Tires ... Before driving the test vehicle onto the dynamometer, be sure to check the vehicle’s tires for proper inflation. Inspect the tires for any signs of damage and remove any embedded objects from the tread. Contrôler lespneus ... Avant de conduire le véhicule d’essai sur le dynamomètre, s’assurer que les pneus du véhicule soient bien gonflés. Inspecter les pneus en recherchant les signes de dommages et retirer tout objet incrusté dans la bande de roulement. Restrain Vehicle M ovement ... During dynamometer operation, make sure that the restraints are in position. Empêcher le mouvement du véhicule ... Pendant le fonctionnement du dynamomètre, s’assurer que les dispositifs de blocage soient en place. Proper Clearance ... Always ensure that there is a clearance of at least four (4) feet to the front, rear, and sides of the dynamometer. Assurer un bon dégagement ... Toujours s’assurer qu’il y ait un dégagement d’au moins 1,20 mètres à l’avant, à l’arrière et sur les côtés du dynamomètre. Stay Seated ... The vehicle operator MUST remain in the driver’s seat at all times during a drive-cycle test. Do NOT attempt to get in or out of the vehicle when the dynamometer rolls are moving. Rester assis ... Le conducteur du véhicule DOIT rester en permanence assis sur le siège du conducteur pendant un essai de cycle de conduite. NE PAS essayer de rentrer ni de sortir du véhicule lorsque les rouleaux du dynamomètre sont en fonctionnement.


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I f in Doubt, STOP! ... Stop the equipment immediately if you have any doubt about the safe operating condition of the dynamometer and/or the correctness of any procedures that you are performing. En casdedoute ARRÊTER! ... Arrêter l’équipement immédiatement en cas de doute sur la sûreté des conditions de fonctionnement du dynamomètre ou sur la validité des procédures effectuées.

1.4 MAINTENANCE SAFETY ISSUES CONSIGNES DE SÉCURITÉ D’ENTRETIEN Electrical Shock Hazard ... 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 or motor. Risqued’électrocution ... Couper l’alimentation électrique du système avant d’effectuer tout travail d’entretien. Couper le disjoncteur principal du boîtier de disjoncteurs avant de travailler sur tout élément relatif au PAU ou au moteur. No Jewelry ... Remove any jewelry before performing any electrical or mechanical troubleshooting, repair, etc. on the dynamometer. Pasdebijou ... Retirer les bijoux avant d’effectuer tout dépannage électrique ou mécanique, toute réparation, etc. sur le dynamomètre. Cover Panels ... Use extreme caution around drive mechanisms and moving parts when operating the dynamometer with any of its cover panels removed from the chassis assembly. Panneaux deprotection ... Être très prudent à proximité des mécanismes d’entraînement et des pièces en mouvement lors de l’utilisation du dynamomètre avec un de ses panneaux de protection déposé du châssis. Avoid Straining Yourself ... Be careful when lifting dynamometer cover panels. Be careful when replacing belts, couplings, or bearings. Éviter lesélongations ... Être prudent lors du levage des panneaux de protection du dynamomètre. Être prudent lors du remplacement des courroies, des accouplements, ou des paliers. Air Pressure ... Make sure that there is no shop air to the dynamometer when working on lift plates or air bags. Pression d’air ... S’assurer qu’il n’y ait pas d’alimentation en air sous pression de l’atelier sur le dynamomètre lors du travail sur les plaques de levage ou les sacs gonflables. Watch Your Hands ... Never put your hand between the lift plate and roll when shop air supply is connected to the dynamometer. Attention aux mains ... Ne jamais mettre les mains entre les plaques de levage et les rouleaux lorsque l’air sous pression de l’atelier est connecté au dynamomètre. NEVER, NEVER, NEVER! ... Never pull on the drive belt in order to spin the rolls. JAMAI S, JAMAI S, JAMAI S! ... Ne jamais tirer sur la courroie d’entraînement pour faire tourner les rouleaux. Check Tightness ... Make sure that all bolts on the dynamometer are tight and all couplings are properly secured. Vérifier le serr age ... S’assurer que tous les boulons du dynamomètres soient serrés et que tous les accouplements soient correctement bloqués. M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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1.5 ENVIRONMENTAL DATA This equipment is rated for the following environmental conditions: Indoor use only. Temperature:

-10o to 49oC

Maximum Relative Humidity:

95% Noncondensing

Altitude:Up to 2000 meters Pollution Degree 1 in accordance with IEC 664

1.6 INSTALLATION DATA The equipment requires the following electrical service: 230 Vac, 30 Amps, Single Phase, 60 Hertz ESP provides external circuit breaker rated for 230 Vac, 30 Amp service. It is recommended that the circuit breaker be located in close proximity to the dynamometer, at minimum, within the same room. Installation and mounting hardware are provided with every Dynamometer and shall be used regardless of a Pit or Floor mount installation. Hardware provided is as follows: (4) 5/8 X 4.5” Thunderstuds (MD# 20013614), (1) 5/8 X 7” Thunderstud (MD# 20008116) and (4) Dog Ears (MD# 20001704). Anchor stud hole locations can be found on attached drawing, MD# 20014882. Tools Required: 1 - Hammer Drill with 5/8” concrete or Masonry bit. 1 - Hammer. 1 - 3/4” Open end wrench. Various sizes flat Steel shim stock. 1 - 4’ level. Using hammer drill mark and drill holes in concrete a minimum of 4.5” deep for 4.5 thunderstud and 7” deep for 7” thunderstud per MD DWG # 20014882. Ensure holes are clean of any debris prior to attempting installation of Thunderstud. Place Dynamometer into pit or onto floor at installation site. Check level of dynamometer, use flat steel shim stock (customer supplied) as necessary to level dynamometer to floor. Level dynamometer in two planes; (1) Place level on top of rolls parallel with a roll and (2) place level across a front roll and rear roll. Shim unit by positioning shim near all the anchor locations as well as every 12” under the main frame rails. Additionally, position shim stock, as necessary, under the air bag channel near the PAU end of dynamometer. The air bag channel must be supported at this location. Using provided anchor foot, MD # 20001704, drawing attached, insert thunderstud with flat washer and nut attached into anchor foot and hole previously drilled into concrete. Using hammer, pound thunderstud into hole until nut is flush with anchor foot. Ensure anchor foot is also in contact with dynamometer frame. Using ¾” wrench, tighten nut to 50 ft lbs. When pounding 7” thunderstud, ensure frame bearing support tube is not damaged. Take care not to over tighten the nuts, as this may cause damage to the frame of the dynamometer, the thunderstud, or the concrete.

1.7 NAMEPLATE DATA The nameplate on the dynamometer frame contains valuable information should it be necessary to contact Mustang. Besides the model number, date manufactured, and revision level data, the nameplate contains the dynamometer serial number. Have this number handy when contacting Mustang Dynamometer.

1.8 IF YOU NEED HELP M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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Much effort has been extended to make this manual complete and accurate. However, if there are any questions please contact a Mustang Dynamometer representative at:

Mustang Dynamometer 2300 Pinnacle Parkway Twinsburg, Ohio 44087USA Telephone:(330) 963-5400 Fax: (330) 425-3310


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SECTION

PREVENTIVE MAINTENANCE C ONTENTS

2.1 INTRODUCTION .................................................................................................2-3 2.2 PREVENTIVE MAINTENANCE ...............................................................................2-4 2.3 LUBRICATION ...................................................................................................2-5 2.4 INSPECTION......................................................................................................2-6


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2.1 INTRODUCTION This section contains information and procedures for preventive maintenance of the dynamometer. Refer to Table 2.1 for a list of recommend tools and Table 2.2 for a list of consumable items necessary for maintenance of the dynamometer. A Preventive Maintenance Time Table, Table 2.3, provides recommended service intervals. Preventive maintenance procedures follow.

