Obd Dyne Manual

- 1 -MODEL OBD DYNE MAINTENANCE AND SERVICE

MAINTENANCEAND

SERVICE MANUAL

MODEL MD-OBD-DYNESERIES

MUSTANG DYNAMOMETER

Revision Release Date InitialA 09 July 98 KSB 15 July 98 KSC 21 September 98 KSD 30 November 98 KSE 1 April 99 JHF 11 June 1999 JHG 25 October, 1999 DFH 14 March , 2002 DF

http://www.getpdf.com

MUSTANG DYNAMOMETER

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 2 -

Information in this document is subject to change without notice. Nopart of this document may be reproduced or transmitted in any formor by any means, electrical or mechanical, for any purpose, withoutthe express written permission of Mustang Dynamometer.

Copyright 1999Ganzcorp Investments, Inc. dba Mustang Dynamometer

All rights reserved

Mustang Dynamometer2300 Pinnacle Parkway

Twinsburg, Ohio 44087 USA

Telephone: (330) 963-5400 * Fax: (330) 425-3310


MUSTANG DYNAMOMETER


NOTICEThis manual has been designed and written to provide useful informationabout Mustang Dynamometer equipment and systems. Every effort hasbeen made to make this manual as complete as possible, but nowarranty 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 ofMustang Dynamometer shall have either liability or responsibility to anyperson or entity with respect to any loss or damages arising from theinformation contained in this manual.

AVISCe manuel a été conçu et écrit pour fournir de l’information utile surl’équipement et les systèmes Mustang Dynamometer. Toutes lesprécautions ont été prises pour rendre ce manuel aussi complet quepossible, mais aucune garantie d’adaptation ni autre n’est implicite.

L’information contenue dans ce manuel est fournie « telle quelle ». Nil’auteur de ce manuel ni la direction ni les propriétaires de MustangDynamometer ne seront responsables envers quiconque ni enversquelque entité que ce soit des pertes ou dommages résultants del’information contenue dans ce manuel.


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WARRANTYLIMIT OF LIABILITY

Mustang warrants that the product(s) that is the subject of this sale is free from defects inmaterial. The duration of this warranty is one year from date of shipment on all Mustang-relatedcomponents. Components not manufactured by Mustang will carry the original manufacturer’swarranty, typically 90 days for all electronic-related components. All warranty claims must beprocessed through Mustang.

If a problem arises within the applicable warranty period, it is the responsibility of the purchaserto (a) promptly notify Mustang in writing (b) obtain a RMA Number from Mustang (c) return toMustang the component(s) that are claimed to be defective (transportation charges must beprepaid by the purchaser). RMA Number must be clearly marked on outside of package(s).

Within a reasonable time after such notification, Mustang will correct any defect(s) incomponent(s). If Mustang is unable to repair the component after a reasonable number ofattempts, or if Mustang determines at any time the repair is impracticable, Mustang will providea replacement with like or similar component(s). The purchaser is responsible for alltransportation expenses to and from Mustang and all labor expenses associated with removal andreplacement of the component(s) as well as labor involved to repair component(s). Mustang willbear the expense of parts only. These remedies are the Purchaser’s sole remedies for breach ofwarranty.

The expiration of the warranty period, use of the product for purposes other than those for whichit 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 basedupon 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 ofuse of the product or any associated equipment, cost of capital, cost of any substitute equipment,facilities or services, downtime, the claims of third parties including customers, and injury toproperty.

Unless modified in writing and signed by officers of both parties, this agreement is understood tobe the complete and exclusive agreement between the parties, superseding all prior agreements,oral or written and all other communications between the parties relating to the subject matter ofthe agreement.

GANZCORP INVESTMENTS INC. dba MUSTANG DYNAMOMETER


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DANGER

Keep limbs, hair, jewelry and clothing away fromthe moving rolls. When operating a vehicle on themachine, remain inside vehicle until the rolls havestopped. Cover the rolls when the equipment is notin use.

DANGER

Garder les membres, les cheveux, les bijoux et lesvêtements éloignés des rouleaux en mouvement.Lors de l’utilisation d’un véhicule sur l’équipement,rester à l’intérieur du véhicule jusqu’à ce que lesrouleaux se soient arrêtés. Couvrir les rouleauxlorsque l’équipement ne sert pas.