Table 2.1

LIST OF RECOMMENDED TOOLS

ITEM

USE ON

(2) 1-1/8-inch combination wrenches 15/16-inch socket 15/16-inch wrench

Brake Pad replacement

3/4-inch socket 3/4-inch wrench

1-1/2-inch Pillow Block Bearing Bolts Large Roll Pulley Bolts Load Cell Mounting Bolts Motor Mounting Bolts Air Bag Mounting Bolts (Two) Motor Pulley Bushing Bolts Small Roll Pulley Bolts Limit Switch Bracket Bolts Coupling set screws Speed sensor Small Pulley Bushing and Coupling Set Screws 1-1/2-inch Pillow Block Bearing Set Screws 1-3/4 and 2-inch Pillow Block Bearing Set Screws PAU Pulley Bolts (ESP30184-9 and -11) PAU Pulley Bolts (ESP30184-1, -6, -7 and -8) Air Bag Mounting Bolts (Four) Torque Measurements Torque Measurements Brake Pad replacement Speed Sensor Belt Tension Belt Tension Electrical signals and connections

1-3/4 and 2-inch Pillow Block Bearing Bolts PAU Bracket Bolts Idler Attachment Bolts

9/16-inch socket 9/16-inch wrench 7/16-inch socket 1/8-inch Allen wrench 9/64-inch Allen wrench 3/32-inch Allen wrench 5/32-inch Allen wrench 3/16-inch Allen wrench 1/4-inch Allen wrench 1/4-inch, 12-point, deep socket 7/32-inch Allen wrench Torque wrench, 0-250 inch-pounds. Torque wrench, 0-100 foot-pounds. Pipe wrench Feeler gauges Belt Tension Tester Straight Edge Digital Multi-Meter

Table 2.2 Item

LIST OF CONSUMABLE ITEMS Mustang Part Number

Designation

Coupling Grease

20010651

Mobil Mobilith AW 2

PAU Grease

20010651

Mobil Mobilith AW 2

Bearing Grease

20014314

Polyrex EM

Brake Cleaner

20014315

Brake cleaner

Thread Lock

20010654

Locktite 262

Teflon Tape

20014810

1/4-inch Teflon tape

2.2 PREVENTIVE MAINTENANCE M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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The activities listed in Table 2.3, Preventive Maintenance Time Table, should be performed at the time intervals indicated. Perform initial startup inspections after installation, after 8 hours of operation, and after the first forty hours of operation. After startup inspections are complete and the dynamometer is operating satisfactorily, perform the regular preventive maintenance inspections and lubrications as indicated.

Table 2.3

Preventive Maintenance Time Table

Maintenance Procedure

Initial Startup Inspections

Every Three Months

Every Six Months

Every Twelve Months

LUBRICATION Lubricate Pillow Block Bearings

•

Lubricate Couplings

•

Lubricate PAU

•

Lubricate Motor

•

INSPECTION Inspect Bearings

•

•

Inspect Couplings

•

•

Inspect Brake Pads

•

•

Check Motor to Roll Belt Tension

•

•

Check Roll to PAU Belt Tension

•

•

Check PAU Bracket Bolts

•

•

Inspect PAU Pulley Bolts

•

•

Inspect Roll Pulley Bolts

•

•

Inspect Motor Mounting Bolts

•

•

Inspect Motor Pulley Bolts

•

•

Inspect Idler Assembly

•

•

Inspect Restraint Assembly

•

•

Inspect Lift Assembly

•

•

Inspect Air Bags

•

•

Inspect Air Lines and Lift Solenoid

•

•

Inspect PAU Load Cell Assembly

•

•

Inspect Speed Sensors

•

•

Inspect Scale (ESP30184-1 AND –7)

•

•

Inspect and Clean Dynamometer

•

•

Inspect and Clean Pit

•

•

2.3 LUBRICATION CAUTION M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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M US TA N G D Y N A M OM ET ER Bearings and couplings must be lubricated with recommended lubricants. Lubricants must be fresh and free from contamination. Failure to lubricate or to use incorrect or contaminated lubricants will result in reduced life expectancy and/or damage to bearings and couplings. Too much grease can change parasitic losses of the dynamometer and will cause overheating of roll and PAU bearings in high-speed operation of the dynamometer.

ATTENTION Les paliers et les accouplements doivent être lubrifiés avec des lubrifiants recommandés. Les lubrifiants doivent être frais et non pollués. Ne pas lubrifier ou bien utiliser du lubrifiant incorrect ou pollué résulte en une durée de vie réduite ou en dégâts des paliers et des accouplements.

Trop de graisse peut modifier les pertes parasites du dynamomètre et causer une surchauffe des paliers de rouleau et de PAU lors du fonctionnement à haute vitesse du dynamomètre. Adequate lubrication is essential for satisfactory operation of the dynamometer. Lubrication of the dynamometer pillow block bearings, couplings, and PAU should be done as a part of a planned maintenance schedule. The recommended lubrication intervals in the Preventive Maintenance Time Table should be used as a guide to establish this schedule. These intervals are based on 24 hours of actual machine usage per week. For extreme or unusual operating conditions, lubricate more often. Even if the dynamometer is used less than 24 hours per week, the lubrication schedule should be followed in order to purge the system of potential contaminants.

2.3.1 LUBRICATE PILLOW BLOCK BEARINGS Remove the plug or temperature probe and replace it with a zerk fitting. Using a hand pump grease gun filled with (Exxon) Andok C grease, insert the gun into the fitting and add three grams of grease while rotating the dynamometer rolls by hand. Experiment with your particular grease gun to determine how many pumps equate to three grams of grease. It should be roughly equivalent to three pumps using a normal grease gun. Remove the zerk fitting and carefully replace the plug or temperature probe. Repeat for each of the 10 pillow block bearings on the dynamometer. When finished with greasing all the pillow block bearings, run the dynamometer with a vehicle properly restrained at approximately 20 mph for 15 minutes to evenly distribute the grease. Run warm-up, parasitic, and coastdown tests.


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2.3.2 LUBRICATE COUPLINGS Remove the two (2) grease plugs from the coupling sleeves and insert grease fitting into one of the holes. Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the grease fitting and pump the handle until grease comes out of the other hole. Replace both grease plugs. Tighten all plugs until they are snug and are approximately 1/16-inch above the surface - DO NOT OVER-TIGHTEN THE PLUGS. The plugs should not be flush with the coupling sleeves. If the plug falls below the surface of the coupling sleeve, remove it, wrap the threads with Teflon tape, and reinstall. Remove excess grease.

2.3.3 LUBRICATE PAU The zerk fitting is located on the bottom of the stator frame. Wipe off any dirt or other contaminates that may be on the grease fitting. Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the fitting and add twenty (20) grams of grease while rotating the PAU by hand. Experiment with your particular grease gun to determine how many pumps equate to twenty grams of grease. It should be roughly equivalent to twenty pumps using a normal grease gun.

2.3.4 LUBRICATE MOTOR Wipe off any dirt or other contaminates that may be on the grease fitting. Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the fitting and add eight grams of grease while rotating the motor by hand. Experiment with your particular grease gun to determine how many pumps equate to eight grams of grease. It should be roughly equivalent to eight pumps using a normal grease gun.

2.4 INSPECTION Table 2.4

Torque Chart

Description

Bolt Size

Socket/Key Size

Qt y.

Torque

1-1/2-inch Pillow Block Bearing Set Screws 1-3/4-inch and 2-inch Pillow Block Bearing Set Screws Coupling Set Screws Coupling Set Screws (Models ESP30184-12 and –13) 1-1/2-inch Pillow Block Bearing Bolts 1-3/4-inch Pillow Block Bearing Bolts 2-inch Pillow Block Bearing Bolts PAU Bracket Bolts PAU Pulley Bolts (Models ESP30184-9 and –11)

5/1624 3/8-24

5/32 Allen

14

140 inch-pounds.

3/16 Allen

6

250 inch-pounds.

1/4-28 10-32

1/8 Allen 3/32 Allen

8 4

75 inch-pounds. 30 inch pounds

1/2-13

3/4

14

50 foot-pounds.

5/8-11

15/16

2

70 foot-pounds.

5/8-11 5/8-11 5/1618

15/16 15/16 1/4 Allen

4 4 3

70 foot-pounds. 70 foot-pounds. 220 inch-pounds. Refer to procedure for torque method.


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Table 2.4

Torque Chart

Description

Bolt Size

Socket/Key Size

Qt y.

Torque

PAU Pulley Bolts (Models ESP30184-1, -6, -7, and –8)

1/4-20

1/4 12 Point

3

PAU Pulley Set Screws (Models ESP30184-12, –13, -18, and ESP30556-1) Motor Mounting Bolts Motor Pulley Bolts Large Roll Pulley Bolts Small Roll Pulley Bolts Small Pulley Bushing set screw Idler Attachment Bolts Restraint Limit Switch Bracket Bolts Air Bag Mounting Bolts (center) Air Bag Mounting Bolts (outboard) Load Cell Bolts

3/8-24

3/16 Allen

2

220 inch-pounds. Refer to procedure for torque method. 250 inch-pounds

3/8-16 1/4-20 1/2-13 1/4-20 #10-24 5/8-11 1/4-20

9/16 7/16 3/4 7/16 3/32 Allen 15/16 7/16

8 2 3 3 1 2 2

30 foot-pounds. 9 foot-pounds. 60 foot-pounds. 9 foot-pounds. 60 inch-pounds. 70 foot pounds. 9 foot-pounds.

3/8-16 3/8-16

9/16 7/32 Allen

2 4

30 foot-pounds. 15 foot-pounds.

1/2-13

3/4

4

50 foot-pounds.

2.4.1 INSPECT PILLOW BLOCK BEARINGS NOTE Three different size pillow block bearings are used. 1-1/2-inch bearings are used six places on the rolls and one is used on the PAU. One 1-3/4-inch bearing is used on the other end of the PAU, and two 2-inch bearings are used on the drive end of the rolls.

REMARQUE Trois différentes dimensions de palier à chapeau sont utilisées. Les paliers de 1-1/2 pouces sont utilisés en six emplacements sur les rouleaux et en un sur le PAU. Un palier de 1-3/4 pouce est utilisé sur l’autre extrémité du PAU et deux paliers de 2 pouces sont utilisés sur l’extrémité d’entraînement des rouleaux. Using a torque wrench with a 3/4-inch socket, check that the 1-1/2-inch roll bearing mounting bolts are torqued to 50 foot-pounds. If bolts are loose, remove bearing mounting bolts and bearing plate, clean threads with brake cleaner, apply a few drops of Locktite 262, reassemble plate and bolts and torque to 50 footpounds. Using a 5/32-inch Allen wrench, check to make sure all bearing set screws are tight. If set screws are loose, remove, clean with brake cleaner, apply a drop of Locktite 262, insert set screws, and torque to 140 inch-pounds. Using a torque wrench with a 15/16-inch socket, check that the 1-3/4-inch and 2-inch pillow block bearing mounting bolts are torqued to 70 foot-pounds.


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INSPECT PILLOW BLOCK BEARINGS (CONTINUED) If bolts are loose, remove bearing mounting bolts and bearing plate, clean threads with brake cleaner, apply a few drops of Locktite 262, reassemble plate and bolts and torque to 70 footpounds. Using a 3/16-inch Allen wrench, check to make sure all bearing set screws are tight. If set screws are loose, remove, clean with brake cleaner, apply a drop of Locktite 262, insert set screws, and torque to 250 inch-pounds. Using a 7/16-inch open end wrench, make sure the temperature probes are securely screwed into the bearing housings. Check the temperature probe wires to make sure they are secure and do not rub against any moving parts.

2.4.2 INSPECT CONDITION OF COUPLINGS For models ESP30184-1, -6, -7, -8 -9 and –11, using a 1/8-inch Allen wrench, check to make sure both set screws in each coupling assembly are tight (four coupling assemblies). If set screws are loose, clean with brake cleaner, apply a drop of Locktite 262, insert set screws, and torque to 75 inch-pounds. For models ESP30184-12 and –13, using a 1/8-inch Allen wrench, check to make sure the set screw in each rigid hub is tight. Using a 1/8-inch or 3/32-inch Allen wrench (one or the other will be present), check to make sure the set screw in each flex hub is tight (four coupling assemblies). If set screws are loose, clean with brake cleaner, apply a drop of Locktite 262, insert set screws, and torque to 75 inch-pounds for the 1/8-inch Allen wrench or 30 inch-pounds for the 3/32-inch Allen wrench.

2.4.3 INSPECT BRAKE PADS WARNING Make sure that the air lift will not be accidentally raised while performing this inspection. Failure to turn off shop air after lowering the lift plate may allow the lift plate to raise and cause injury.

AVERTISSEMENT S’assurer que le levage pneumatique ne soit pas levé accidentellement pendant cette inspection. Ne pas couper l’alimentation pneumatique de l’atelier après avoir abaissé la plaque de levage peut laisser la plaque de levage monter et causer des blessures. Lower the lift plate and disconnect the shop air supply to the dynamometer. Visually inspect the brake pads for wear. If the average brake pad thickness is less than 1/8 inch or if any spot is less than 1/16 inch, replace the brake pad. Refer to the service section of this manual for replacement instructions.

2.4.4 CHECK MOTOR-TO-ROLL BELT TENSION M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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M US TA N G D Y N A M OM ET ER Visually inspect the toothed drive belt to ensure that there are no signs of wear, damage, or deterioration. The belt should have a snug fit, neither too taut nor too loose. Observe the belt during the dynamometer calibration sequence. The belt should not slip. If the belt slips, is too loose or too taut, or needs replacement, refer to the service section of this manual for procedures to service the belt.

2.4.5 CHECK ROLL-TO-PAU BELT TENSION Visually inspect the drive belt to ensure that there are no signs of wear, damage, or deterioration. The belt should have a snug fit, neither too taut nor too loose. If the belt slips, is too loose or too taut, or needs replacement, refer to the service section of this manual for procedures to service the belt.

2.4.6 INSPECT PAU BRACKET BOLTS Using a torque wrench with a 15/16-inch socket, check that four (4) PAU bracket bolts are torqued to 70 foot-pounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 70 foot-pounds.

2.4.7 INSPECT PAU PULLEY BOLTS (MODEL ESP30184-9 AND -11) Using a torque wrench with a 1/4-inch Allen wrench, check that three (3) PAU pulley bolts are torqued to 220 inch-pounds. If bolts are loose, refer to the service section of this manual for a procedure to torque the bolts.

2.4.8 INSPECT PAU PULLEY BOLTS (MODEL ESP30184-1, -6, -7, AND -8) Using a torque wrench with a 1/4-inch, 12-point socket, check that three (3) PAU pulley bolts are torqued to 220 inch-pounds. If bolts are loose, refer to the service section of this manual for a procedure to torque the bolts.

2.4.9 INSPECT PAU PULLEY SET SCREWS (MODEL ESP30184-12, –13, -18, AND MODEL ESP30556-1) Using a torque wrench with a 3/16-inch Allen wrench, check that the two set screws on the PAU pulley are torqued to 250 inch-pounds. If set screws are loose, remove, clean with brake cleaner, apply a drop of Locktite 262, insert set screws, and torque to 250 inch-pounds.

2.4.10INSPECT ROLL PULLEY BOLTS Using a torque wrench with a 3/4-inch socket, check that the three (3) large roll pulley bolts are torqued to 60 foot-pounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 60 foot-pounds. Using a torque wrench with a 7/16-inch socket, check that the three (3) small pulley bolts are torqued to 9 foot-pounds.

INSPECT ROLL PULLEY BOLTS (CONTINUED) M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 9 foot-pounds. Using a 3/32-inch Allen wrench, check to make sure all set screws in the small pulley bushing are tight. If set screws are loose, remove, clean with brake cleaner, apply a drop of Locktite 262, insert set screws, and torque to 60 inch-pounds.

2.4.11INSPECT MOTOR MOUNTING BOLTS Using a torque wrench with a 9/16-inch socket, check that the four (4) motor swivel base frame mounting bolts and the four (4) motor base to motor swivel base bolts are torqued to 30 footpounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 30 foot-pounds.

2.4.12INSPECT MOTOR PULLEY BOLTS Using a torque wrench with a 7/16-inch socket, check that two (2) motor pulley bolts are torqued to 9 foot-pounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 9 foot-pounds.

2.4.13INSPECT IDLER ATTACHMENT BOLTS Using a torque wrench with a 15/16-inch socket, check that the two (2) idler attachment bolts are torqued to 70 foot-pounds. If bolts are loose, refer to the service section of this manual for idler and belt service instructions.

2.4.14INSPECT RESTRAINT LIMIT SWITCH ASSEMBLY Using a torque wrench with a 7/16-inch socket, check that the two (2) restraint limit switch bracket bolts are torqued to 9 foot-pounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 9 foot-pounds. Make sure wire connections are secure and switch is adjusted properly.

2.4.15INSPECT LIFT ASSEMBLY Using a torque wrench with a 7/32-inch Allen wrench bit, check that the four outboard air bagto-lift plate attachment bolts (two per end) are torqued to 15 foot-pounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 15 foot-pounds. Using a torque wrench with a 9/16-inch socket, check that the two (2) center air bag attachment bolts are torqued to 30 foot-pounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 30 foot-pounds.