DANGER

Do not operate or perform any maintenance on yourequipment until you have carefully read this manualin its entirety making sure that you understand allof the material presented in each section.

DANGER

Ne pas utiliser l’équipement ni effectuer sonentretien avant d’avoir lu attentivement ce manuelen entier et d’avoir compris tout le matérielprésenté dans chaque section.


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CAUTIONUnsafe operating practices can lead to potentiallydangerous situations when your machine is running.Only properly trained and responsible personnelshould attempt to operate this machine.

ATTENTIONDes pratiques d’utilisation non sûres peuvent conduireà des situations potentiellement dangereuses lors dufonctionnement de l’équipement.Seul le personnel responsable et correctementinstruit doit entreprendre d’utiliser cetéquipement.

CAUTIONRemoval and disassembly instructions in this manualhave been reduced to a minimum for ease ofreadability.Only experienced maintenance personnel shouldattempt to install and/or make repairs to thismachine.

ATTENTIONLes instructions de dépose et de démontage donnéesdans ce manuel ont été réduites au minimum pour enfaciliter la lecture.Seul du personnel d’entretien expérimenté doitentreprendre d’installer ou de faire des réparationssur cet équipement.

SECTION


MUSTANG DYNAMOMETER


INTRODUCTION

CONTENTS

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 ChassisDynamometers. Table 1.1 lists part numbers and descriptions of the dynamometers. Mostmaintenance and service procedures are similar for all model dynamometers. Specificprocedures 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. Majordynamometer 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 SeriesDynamometers.


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1.2 GENERAL SAFETY ISSUESCONSIGNES GÉNÉRALES DE SÉCURITÉ

Be Knowledgeable ... Do not attempt to operate, maintain or service your Mustang ChassisDynamometer System until you have familiarized yourself with the equipment by reading theinstructions in this manual.

Être instruit ... Ne pas essayer d’utiliser, d’entretenir ni de réparer le système dynamométriquede châssis (banc d’essai) Mustang avant de s’être familiarisé avec l’équipement en lisant lesinstructions de ce manuel.

Act Responsibly ... Exercise caution and discretion when operating or performing maintenanceon the dynamometer. Always observe typical, common sense test area precautions.

Agir de manière responsable ... Exercer prudence et bon jugement lors de l’utilisation ou del’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. Wearapproved safety glasses when in the vicinity of the vehicle being tested.

Attention aux projectiles ... Les pneus en rotation peuvent projeter des pierres et autresprojectiles. 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 thedynamometer.

Protéger les oreilles ... Toujours porter une protection approuvée pour les oreilles lors du travailprès du dynamomètre.

Beware of Being Grabbed ... Keep limbs, hair, jewelry, and clothing away from the movingdynamometer components.

Attention de ne pas être happé ... Garder les membres, les cheveux, les bijoux et les vêtementséloignés 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 ISSUESCONSIGNES DE SÉCURITÉ DE FONCTIONNEMENT

Your dynamometer comes standard with “Drop-In” style Restraints. One is for the left wheeland the other for the right wheel. The “Drop-In” style restraints are for ASM 50/15 and ASM25/25 testing ONLY. The maximum speed for the “Drop-In” style restraints are 25 MPH. Priorto performing an ASM 50/15 or ASM 25/25 test, ensure the “Drop-IN” style restraints areproperly positioned and rubber wheel chocks are placed in the appropriate places of the non-drive axle.

For ALL other types of testing, use chains, straps, Ratchet binders or strap ratchet binders ofsuitable size with floor anchors and wheel chocks to safely perform testing. Be careful not over-tension 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 of3/8” diameter chain with 3/8” Ratchet binders. For front wheel drive vehicles, two chains andbinders should be used to restrain the front axle and a minimum of one chain/binder for the rearaxle. 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 engineexhaust can be deadly. Do not operate your dynamometer without proper ventilation. Theventilation system should provide four (4) air changes an hour in the shop and six (6) airchanges an hour for the pit.

Dégazer les échappements du moteur ... Fournir une aération adéquate de la pièce. Uneconcentration élevée de gaz d’échappement du moteur peut être mortelle. Ne pas faire fonctionnerle 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 lafosse.

Monitor Carbon Monoxide ... Make sure you have installed a carbon monoxide monitor in thedynamometer bay.

Contrôler le niveau d’oxyde de carbone ... S’assurer d’avoir installé un contrôleur d’oxyde decarbone dans la baie du dynamomètre.