2.4.16INSPECT AIRBAGS M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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M US TA N G D Y N A M OM ET ER Remove the lift plates and visually inspect the airbags for any wear, cracks, or dry rot. If air bags need replacement, refer to the service section of this manual.

2.4.17INSPECT AIR LINES AND LIFT SOLENOID Inspect air lines for leaks. Replace faulty air lines if necessary. Check all fittings on the lift solenoid to make sure they are secure and there are no air leaks. Make sure all wire connections are secure.

2.4.18INSPECT PAU LOAD CELL ASSEMBLY Place a small level on top of the PAU bracket and make sure the P AU is level. If necessary, level the PAU using a 3/4-inch wrench to remove the mounting bolt and adjusting the rod end assembly up or down as necessary. Make sure rod ends do not touch center body of load cell. Using a torque wrench with a 3/4-inch socket, check that the top PAU load cell mounting bolt is torqued to 50 foot-pounds. If the bolt is loose, remove bolt, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolt and torque to 50 foot-pounds. Using a torque wrench with a 3/4-inch socket, check that the bottom PAU load cell eye bolt (bearing) is torqued to 50 foot-pounds. If the bolt is loose, remove bolt, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolt and torque to 50 foot-pounds. Using a torque wrench with a 3/4-inch socket, check that the two load cell bracket mounting bolts are torqued to 50 foot-pounds. If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262, reassemble bolts and torque to 50 foot-pounds. It may be necessary to use a 3/4-inch end wrench on one of the bolts. Make sure load cell and PAU are not touching each other.

2.4.19INSPECT SPEED SENSOR ASSEMBLIES Verify that the primary speed sensor is snug. If it is loose, refer to the service section of this manual. Note: the notch must face up. Using feeler gauges verify that the spacing between the primary speed sensor and the top of the pulley teeth is between 0.020 and 0.030 inches. Verify that the secondary speed sensor is snug. If it is loose, refer to the service section of this manual. Using feeler gauges verify that the spacing between the secondary speed sensor and the top of the pulley teeth is between 0.020 and 0.030 inches.

2.4.21INSPECT AND CLEAN THE DYNAMOMETER, F RAME, C ONTROL BOX AND PIT Check to make sure the frame is level and shims and/or anchor bolts have not settled or moved. Level the dynamometer using steel shim stock as necessary. M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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Tighten frame anchor bolts (“Thunderstuds”). Refer to Table 2.3 and check all torque values listed. If bolts are loose, clean bolts, apply a few drops of Locktite 262 on the threads, and torque to the specified value.

CAUTION Do not use pressurized water or compressed air to clean the dynamometer. Using pressurized cleaning techniques can force contaminants into bearings and cause bearing failure.

ATTENTION Ne pas utiliser d’eau pressurisée ni d’air sous pression pour nettoyer le dynamomètre. Utiliser des techniques de nettoyage sous pression peut forcer l’entrée de polluants dans les paliers et entraîner des défaillances des paliers.

INSPECT AND CLEAN THE DYNAMOMETER, F RAME, C ONTROL BOX, AND PIT (CONTINUED) Clean the dynamometer using a cloth that has been lightly wetted with water or a mild soap solution.

CAUTION Pay special attention to the air bags and the area surrounding them. A build-up of dirt in this area can cause wear and premature air bag failure.

ATTENTION Faire particulièrement attention aux sacs gonflables et à la zone qui les entoure. Une accumulation de saleté dans cette zone peut entraîner de l’usure et une défaillance prématurée du sac gonflable. After cleaning the dynamometer, use an anticorrosive spray on all exposed metal to prevent damage from rust or corrosion. Clean the pit of all foreign objects and debris. Use a small paint scraper to loosen any built-up dirt. Use a small vacuum cleaner to pick up any smaller debris. Wipe clean any excessive grease thrown from moving parts. Make sure the drains are clear. Clean the inside of the control bo x with a clean rag and small vacuum cleaner. Check all terminals in the control box for loose wires. Tighten if necessary. Make sure the motor, PAU, and signal cables are secure. Tighten if necessary. Make sure the switches on the lid of the control box are secure. Tighten if necessary.


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SECTION

REPAIR MAINTENANCE C ONTENTS

3.1 INTRODUCTION .................................................................................................3-3 3.2 REPAIR MAINTENANCE ......................................................................................3-4


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3.1 INTRODUCTION This section contains complete disassembly and repair procedures for the Mustang Dynamometer OBD Series Chassis Dynamometers. Disassemble the dynamometer only to the level needed for repair. Most maintenance and service procedures are similar for all model dynamometers. Specific procedures for some model numbers are given. Refer to Figure 3.1 for the locations of major components. Refer to Table 3.1 for a list of special tools. Refer to Table 3.2 for a list of consumable items.

TABLE 3.1

LIST OF SPECIAL TOOLS

ITEM

USE ON

Belt Tension Testing Tool. Mustang part number 20014355

Belt tensioning

Level

PAU alignment

Square

PAU alignment

Four point pulley alignment tool, Mustang part number 20014354

Roll alignment

Long straight edge

Roll alignment

Torque wrench, 0-100 foot-pounds.

Torque Measurements

Feeler gauges

Speed Sensor, scale

Straight Edge

Belt Tension

TABLE 3.2 ITEM

LIST OF CONSUMABLE ITEMS MUSTANG PART NUMBER

DESIGNATION

Coupling Grease

20010651

Mobil Mobilith AW 2

PAU Grease

20010651

Mobil Mobilith AW 2

Bearing Grease

20014314

Polyrex EM

Brake Cleaner

20014315

Brake cleaner

Thread Lock

20010654

Locktite 262

Teflon Tape

20014810

1/4-inch Teflon tape


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3.2 REPAIR MAINTENANCE 3.2.1 REMOVE AND REPLACE COVERS Remove center cover plate by removing the button head cap screws using a 5/16-inch Allen wrench. Remove the center cover plate from the dynamometer. Remove PAU/Inertia weight cover by loosening the hex head cap screws using a 9/16-inch wrench and removing the cover. Remove bearing cover plate by removing the two (2) button head cap screws using a 5/16-inch Allen wrench and removing the cover. If necessary, remove the frame endcap plate from the PAU side by removing the sheet metal screws and plate using a screwdriver. Clean fasteners with brake cleaner before installation. To replace covers, locate covers and plates with existing hardware and using a torque wrench with a 5/16-inch Allen wrench, torque all hardware to 30 foot-pounds.

NOTE Before replacing covers, inspect and clean the frame and pit and perform an operational check of the dynamometer.

REMARQUE Avant de remplacer les panneaux de protection, inspecter et nettoyer le châssis et la fosse et effectuer un contrôle optionnel du dynamomètre.

3.2.2 REMOVE AND REPLACE IDLER ASSEMBLY AND DRIVE BELT Note and mark the location of any shims if they are present. To remove the drive belt, remove the idler assembly bolts using a 15/16-inch socket wrench. Remove the idler assembly. Disconnect the three air line connections at the PAU end of the dynamometer by pushing in the green hub on the press lock fittings and pulling out the air line. Slide the belt off the PAU pulley and gently slide the belt over the flanges on the roll pulleys. Clean idler assembly bolts with brake cleaner.

TABLE 3.3 DRIVE BELTS ESP PART NUMBER

MUSTANG PART NUMBER

ESP30184-1, -6, -7

20013412

ESP30184-9, -11

20013999

ESP30184-12, -13, -18

20014659

ESP30556-1

Refer to Table 3.3 for replacement drive belt part numbers. To replace the drive belt slide the belt over the flanges of the roll pulleys and then gently slide it over the flanges of the PAU pulley. Push belt in the slack area so it is snug around the pulleys. Confirm that the belt is M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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M US TA N G D Y N A M OM ET ER properly engaged on the three pulleys. The belt must not come in contact with any of the frame parts or interfere with the air lines. Apply a few drops of Loctite 262 to the clean threads of the two (2) idler attachment bolts, and install the idler assembly and bolts using a 15/16-inch socket wrench. Replace any shims that were present. Using a torque wrench with a 15/16-inch socket, torque the bolts to 70 footpounds.

REMOVE AND REPLACE IDLER ASSEMBLY AND DRIVE BELT (CONTINUED) CAUTION The drive belt must be correctly aligned before operation of the dynamometer. Improper alignment of the drive belt can result in damage to the belt, pulleys, and bearings.