Guarding ... Provide floor markings and protective guard railings for customer/operatorprotection. NEVER operate the dynamometer with any cover panels removed unless specificallydirected to do so elsewhere in this manual.

Barrières de protections ... Prévoir un marquage au sol et des rails de protection des clients etdes opérateurs. NE JAMAIS faire fonctionner le dynamomètre avec des panneaux de protectiondéposés sauf instructions contraires spécifiques ailleurs dans ce manuel.

Keep Clear of Rolls ... Stay away from the rolls when in operation.

Rester éloigné des rouleaux ... Rester éloigné des rouleaux pendant le fonctionnement.

Check Tires ... Before driving the test vehicle onto the dynamometer, be sure to check thevehicle’s tires for proper inflation. Inspect the tires for any signs of damage and remove anyembedded objects from the tread.

Contrôler les pneus ... Avant de conduire le véhicule d’essai sur le dynamomètre, s’assurer queles pneus du véhicule soient bien gonflés. Inspecter les pneus en recherchant les signes dedommages et retirer tout objet incrusté dans la bande de roulement.

Restrain Vehicle Movement ... During dynamometer operation, make sure that the restraintsare in position.

Empêcher le mouvement du véhicule ... Pendant le fonctionnement du dynamomètre, s’assurerque 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 1,20mètres 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 adrive-cycle test. Do NOT attempt to get in or out of the vehicle when the dynamometer rolls aremoving.

Rester assis ... Le conducteur du véhicule DOIT rester en permanence assis sur le siège duconducteur pendant un essai de cycle de conduite. NE PAS essayer de rentrer ni de sortir duvéhicule lorsque les rouleaux du dynamomètre sont en fonctionnement.


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If in Doubt, STOP! ... Stop the equipment immediately if you have any doubt about the safeoperating condition of the dynamometer and/or the correctness of any procedures that you areperforming.

En cas de doute ARRÊTER! ... Arrêter l’équipement immédiatement en cas de doute sur lasûreté des conditions de fonctionnement du dynamomètre ou sur la validité des procédureseffectuées.

1.4 MAINTENANCE SAFETY ISSUESCONSIGNES DE SÉCURITÉ D’ENTRETIEN

Electrical Shock Hazard ... Turn off electrical service to the system before performing anymaintenance activity. Turn off the main breaker in your breaker box before working on anythingrelated to the PAU or motor.

Risque d’électrocution ... Couper l’alimentation électrique du système avant d’effectuer touttravail d’entretien. Couper le disjoncteur principal du boîtier de disjoncteurs avant de travailler surtout élément relatif au PAU ou au moteur.

No Jewelry ... Remove any jewelry before performing any electrical or mechanicaltroubleshooting, repair, etc. on the dynamometer.

Pas de bijou ... Retirer les bijoux avant d’effectuer tout dépannage électrique ou mécanique, touteréparation, etc. sur le dynamomètre.

Cover Panels ... Use extreme caution around drive mechanisms and moving parts whenoperating the dynamometer with any of its cover panels removed from the chassis assembly.

Panneaux de protection ... Être très prudent à proximité des mécanismes d’entraînement et despièces en mouvement lors de l’utilisation du dynamomètre avec un de ses panneaux de protectiondéposé du châssis.

Avoid Straining Yourself ... Be careful when lifting dynamometer cover panels. Be carefulwhen replacing belts, couplings, or bearings.

Éviter les élongations ... Être prudent lors du levage des panneaux de protection dudynamomètre. Être prudent lors du remplacement des courroies, des accouplements, ou despaliers.

Air Pressure ... Make sure that there is no shop air to the dynamometer when working on liftplates or air bags.

Pression d’air ... S’assurer qu’il n’y ait pas d’alimentation en air sous pression de l’atelier sur ledynamomètre 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 supplyis connected to the dynamometer.

Attention aux mains ... Ne jamais mettre les mains entre les plaques de levage et les rouleauxlorsque 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.

JAMAIS, JAMAIS, JAMAIS! ... Ne jamais tirer sur la courroie d’entraînement pour fairetourner les rouleaux.

Check Tightness ... Make sure that all bolts on the dynamometer are tight and all couplings areproperly secured.

Vérifier le serrage ... S’assurer que tous les boulons du dynamomètres soient serrés et que tousles accouplements soient correctement bloqués.