ATTENTION La courroie d’entraînement doit être correctement alignée avant la mise en fonctionnement du dynamomètre. Un mauvais alignement de la courroie d’entraînement peut entraîner des dégâts de la courroie, des poulies et des paliers. Rotate the belt by moving the rolls by hand. Inspect the belt for damage and insure belt does not ride on the edges of the pulleys. The belt may walk from side to side and may change direction when rotated in the opposite direction. If the belt rides excessively on one edge of the pulley flanges, shim the idler arm as necessary to align the belt. If the belt moves toward the flange in one direction and toward the other flange when rotated in the other direction but does not ride on either flange, do not shim the idler arm. To shim the idler arm, loosen the idler arm and place the shims half way between the idler arm and the frame. Always install the same number of shims on both sides of the arm. Put shims on the top of the idler arm to move the belt away from the PAU. Put shims on the bottom to move the belt toward the PAU. Reconnect the air lines by sliding the air line into the fitting. To check for air leaks turn on the shop air to the dynamometer and listen for leaks.

DRIVE BELT TENSIONING Refer to Figure 3.2 and check the tension of the belt using belt tension measurement tool, Mustang part number 20014355 (ESP30402-1), and Dynamometer Drive Belt Adjustment Bar, ESP106441. Lower the lift plate so the dynamometer rolls are free to turn. The lift must be lowered to obtain the correct belt tension measurements.

WARNING Make sure the dynamometer cannot be operated while the belt tension is being adjusted. Severe injury can occur if the power is applied to the dynamometer during this procedure.

AVERTISSEMENT M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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S’assurer que le dynamomètre ne puisse pas être utilisé pendant que la tension de la courroie est réglée. Des blessures graves peuvent se produire si l’alimentation est appliquée sur le dynamomètre pendant cette procédure. Turn the dynamometer power to OFF. Remove the belt drive access cover if not already removed.

FIG 3.2

DRIVE BELT TENSIONING For models ESP30184-1, -6, -7, and –8, set the large O-ring on the body of the tension tester to the “25” mark on the body of the tool (about 3/8-inch from the end of the tool). Set the small Oring on the plunger against the body of the tension tester. For models ESP30184-9, -11, -12, -13, -18, and ESP30556-1 set the large O-ring on the body of the tension tester to the “15” mark on the body of the tool (about 1/4-inch from the end of the tool). Set the small O-ring on the plunger against the body of the tension tester. Place the alignment bar over the upper pulley as shown and center the bar across the width of the belt. With the tension tester positioned in the correct alignment tool hole and perpendicular to the alignment bar, push on the tension tester and deflect the belt until the large O-ring just contacts the alignment bar. Release pressure and read pounds of force at the O-ring on the plunger. Refer to Table 3.4 for proper drive belt tension.

TABLE 3.4

DRIVE BELT TENSION


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DYNAMOMETER

FORCE READING

ESP30184-1, -6, -7, -8

25 Pounds

ESP30184-9, -11, -12, -13, -18 ESP30556-1, OBD DYNES

15 Pounds

DRIVE BELT TENSIONING (CONTINUED) CAUTION Do not apply too much tension to the drive belt. Too much tension on the drive belt can result in damage to the belt, pulleys, and bearings.

ATTENTION Ne pas appliquer trop de tension sur la courroie d’entraînement. Trop de tension sur la courroie d’entraînement peut entraîner des dégâts de la courroie, des poulies et des paliers. Tighten the belt by loosening the two idler bolts using a 15/16-inch wrench, loosening the adjustment stop bolt, and tightening the adjustment nut. Be sure to torque the idler mounting bolts to 70 foot-pounds. Apply a few drops of Loctite 262 to the threads of the stop nut.

3.2.3 REMOVE AND REPLACE MOTOR ASSEMBLY AND MOTOR BELT To remove the motor belt use a 9/16-inch socket with long extension and loosen the adjustment screw on the motor pivot plate to give slack to the belt. Remove the belt. Swivel the motor for access to the bolts and using a 9/16-inch socket wrench with long extension remove the four (4) motor mounting bolts, flat washers, and lock washers. Clean hardware with brake cleaner prior to installation. To replace the motor assembly place the motor on the motor support plate. Apply a few drops of Loctite 262 to the threads of the four (4) motor mounting bolts and insert them with flat washers and lock washers into the motor and motor mounting plate. Swivel the motor for access to the bolts and using a torque wrench with a 9/16-inch socket and extension torque the motor mounting bolts to 30 foot-pounds. To replace the motor belt place the belt over the pulleys.

MOTOR BELT TENSIONING METHOD 1 – Refer to Figure 3.2 and check the tension of the belt using belt tension measurement tool, ESP30402, and a straight edge. Set the large O-ring on the body of the tension tester to 1/4-inch from the end of the body. Set the small O-ring on the plunger against the body of the tension tester. Place the straight edge on the belt. With the tension tester in the middle of the belt and perpendicular to the span, push on the tension tester and deflect the belt until the large O-ring is in line with the straight edge. Release pressure and read pounds of force at the O-ring on the plunger. For all models, the belt should deflect 1/4-inch when fifteen (15) pounds of force is applied. Tighten the belt, if necessary, using a 9/16-inch socket and long extension to tighten the adjustment screw on the motor pivot plate below the motor. Apply a few drops of Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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wrench tighten the adjustment screw jam nut. Apply a few drops of Loctite 262 to the threads of the jam nut.

METHOD 2 – Check the tension of the motor belt by running a dynamometer calibration sequence. If the belt slips during the test, tighten it using a 9/16-inch socket and long extension to tighten the adjustment screw on the motor pivot plate below the motor. Apply a few drops of Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end wrench tighten the adjustment screw jam nut. Apply a few drops of Loctite 262 to the threads of the jam nut.

MOTOR BELT TENSIONING (CONTINUED) METHOD 3 – The belt tension may be checked by grasping the belt at mid span between the thumb and index finger. Attempt to twist the belt. Properly adjusted, the belt should easily rotate between 90 and 180 degrees. Tighten the belt, if necessary, using a 9/16-inch socket and long extension to tighten the adjustment screw on the motor pivot plate below the motor. Apply a few drops of Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end wrench tighten the adjustment screw jam nut. Apply a few drops of Loctite 262 to the threads of the nut.

3.2.4 REMOVE AND REPLACE PAU ASSEMBLY Release the tension of the drive belt. Refer to Remove and Replace Idler Assembly. Refer to Figure 3.3, and using a 3/4-inch socket wrench and 3/4-inch open end wrench remove the two (2) 1-1/2-inch pillow block bearing mounting bolts, flat washers, lock washers, and nuts from the rear end of the dynamometer. Using a 15/16-inch socket wrench and 15/16-inch open end wrench remove the two (2) 1-3/4-inch pillow block bearing mounting bolts, flat washers, lock washers, and nuts at the pulley end. Clean hardware using brake cleaner and remove all traces of Loctite prior to installation.

FIG 3.3 PAU


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M US TA N G D Y N A M OM ET ER Using a 3/4-inch open end wrench, remove the load cell from the load cell bracket. Loosen one bearing stop screw from the outboard side of each pillow block bearing using a 9/16-inch wrench. Do not remove both bearing stop screws from any bearing.

REMOVE AND REPLACE PAU ASSEMBLY (CONTINUED) WARNING The PAU assembly is extremely heavy. Be sure the PAU assembly is properly supported when removing it from the frame. Failure to observe these precautions may result in damage to equipment, injury to personnel, or both.

AVERTISSEMENT L’ensemble PAU est extrêmement lourd. S’assurer que l’ensemble PAU soit correctement supporté lors de sa dépose du châssis. Ne pas observer ces précautions peut entraîner des dégâts de l’équipement, des blessures du personnel, ou les deux. Using proper lifting equipment remove the PAU. Note and mark the location of any shims located under the bearings. The shims must be replaced in the same position when the PAU is replaced. Do not attempt to service the PAU. Consult the factory for repair. Before replacing the PAU, inspect the pulley for dings on the flange or burrs on the cutouts. The pulley should be loose on the pulley bushing. To replace the PAU, place the PAU and any shims that were installed under the PAU bearings on top of the frame. Make sure the load cell bracket is facing upward. Apply a few drops of Loctite 262 to the clean threads of two (2) 5/8-11 x 4-1/2-inch bolts (5/8-11x 5-1/2-inch bolts for models ESP30184-12 , –13 and -18) and insert them with flat washers into the 1-3/4-inch pillow block bearing mounting holes at the pulley end of the PAU. Apply a few drops of Loctite 262 to the clean threads of two (2) 1/2-13 x 4-1/2-inch bolts (1/2-13 x 5-1/2-inch bolts for models ESP30184-12, –13, and -18) and insert them with flat washers into the 1-1/2-inch pillow block bearings mounting holes at the rear end of the PAU. Place the bearing bolt nuts, flat washers, and lock washers under the bearing supports at both ends of the PAU and lightly screw in the bolts. Do not torque the bolts at this time. Snug up the bearing stop screws. Do not tighten the jam nut. Apply a few drops of Loctite 262 to the threads of the load cell mounting bolts and install the load cell. Do not torque the bolts at this time. Make sure the load cell is vertical on the outboard side of the PAU and there is clearance between the PAU and the motor.