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1.5 ENVIRONMENTAL DATAThis 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 DATAThe 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 recommendedthat the circuit breaker be located in close proximity to the dynamometer, at minimum, withinthe same room.

Installation and mounting hardware are provided with every Dynamometer and shall be usedregardless 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” Openend 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 thunderstudand 7” deep for 7” thunderstud per MD DWG # 20014882. Ensure holes are clean of any debrisprior to attempting installation of Thunderstud. Place Dynamometer into pit or onto floor atinstallation site. Check level of dynamometer, use flat steel shim stock (customer supplied) asnecessary to level dynamometer to floor. Level dynamometer in two planes; (1) Place level on topof rolls parallel with a roll and (2) place level across a front roll and rear roll. Shim unit bypositioning 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 ofdynamometer. The air bag channel must be supported at this location. Using provided anchorfoot, MD # 20001704, drawing attached, insert thunderstud with flat washer and nut attached intoanchor foot and hole previously drilled into concrete. Using hammer, pound thunderstud into holeuntil 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 bearingsupport 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 DATAThe nameplate on the dynamometer frame contains valuable information should it be necessary tocontact Mustang. Besides the model number, date manufactured, and revision level data, thenameplate contains the dynamometer serial number. Have this number handy when contactingMustang Dynamometer.

1.8 IF YOU NEED HELP


MUSTANG DYNAMOMETER


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

Mustang Dynamometer2300 Pinnacle Parkway

Twinsburg, Ohio 44087USATelephone:(330) 963-5400

Fax: (330) 425-3310


MUSTANG DYNAMOMETER


SECTION

PREVENTIVE MAINTENANCE

CONTENTS

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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MUSTANG DYNAMOMETER


2.1 INTRODUCTION

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

Table 2.1 LIST OF RECOMMENDED TOOLS

ITEM USE ON(2) 1-1/8-inch combinationwrenches

Brake Pad replacement

15/16-inch socket15/16-inch wrench

1-3/4 and 2-inch Pillow Block Bearing BoltsPAU Bracket BoltsIdler Attachment Bolts


1-1/2-inch Pillow Block Bearing BoltsLarge Roll Pulley BoltsLoad Cell Mounting Bolts


Motor Mounting BoltsAir Bag Mounting Bolts (Two)

7/16-inch socket Motor Pulley Bushing BoltsSmall Roll Pulley BoltsLimit Switch Bracket Bolts

1/8-inch Allen wrench Coupling set screws9/64-inch Allen wrench Speed sensor3/32-inch Allen wrench Small Pulley Bushing and Coupling Set Screws5/32-inch Allen wrench 1-1/2-inch Pillow Block Bearing Set Screws3/16-inch Allen wrench 1-3/4 and 2-inch Pillow Block Bearing Set Screws1/4-inch Allen wrench PAU Pulley Bolts (ESP30184-9 and -11)1/4-inch, 12-point, deep socket PAU Pulley Bolts (ESP30184-1, -6, -7 and -8)7/32-inch Allen wrench Air Bag Mounting Bolts (Four)Torque wrench, 0-250 inch-pounds. Torque MeasurementsTorque wrench, 0-100 foot-pounds. Torque MeasurementsPipe wrench Brake Pad replacementFeeler gauges Speed SensorBelt Tension Tester Belt TensionStraight Edge Belt TensionDigital Multi-Meter Electrical signals and connections

Table 2.2 LIST OF CONSUMABLE ITEMS

Item Mustang Part Number Designation

Coupling Grease 20010651 Mobil Mobilith AW 2PAU Grease 20010651 Mobil Mobilith AW 2Bearing Grease 20014314 Polyrex EMBrake Cleaner 20014315 Brake cleanerThread Lock 20010654 Locktite 262Teflon Tape 20014810 1/4-inch Teflon tape

2.2 PREVENTIVE MAINTENANCE


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

Table 2.3Preventive Maintenance Time Table

Maintenance ProcedureInitial

StartupInspections

EveryThree

Months

EverySix

Months

EveryTwelveMonths

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


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Bearings and couplings must be lubricated withrecommended lubricants. Lubricants must be fresh andfree from contamination. Failure to lubricate or to useincorrect or contaminated lubricants will result in reducedlife expectancy and/or damage to bearings and couplings.

Too much grease can change parasitic losses of thedynamometer and will cause overheating of roll and PAUbearings in high-speed operation of the dynamometer.

ATTENTION

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

Trop de graisse peut modifier les pertes parasites dudynamomètre et causer une surchauffe des paliers derouleau et de PAU lors du fonctionnement à haute vitessedu dynamomètre.

Adequate lubrication is essential for satisfactory operation of the dynamometer. Lubrication ofthe dynamometer pillow block bearings, couplings, and PAU should be done as a part of aplanned maintenance schedule. The recommended lubrication intervals in the PreventiveMaintenance Time Table should be used as a guide to establish this schedule. These intervalsare based on 24 hours of actual machine usage per week. For extreme or unusual operatingconditions, 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 potentialcontaminants.

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 thefitting and add three grams of grease while rotating the dynamometer rolls by hand. Experimentwith 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 vehicleproperly 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 ofthe holes.

Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the greasefitting 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 - DONOT 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 withTeflon tape, and reinstall.

Remove excess grease.

2.3.3 LUBRICATE PAUThe zerk fitting is located on the bottom of the stator frame. Wipe off any dirt or othercontaminates that may be on the grease fitting.

Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the fittingand add twenty (20) grams of grease while rotating the PAU by hand. Experiment with yourparticular grease gun to determine how many pumps equate to twenty grams of grease. It shouldbe 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 fittingand add eight grams of grease while rotating the motor by hand. Experiment with yourparticular grease gun to determine how many pumps equate to eight grams of grease. It shouldbe roughly equivalent to eight pumps using a normal grease gun.

2.4 INSPECTION

Table 2.4 Torque ChartDescription Bolt

SizeSocket/KeySize

Qty.

Torque

1-1/2-inch Pillow Block BearingSet Screws

5/16-24

5/32 Allen 14 140 inch-pounds.

1-3/4-inch and 2-inch PillowBlock Bearing Set Screws

3/8-24 3/16 Allen 6 250 inch-pounds.

Coupling Set Screws 1/4-28 1/8 Allen 8 75 inch-pounds.Coupling Set Screws (ModelsESP30184-12 and –13)

10-32 3/32 Allen 4 30 inch pounds

1-1/2-inch Pillow Block BearingBolts

1/2-13 3/4 14 50 foot-pounds.

1-3/4-inch Pillow Block BearingBolts

5/8-11 15/16 2 70 foot-pounds.

2-inch Pillow Block Bearing Bolts 5/8-11 15/16 4 70 foot-pounds.PAU Bracket Bolts 5/8-11 15/16 4 70 foot-pounds.PAU Pulley Bolts (ModelsESP30184-9 and –11)

5/16-18

1/4 Allen 3 220 inch-pounds.Refer to procedurefor torque method.


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Table 2.4 Torque ChartDescription Bolt

SizeSocket/KeySize

Qty.

Torque

PAU Pulley Bolts (ModelsESP30184-1, -6, -7, and –8)

1/4-20 1/4 12 Point 3 220 inch-pounds.Refer to procedurefor torque method.

PAU Pulley Set Screws (ModelsESP30184-12, –13, -18, andESP30556-1)

3/8-24 3/16 Allen 2 250 inch-pounds

Motor Mounting Bolts 3/8-16 9/16 8 30 foot-pounds.Motor Pulley Bolts 1/4-20 7/16 2 9 foot-pounds.Large Roll Pulley Bolts 1/2-13 3/4 3 60 foot-pounds.Small Roll Pulley Bolts 1/4-20 7/16 3 9 foot-pounds.Small Pulley Bushing set screw #10-24 3/32 Allen 1 60 inch-pounds.Idler Attachment Bolts 5/8-11 15/16 2 70 foot pounds.Restraint Limit Switch BracketBolts

1/4-20 7/16 2 9 foot-pounds.

Air Bag Mounting Bolts (center) 3/8-16 9/16 2 30 foot-pounds.Air Bag Mounting Bolts(outboard)

3/8-16 7/32 Allen 4 15 foot-pounds.

Load Cell Bolts 1/2-13 3/4 4 50 foot-pounds.

2.4.1 INSPECT PILLOW BLOCK BEARINGS

NOTEThree different size pillow block bearings are used. 1-1/2-inchbearings 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 two2-inch bearings are used on the drive end of the rolls.