PAU ALIGNMENT Verify the horizontal alignment of the PAU to the rolls using a small level. Place the level flat on top of the inertia weight and on top of rolls #3 and #4. Note the position of the bubble on the level. The bubble on the level should be in the same position for all three locations. If the alignment is not level then shim the PAU or roll as necessary by placing shim stock under the roll or PAU bearings. Refer to Figure 3.4 and verify the alignment of the PAU to the rolls by placing a square between the face of the inertia weight and roll #4. Visually inspect the alignment. If the PAU is not square loosen the jam nuts and use the bearing stop screws on the PAU bearings to set the square flat to the PAU. Recheck the PAU alignment using the square. Realign if necessary. M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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FIG 3.4 PAU ALIGNMENT

Using a torque wrench with a 3/4-inch socket and a 3/4-inch open end wrench torque the 1-1/2inch pillow block bearing mounting bolts at the end of the PAU to 50 foot-pounds. Using a torque wrench with a 15/16-inch socket and a 15/16-inch open end wrench torque the 1-3/4-inch pillow block bearing mounting bolts at the pulley end of the PAU to 70 foot-pounds. Tighten the bearing stop screws and fully tighten the jam nuts. Apply a few drops of Loctite 262 to the threads of the bearing stop screws and jam nuts. Recheck the PAU alignment using the square. Realign if necessary. Using a torque wrench with a 3/4-inch socket, torque the PAU load cell mounting bolts to 50 foot-pounds.

PAU PULLEY INSTALLATION

NOTE

Do not use lubricants in this installation Inspect the PAU shaft, bushing, and mating hub. Remove all nicks, paint, dirt, grease, etc. from mating surfaces. Wash or wipe bushing taper and tapped holes with brake cleaner to remove any contaminates that may interfere in the assembly.

REMARQUE Ne pas utiliser de lubrifiants dans cette installation. Inspecter l’arbre de PAU, le coussinet et le moyeu apparié. Retirer toutes les encoches, la peinture, la saleté, la graisse, etc. des surfaces de contact. Laver ou essuyer le cône de roulement et les trous taraudés avec un produit de nettoyage de frein pour retirer tous les polluants qui peuvent interférer dans l’assemblage.


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FIG 3.5 PAU PULLEY INSTALLATION

CAUTION Do not exceed torque limits. Too much torque to the pulley/bushing assembly will cause damage to the assembly.

ATTENTION

Ne pas excéder les limites de couple. Un couple trop élevé sur la poulie et le coussinet entraînera des dégâts de l’ensemble. For models ESP30184-1, -6, -7 and -8, apply a few drops of Loctite 262 to the key and install the key into the keyway in the shaft. Slide the cleaned bushing onto the shaft and key. The small end of taper must be outboard. Slide the cleaned tapered pulley over the bushing. First, align the shaft key with one of the slots in the mating hub and second, align the drilled holes in the mating pulley with the threaded holes in the bushing. Clean the pulley bolts with brake cleaner if necessary to remove any lubricants. Apply a few drops of Loctite 262 to the clean threads of the pulley bolts and insert one bolt through each drilled hole in the mating hub and into the threaded hole of the bushing. Do not use a lockwasher. NOTE: Once the pulley bolt with Loctite applied has started to be installed, the process must be completed before the Loctite cures to ensure a true torque reading. Refer to Figure 3.5 and using a straight edge and ruler, align the bushing and pulley so there is a 3/16-inch offset from the roll pulley to the PAU pulley. Using a torque wrench with a 1/4-inch, 12-point socket, tighten all pulley bolts evenly and progressively in rotation. First, torque the first pulley bolt to 140 inch-pounds. Torque the second pulley bolt and then the third. Repeat this step two more times. Second, torque the first pulley bolt to 180 inch-pounds. Torque the second pulley bolt and then the third. Repeat this step two more times. Finally, torque the first pulley bolt to 220 inch-pounds. Torque the second pulley bolt and then the third. Repeat this step two more times. M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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PAU PULLEY INSTALLATION (CONTINUED) For models ESP30184-9 and -11, apply a few drops of Loctite 262 to the key and install the key into the keyway in the shaft. Slide the cleaned bushing onto the shaft and key. The small end of taper must be outboard. Slide the cleaned tapered pulley over the bushing. Align the drilled holes in the mating hub with the threaded holes in the bushing. Clean the pulley bolts with brake cleaner if necessary to remove any lubricants. Apply a few drops of Loctite 262 to the clean threads of the pulley bolts and insert one bolt and lockwasher through each drilled hole in the mating hub and into the threaded hole of the bushing. NOTE: Once the pulley bolt with Loctite applied has started to be installed, the process must be completed before the Loctite cures to ensure a true torque reading. Slide the bushing on to the shaft so it is flush with the shaft. Using a torque wrench with a 1/4-inch Allen wrench, tighten all pulley bolts evenly and progressively in rotation. First, torque the first pulley bolt to 140 inch-pounds. Torque the second pulley bolt and then the third. Repeat this step two more times. Next, torque the first pulley bolt to 180 inch-pounds. Torque the second pulley bolt and then the third. Repeat this step two more times. Finally, torque the first pulley bolt to 220 inch-pounds. Torque the second pulley bolt and then the third. Repeat this step two more times. For models ESP30184-12, -13, -18, and ESP30556-1 no bushing is used. Apply a few drops of Loctite 262 to the key and install the key into the keyway in the shaft. Slide the PAU pulley over the shaft and key and using a square or straight edge, align the PAU pulley with the roll pulley. Apply a few drops of Loctite 262 to the threads of the two set screws and using a torque wrench with a 3/16-inch Allen wrench, tighten the set screws to 250 inch-pounds.

3.2.5 REMOVE AND REPLACE SPEED SENSORS (SEE FIGURE 3.6) PRIMARY SPEED SENSOR REMOVAL Using a 9/64-inch Allen wrench loosen the screw on the clamp that holds the sensor in place and remove the primary speed sensor.

SECONDARY SPEED SENSOR REMOVAL Using two 3/4-inch wrenches disassemble the jam nuts and remove the secondary speed sensor.

PRIMARY SPEED SENSOR INSTALLATION To install the primary speed sensor apply a drop of Loctite 262 to the threads of the clamp screw and slide the sensor through the clamp. Secure it using a 9/64-inch Allen wrench. Using feeler gauges set the spacing between the primary speed sensor and the top of the pulley teeth to between 0.020 and 0.030 inches. Ensure notch on body of sensor faces upward.

SECONDARY SPEED SENSOR INSTALLATION To install the secondary speed sensor apply a few drops of Loctite 262 to the threads of the jam nuts, slide the sensor through the bracket, and secure it using two 3/4-inch wrenches to set the jam nuts. Using feeler gauges set the spacing between the secondary speed sensor and the top of the pulley teeth to between 0.020 and 0.030 inches

FIG 3.6 M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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SPEED SENSORS

Fig 3.7 COUPLING DETAILS (ESP30184-1, -6, -7, -8, -9, -10, -11, -18,

AND ESP30556-1)


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Fig 3.8 COUPLING DETAILS (ESP30184-12, -13)

3.2.5 REMOVE AND REPLACE INNER SHAFTS (SEE FIGURES 3.7 AND 3.8) REMOVAL Using a 3/16-inch Allen wrench remove both grease plugs from each coupling sleeve. Using a small flat edged screwdriver insert the screwdriver in the notch of the steel snap ring and gently pry the end of the ring out of the ring groove. Continue removing the ring from the sleeve using a spiral motion. Slide sleeve off flex hub toward the center of the inner shaft. Repeat this procedure to remove the other coupling sleeve. Remove inner shaft.