REMARQUETrois différentes dimensions de palier à chapeau sont utilisées. Lespaliers de 1-1/2 pouces sont utilisés en six emplacements sur lesrouleaux et en un sur le PAU. Un palier de 1-3/4 pouce est utilisé surl’autre extrémité du PAU et deux paliers de 2 pouces sont utilisés surl’extrémité d’entraînement des rouleaux.

Using a torque wrench with a 3/4-inch socket, check that the 1-1/2-inch roll bearing mountingbolts are torqued to 50 foot-pounds.

If bolts are loose, remove bearing mounting bolts and bearing plate, clean threads with brakecleaner, apply a few drops of Locktite 262, reassemble plate and bolts and torque to 50 foot-pounds.

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 setscrews, 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 pillowblock 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 brakecleaner, apply a few drops of Locktite 262, reassemble plate and bolts and torque to 70 foot-pounds.

Using a 3/16-inch Allen wrench, check to make sure all bearing set screws are tight.


Using a 7/16-inch open end wrench, make sure the temperature probes are securely screwed intothe bearing housings.

Check the temperature probe wires to make sure they are secure and do not rub against anymoving 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 makesure 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 setscrew in each rigid hub is tight. Using a 1/8-inch or 3/32-inch Allen wrench (one or the otherwill be present), check to make sure the set screw in each flex hub is tight (four couplingassemblies).

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-inchAllen wrench.

2.4.3 INSPECT BRAKE PADS

WARNINGMake sure that the air lift will not be accidentally raisedwhile performing this inspection. Failure to turn off shopair after lowering the lift plate may allow the lift plate toraise and cause injury.

AVERTISSEMENTS’assurer que le levage pneumatique ne soit pas levéaccidentellement pendant cette inspection. Ne pas couperl’alimentation pneumatique de l’atelier après avoir abaisséla plaque de levage peut laisser la plaque de levage monteret 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


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Visually inspect the toothed drive belt to ensure that there are no signs of wear, damage, ordeterioration. The belt should have a snug fit, neither too taut nor too loose. Observe the beltduring 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 thismanual 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, ordeterioration. 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 thismanual 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 aretorqued 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 aretorqued 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 boltsare 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 MODELESP30556-1)

Using a torque wrench with a 3/16-inch Allen wrench, check that the two set screws on the PAUpulley are torqued to 250 inch-pounds.


2.4.10 INSPECT ROLL PULLEY BOLTS

Using a torque wrench with a 3/4-inch socket, check that the three (3) large roll pulley bolts aretorqued to 60 foot-pounds.


Using a torque wrench with a 7/16-inch socket, check that the three (3) small pulley bolts aretorqued to 9 foot-pounds.

INSPECT ROLL PULLEY BOLTS (CONTINUED)


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Using a 3/32-inch Allen wrench, check to make sure all set screws in the small pulley bushingare tight.


2.4.11 INSPECT MOTOR MOUNTING BOLTS

Using a torque wrench with a 9/16-inch socket, check that the four (4) motor swivel base framemounting bolts and the four (4) motor base to motor swivel base bolts are torqued to 30 foot-pounds.


2.4.12 INSPECT MOTOR PULLEY BOLTS

Using a torque wrench with a 7/16-inch socket, check that two (2) motor pulley bolts aretorqued to 9 foot-pounds.


2.4.13 INSPECT IDLER ATTACHMENT BOLTS

Using a torque wrench with a 15/16-inch socket, check that the two (2) idler attachment boltsare torqued to 70 foot-pounds.

If bolts are loose, refer to the service section of this manual for idler and belt serviceinstructions.

2.4.14 INSPECT RESTRAINT LIMIT SWITCH ASSEMBLY

Using a torque wrench with a 7/16-inch socket, check that the two (2) restraint limit switchbracket bolts are torqued to 9 foot-pounds.


Make sure wire connections are secure and switch is adjusted properly.

2.4.15 INSPECT LIFT ASSEMBLY

Using a torque wrench with a 7/32-inch Allen wrench bit, check that the four outboard air bag-to-lift plate attachment bolts (two per end) are torqued to 15 foot-pounds.


Using a torque wrench with a 9/16-inch socket, check that the two (2) center air bag attachmentbolts are torqued to 30 foot-pounds.


2.4.16 INSPECT AIRBAGS


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Remove the lift plates and visually inspect the airbags for any wear, cracks, or dry rot. If airbags need replacement, refer to the service section of this manual.

2.4.17 INSPECT 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.

2.4.18 INSPECT PAU LOAD CELL ASSEMBLY

Place a small level on top of the PAU bracket and make sure the PAU is level. If necessary,level the PAU using a 3/4-inch wrench to remove the mounting bolt and adjusting the rod endassembly 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 istorqued 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 mountingbolts 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 endwrench on one of the bolts.

Make sure load cell and PAU are not touching each other.

2.4.19 INSPECT SPEED SENSOR ASSEMBLIES

Verify that the primary speed sensor is snug. If it is loose, refer to the service section of thismanual. Note: the notch must face up.

Using feeler gauges verify that the spacing between the primary speed sensor and the top of thepulley 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 thismanual.

Using feeler gauges verify that the spacing between the secondary speed sensor and the top ofthe pulley teeth is between 0.020 and 0.030 inches.

2.4.21 INSPECT AND CLEAN THE DYNAMOMETER, FRAME, CONTROL 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.


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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 fewdrops of Locktite 262 on the threads, and torque to the specified value.

CAUTIONDo not use pressurized water or compressed air to cleanthe dynamometer. Using pressurized cleaning techniquescan force contaminants into bearings and cause bearingfailure.

ATTENTIONNe pas utiliser d’eau pressurisée ni d’air sous pressionpour nettoyer le dynamomètre. Utiliser des techniques denettoyage sous pression peut forcer l’entrée de polluantsdans les paliers et entraîner des défaillances des paliers.

INSPECT AND CLEAN THE DYNAMOMETER, FRAME, CONTROL BOX, AND PIT (CONTINUED)

Clean the dynamometer using a cloth that has been lightly wetted with water or a mild soapsolution.

CAUTIONPay special attention to the air bags and the areasurrounding them. A build-up of dirt in this area can causewear and premature air bag failure.

ATTENTIONFaire particulièrement attention aux sacs gonflables et à lazone qui les entoure. Une accumulation de saleté danscette zone peut entraîner de l’usure et une défaillanceprématurée du sac gonflable.

After cleaning the dynamometer, use an anticorrosive spray on all exposed metal to preventdamage from rust or corrosion.

Clean the pit of all foreign objects and debris. Use a small paint scraper to loosen any built-updirt. Use a small vacuum cleaner to pick up any smaller debris. Wipe clean any excessive greasethrown from moving parts.

Make sure the drains are clear.

Clean the inside of the control box 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

CONTENTS

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 MustangDynamometer OBD Series Chassis Dynamometers. Disassemble the dynamometer only to thelevel needed for repair. Most maintenance and service procedures are similar for all modeldynamometers. Specific procedures for some model numbers are given. Refer to Figure 3.1 forthe locations of major components. Refer to Table 3.1 for a list of special tools. Refer to Table3.2 for a list of consumable items.

TABLE 3.1 LIST OF SPECIAL TOOLS

ITEM USE ON

Belt Tension Testing Tool. Mustangpart 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 LIST OF CONSUMABLE ITEMS

ITEM MUSTANG PART NUMBER DESIGNATION

Coupling Grease 20010651 Mobil Mobilith AW 2PAU Grease 20010651 Mobil Mobilith AW 2Bearing Grease 20014314 Polyrex EMBrake Cleaner 20014315 Brake cleanerThread Lock 20010654 Locktite 262Teflon 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 Allenwrench. Remove the center cover plate from the dynamometer. Remove PAU/Inertia weightcover 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-inchAllen wrench and removing the cover. If necessary, remove the frame endcap plate from thePAU side by removing the sheet metal screws and plate using a screwdriver. Clean fastenerswith brake cleaner before installation.

To replace covers, locate covers and plates with existing hardware and using a torque wrenchwith a 5/16-inch Allen wrench, torque all hardware to 30 foot-pounds.

NOTEBefore replacing covers, inspect and clean the frame and pit andperform an operational check of the dynamometer.

REMARQUEAvant de remplacer les panneaux de protection, inspecter et nettoyerle châssis et la fosse et effectuer un contrôle optionnel dudynamomètre.

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, removethe 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 thegreen hub on the press lock fittings and pulling out the air line. Slide the belt off the PAU pulleyand gently slide the belt over the flanges on the roll pulleys. Clean idler assembly bolts withbrake cleaner.