REPLACEMENT To install the inner shafts inspect the shaft, sleeve and hub for nicks, dirt, grease, etc. Clean with brake cleaner to remove any contaminates. Make sure each coupling hub has a rubber ring (Seal for Models ESP30184-12 and –13) on it. If the rubber ring or seal is not present, install it. Hold the inner shaft between the rolls and slide the coupling sleeves over the coupling hubs on both ends. Install the snap ring between the roll rigid hub and the sleeve. Remove the two (2) grease plugs from the coupling sleeves and insert a grease fitting into one of the holes. Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the grease fitting and pump the handle until grease comes out the other hole. Make sure that no grease seeps out through the O-rings or seals. If grease runs through the O-rings or seals replace the O-rings or seals. Remove the grease fitting and replace both grease plugs. Tighten the plugs until they are snug and are approximately 1/16-inch above the surface. DO NOT OVER TIGHTEN THE PLUGS. If any plug is flush or below the surface remove it, wrap it with Teflon tape, and reinstall.


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REMOVE AND REPLACE INNER SHAFTS (CONTINUED) Apply a drop of Loctite 262 to the threads of the set screws, insert set screws into the coupling sleeves and using a torque wrench with a 1/8-inch Allen wrench torque the set screws to 75 inch-pounds.

3.2.6 REMOVE, R EPLACE, AND ALIGN ROLLS NOTE: Rolls are aligned and bearing stops are set at the factory. Do not remove or replace rolls unnecessarily. Remove only those components necessary for service. When replacing rolls, do not loosen any bearing stop screws unless specifically instructed to do so.

WARNING The roll assemblies are extremely heavy. Be sure the roll assemblies are properly supported when removing them from the frame. Failure to observe these precautions may result in damage to equipment, injury to personnel, or both.

AVERTISSEMENT Les rouleaux sont extrêmement lourds. S’assurer que les rouleaux soient correctement supportés lors de leur dépose du châssis. Ne pas observer ces précautions peut entraîner des dégâts de l’équipement, des blessures du personnel, ou les deux.

CAUTION Rolls must be properly aligned for high-speed operation. Roll misalignment can lead to poor machine performance as well as premature component failure.

ATTENTION Les rouleaux doivent être correctement alignés pour le fonctionnement à haute vitesse. Un mauvais alignement des rouleaux peut entraîner une mauvaise performance de l’équipement ainsi qu’une défaillance prématurée des composants. Remove idler assembly and drive belt. Refer to Remove and Replace Drive B elt and Idler Assembly. Remove speed sensors. Refer to Remove and replace Speed Sensors. Remove inner shafts. Refer to the Remove and Replace Inner Shafts. Remove motor belt if necessary. Refer to the Remove and Replace Motor and Belt. Refer to Figure 3.9 for roll positions and bearing locations. Roll #3 is located on the flat side of the dynamometer, away from the restraint tubes. All alignment measurements are made with reference to roll #3.


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FIG 3.9 ROLL AND BEARING POSITIONS

ROLL REMOVAL (ROLLS #3 AND #4) To remove rolls #3 and #4 refer to Figure 3.10 and loosen the two bearing stop screws from the 2-inch pillow block located between the two bearings using a 9/16-inch open end wrench. Using a 3/4-inch socket wrench remove the bearing mounting bolts, lock washers, flat washers, and bearing plates located under the bearing support tube from the 1-1/2-inch pillow block bearings. Using a 15/16-inch socket wrench remove the mounting bolts lock washers, flat washers, and bearing plates located under the bearing support tube from the 2-inch pillow block bearings. Clean all hardware with brake cleaner and chase threads if necessary to remove all traces of Loctite using a 1/2-13 die for the 1-1/2-inch bearings or a 5/8-11 die for the 2-inch bearings.

WARNING The rolls are extremely heavy. Be sure the rolls are properly supported when removing them from the frame. Failure to observe these precautions may result in damage to equipment, injury to personnel, or both.

AVERTISSEMENT Les rouleaux sont extrêmement lourds. S’assurer que les rouleaux soient correctement supportés lors de leur dépose du châssis. Ne pas observer ces précautions peut entraîner des dégâts de l’équipement, des blessures du personnel, ou les deux. Using suitable lifting equipment remove the roll(s) from the frame.

ROLL REMOVAL (ROLLS #1 AND #2) M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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M US TA N G D Y N A M OM ET ER Remove rolls #1 and #2 using a 3/4-inch socket wrench to remove the bearing mounting bolts, lock washers, flat washers, and bearing plates located under the bearing support tubes from the 1-1/2-inch pillow block bearings. Clean all hardware with brake cleaner and chase threads if necessary to remove all traces of Loctite using a 1/2-13 die for the 1-1/2-inch bearings. Using suitable lifting equipment remove the roll(s) from the frame.

FIG 3.10 BEARING STOPS

ROLL REPLACEMENT (ROLLS #1 AND #2) Using suitable lifting equipment set both rear rolls, roll #1 and roll #2 in place with the coupling hubs facing the center of the dynamometer. Apply a few drops of Loctite 262 to the clean threads of two (2) 1/2-13 x 3-inch bolts and insert them with lock washers and flat washers into each pillow block bearing. Hold the bearing plates under the bearing support tubes and start the bolts in the bearing plates. Snug up the bolts but do not torque them. Verify that the rubber Oring is on the coupling rigid hub and the steel snap ring is between the coupling hub and the bearing.

ROLL REPLACEMENT (ROLLS #3 AND #4) Using suitable lifting equipment set roll #3 and #4 in place with the coupling hubs facing the center and the pulleys towards the PAU. Apply a few drops of Loctite 262 to the clean threads of two (2) 1/2-13 x 3-inch bolts and insert them with lock washers and flat washers into the 11/2–inch bearings located in the center of the dynamometer. Apply a few drops of Loctite 262 to the clean threads of two (2) 5/8-11 x 3-inch bolts and insert them with lock washers and flat washers into the 2–inch bearings at the PAU end. The bearing plate under the 2-inch bearing is not symmetrical. The short end of the plate should be oriented near to frame. Hold the bearing plates under the bearing support tubes and start the bolts in the bearing plates. Snug up the bolts but do not torque them. Verify that the rubber O-ring is on the coupling rigid hub and the steel snap ring is between the coupling hub and the bearing. M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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ROLL ALIGNMENT Rolls are aligned at the factory. When replacing rolls extensive realignment may not be necessary. Verify the alignment of the rolls before attempting any alignment procedure. Alignment between roll #3 and the inner wall, between rolls #3, and #4, (four point), between rolls #4 and #2, and between rolls #3 and #1 (straight edge), and between the PAU and rolls (square) is critical and must be checked. Refer to Figure 3.11 and verify the position of roll #3 using a tape measure. The center of the shaft should be 5-1/2-inches from the inner wall of the frame at both ends of the roll. If necessary align roll using the bearing stop bolts to move the roll bearings. Refer to Figure 3.12 and using a small pry bar set the distance between the pulley and the front of the bearing support. For models ESP30184-1, -6, -7, and –8 set the distance to between 1/16 and 1/8 inches. For models ESP30184-9, –11, -12, and -13 set the distance to between 3/4 and 1-inch. Snug up the bearing mounting bolts. Do not torque the bolts or set the jam nut now. Verify the position of roll #4 using a tape measure. The center-to-center distance between the roll shafts should be 17 inches at both ends of the roll. If necessary align roll using the bearing stop bolts to move the roll bearings.

FIG 3.12 ROLL PULLEY LOCATION

Note: On ESP30184-18 and ESP30556-1 the roll sprocket bushing is mounted onto the roll first.


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ROLL ALIGNMENT (CONTINUED) Refer to Figure 3.13 and verify the alignment of the roll pulleys on rolls #3 and #4 by placing the four point pulley alignment tool, Mustang part number 20014354 (see Appendix), across the pulley hub faces. The tool has a cutout that should be located around the flanges of the pulleys. The tool should touch the faces of the hubs at four points. If two points touch on the same roll and none on the other roll, adjust one of the rolls using a small pry bar so that all four points touch. If three points touch, adjust roll #4 using the bearing stop screws to move the roll so all four points touch. Using a torque wrench with a 3/4-inch socket torque the 1-1/2-inch pillow block bearing mounting bolts to 50 foot-pounds on rolls #3 and #4. Using a torque wrench with a 15/16-inch socket torque the 2-inch pillow block bearing mounting bolts to 70 foot-pounds. Recheck the four-point alignment. Realign if necessary. Set the jam nuts on the bearing stops. Apply a few drops of Loctite 262 to the threads of the bearing stop screws. The distance between the inner coupling hubs of roll #2 and roll #4 and between the inner coupling hubs of roll #1 and roll #3 should be 19-1/2 to 19-5/8 inches. Adjust roll #2 or roll #1 if necessary using a small pry bar.

FIG 3.13 FOUR POINT ALIGNMENT


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FIG 3.14 ROLL ALIGNMENT

Refer to Figure 3.14 and check the alignment of roll #2 to roll #4 and of roll #1 to roll #3 by placing a straight edge across the rolls. If the rolls are not aligned, align the rolls using the bearing stop screws on roll #1 or Roll #2. Do not move rolls #3 or #4. Apply a few drops of Loctite 262 to the threads of the bearing stop screws if they were moved. Using a torque wrench with a 3/4-inch socket torque the 1-1/2-inch pillow block bearing mounting bolts to 50 foot-pounds on rolls #1 and #2. Verify the alignment of the rolls. Realign if necessary. Replace inner shafts, idler assembly, belts, and speed sensors. Refer to the procedures in this section.

3.2.8 REMOVE AND REPLACE BRAKE PADS, AIR BAGS, AND LIFT PLATE ASSEMBLY NOTE The lift plate assembly does not have to be removed for brake shoe replacement.

REMARQUE Il n’est pas nécessaire de déposer la plaque de levage pour le remplacement des freins. Remove the brake pads using two 1-1/8-inch crescent wrenches. After one nut is loosened, use a 13-mm open-end wrench to hold the pin while removing the other nut. Remove the brake pads. Clean the hardware with brake cleaner. Note: when replacing the brake pads coat the back of the pads with Mobilith AW 2 grease. To replace brake pads apply a few drops of Loctite 262 to the threads of the brake pad pin and install the brake pads, flat washers, and nuts onto the pin. Using two 1-1/8-inch crescent wrenches tighten the nuts.

REMOVE AND REPLACE BRAKE PADS, AIR BAGS, AND LIFT PLATE ASSEMBLY (CONTINUED) M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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Using a 7/32-inch Allen wrench remove the bolts from the two outboard air bags. Using a 9/16inch socket wrench remove the bolts from the center air bag. Raise the lift plate and slide it over the rolls placing a board under the lift plate to prevent damage to the rolls. To replace air bags, remove the air bag and gently pull the air line from the fitting. On the replacement air bag press the air line into the fitting and place the air bag on the center support.

NOTE When replacing the lift plate coat the ends of the plate that slide in the frame guides with Mobilith AW 2 grease.

REMARQUE Lors du remplacement de la plaque de levage, enduire les extrémités de plaque qui coulissent dans les guides du châssis avec de la graisse Mobilith AW 2. To replace the lift plate slide the lift plate onto the airbags. Apply a few drops of Loctite 262 to the threads of the four (4) outboard air bag attachment bolts and using a torque wrench with a 7/32-inch Allen wrench torque the bolts to 15 foot-pounds. Apply a few drops of Loctite 262 to the threads of the two (2) center air bag attachment bolts and using a torque wrench with a 9/16inch socket torque the bolts to 30 foot-pounds.

3.2.9 REMOVE AND REPLACE LIMIT SWITCH TRIP ARMS Remove limit switch trip arm by removing the spring and the cotter pin from the pin. When replacing the limit switch trip arm coat the pin with Mobilith AW 2 grease. Make sure the spring is facing upward and the arm pivots freely.

3.2.10 PAU GROUND SHORT CHECK/REPAIR The twelve PAU Coils, designated 1N through 12S, are wired in series as shown in the wiring diagram in Figure 3.15. Shorts to ground can be due to a faulty coil, jumper wire, or terminal block in the PAU. To find a shorted coil, disconnect the PAU from the power supply. Using an ohmmeter, check the PAU coils for shorts to ground at the PAU cable connector. Resistance should be at least one Megohm. If a shorted coil is suspected, systematically check half of the coils at a time as follows: Remove the blue lead of coil 7N to divide the coils into two groups of six, 1N through 6S, and 7N through 12S. Connect one lead of the ohmmeter to the PAU ground and the other lead to the first group of six coils and then to the other group of coils to determine which group of six coils has the short. Divide the shorted group into two groups of three coils each and use the ohmmeter to check which group has the short. Keep separating and isolating coils until the short is located. If the short is in a coil, disconnect both leads of the coil from the terminal block and install a jumper wire across the terminals. Up to three coils can be disconnected without adversely affecting PAU performance. If the short is in the terminal block, replace the terminal block. M ODEL MD-OBD-D YNE M AINTENANCE AND S ERVICE

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M US TA N G D Y N A M OM ET ER If the short is in a jumper wire, either replace the wire or wrap insulation tape over the wire. Check the resistance of the PAU by connecting one lead of an ohmmeter to the main red terminal and one to the blue terminal. Resistance should be approximately 3 Ohms. Reconnect all wires and recheck for shorts. After all shorts have been eliminated, reconnect the.


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SECTION

TROUBLESHOOTING C ONTENTS

4.1 INTRODUCTION .....................................................................................................4-3 4.2 TROUBLESHOOTING GUIDE ...................................................................................4-3


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INTRODUCTION This section contains information and procedures for isolating and correcting problems with the dynamometer. Table 4.1, the Troubleshooting Guide, lists problems, possible causes, and recommended corrections. Refer to the Repair section of this manual for repair instructions for major components of the dynamometer.

4.2

TROUBLESHOOTING GUIDE

TABLE 4.1


Problem

Possible Cause

Correction

Vibration and/or Noise

Structural frame of dynamometer is not secured to pit floor.

Check anchor bolts on dynamometer frame and tighten to proper specification.

Dynamometer is not level to the floor.

Level dynamometer and be sure shims are in place under frame where needed.

Roll coupling is out of tolerance or alignment.

Repair or realign couplings.

Coupling between rolls is worn.

Replace coupling.

Roll pillow block bearings not secured to the frame.

Tighten bolts to proper specification.

Bearing failure on rolls.

Replace bearings.

Bearing Failure on PAU.

Replace bearing.

Roll has spun on bearing and is worn.

Check roller shaft for wear. Tighten setscrews to proper specification or replace roll.

Roll is out of balance.

Check for loose weights on roll. Replace roll if necessary.

Lift Override switch is in “UP” position.

Turn Lift Override switch to ”DOWN” position.

Lift override module on lift solenoid is in the vertical position

Turn screw on override module to the horizontal position.

No lubrication

Coat the ends of the plate that slide in the frame guides with Mobilith AW 2 grease.

Air supply to dynamometer has not been turned on.

Turn on air supply. Dry air, regulated to a MAXIMUM of 80 psi must be supplied to the dynamometer.

Air lift solenoid coil has failed.

Check for +12 VDC across pins 8 and 9 of the I/O board in the Control Unit. Replace coil if necessary.

Air lift valve has failed.

Replace valve.

Lift Fails to Lower

Lift Fails to Raise


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TABLE 4.1


Problem

Possible Cause

Correction

Lift Fails to Raise (Continued)

Power supply failing to operate properly.

Check all connections in both control unit and solenoid valve cable. Repair or replace defective components if necessary.

Air bag has ruptured.

Replace air bag.

No lubrication

Coat the ends of the plate that slide in the frame guides with Mobilith AW 2 grease.

Roll speed other than zero is being displayed.

Troubleshoot speed sensor and wiring. Perform zero calibration in control box and EIS system cabinet.

Low air pressure.

Adjust dry, regulated air pressure supplied to dynamometer to a maximum of 80 psi.

Defective or improperly wired air pressure switch.

Verify correct wiring and test opening and closing of pressure switch contacts.

Defective cable or wiring.

Inspect all electrical wiring and replace any defective cables and/or contacts.

“Digital Enable” signal from host computer not present.

Troubleshoot software system. Troubleshoot dynamometer control unit.

Brake pads are worn.

Replace brake pads.

Air leak in pneumatic system.

Inspect and replace any defective tubing, connectors, and/or air bags.

Low air pressure

Adjust dry, regulated air pressure supplied to dynamometer to a maximum of 80 psi.

Loose interface connection.

Make sure all cable connections are properly seated. Verify all connections inside the control box are secure.

Bad load cell connection.

Check all load cell connection. Repair if necessary.

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 to 0.030 inches.

Magnetic Pickup failure. Bad electrical connections.

Replace Magnetic Pickup. Check all electrical connections in the system.

Rolls Do Not Lock

Display Values Not Stable (Floating, Fluctuating, etc.)

No Speed Readout

No Torque Readout


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