TABLE 3.3DRIVE

BELTSESP PART NUMBER MUSTANG PART NUMBER

ESP30184-1, -6, -7 20013412

ESP30184-9, -11 20013999

ESP30184-12, -13, -18

ESP30556-1

20014659

Refer to Table 3.3 for replacement drive belt part numbers. To replace the drive belt slide thebelt over the flanges of the roll pulleys and then gently slide it over the flanges of the PAUpulley. Push belt in the slack area so it is snug around the pulleys. Confirm that the belt is


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properly engaged on the three pulleys. The belt must not come in contact with any of the frameparts or interfere with the air lines.

Apply a few drops of Loctite 262 to the clean threads of the two (2) idler attachment bolts, andinstall the idler assembly and bolts using a 15/16-inch socket wrench. Replace any shims thatwere present. Using a torque wrench with a 15/16-inch socket, torque the bolts to 70 foot-pounds.

REMOVE AND REPLACE IDLER ASSEMBLY AND DRIVE BELT (CONTINUED)

CAUTIONThe drive belt must be correctly aligned before operation of thedynamometer. Improper alignment of the drive belt can result indamage to the belt, pulleys, and bearings.

ATTENTIONLa courroie d’entraînement doit être correctement alignée avant lamise en fonctionnement du dynamomètre. Un mauvais alignementde la courroie d’entraînement peut entraîner des dégâts de lacourroie, des poulies et des paliers.

Rotate the belt by moving the rolls by hand. Inspect the belt for damage and insure belt does notride on the edges of the pulleys. The belt may walk from side to side and may change directionwhen rotated in the opposite direction. If the belt rides excessively on one edge of the pulleyflanges, shim the idler arm as necessary to align the belt. If the belt moves toward the flange inone direction and toward the other flange when rotated in the other direction but does not rideon 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 armand the frame. Always install the same number of shims on both sides of the arm. Put shims onthe top of the idler arm to move the belt away from the PAU. Put shims on the bottom to movethe belt toward the PAU.

Reconnect the air lines by sliding the air line into the fitting. To check for air leaks turn on theshop 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, Mustangpart number 20014355 (ESP30402-1), and Dynamometer Drive Belt Adjustment Bar, ESP10644-1.

Lower the lift plate so the dynamometer rolls are free to turn. The lift must be lowered to obtainthe correct belt tension measurements.

WARNING

Make sure the dynamometer cannot be operatedwhile the belt tension is being adjusted. Severeinjury can occur if the power is applied to thedynamometer during this procedure.

AVERTISSEMENT


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S’assurer que le dynamomètre ne puisse pas êtreutilisé pendant que la tension de la courroie estréglée. Des blessures graves peuvent se produire sil’alimentation est appliquée sur le dynamomètrependant cette procédure.

Turn the dynamometer power to OFF. Remove the belt drive access cover if not alreadyremoved.

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 tothe “25” mark on the body of the tool (about 3/8-inch from the end of the tool). Set the small O-ring 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 ofthe tension tester to the “15” mark on the body of the tool (about 1/4-inch from the end of thetool). 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 ofthe belt. With the tension tester positioned in the correct alignment tool hole and perpendicularto the alignment bar, push on the tension tester and deflect the belt until the large O-ring justcontacts the alignment bar. Release pressure and read pounds of force at the O-ring on theplunger. 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, -18ESP30556-1, OBD DYNES

15 Pounds

DRIVE BELT TENSIONING (CONTINUED)

CAUTION

Do not apply too much tension to the drive belt. Toomuch tension on the drive belt can result in damageto the belt, pulleys, and bearings.

ATTENTIONNe pas appliquer trop de tension sur la courroied’entraînement. Trop de tension sur la courroied’entraînement peut entraîner des dégâts de lacourroie, des poulies et des paliers.

Tighten the belt by loosening the two idler bolts using a 15/16-inch wrench, loosening theadjustment stop bolt, and tightening the adjustment nut. Be sure to torque the idler mountingbolts 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 adjustmentscrew 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 longextension remove the four (4) motor mounting bolts, flat washers, and lock washers. Cleanhardware with brake cleaner prior to installation.

To replace the motor assembly place the motor on the motor support plate. Apply a few drops ofLoctite 262 to the threads of the four (4) motor mounting bolts and insert them with flat washersand lock washers into the motor and motor mounting plate. Swivel the motor for access to thebolts and using a torque wrench with a 9/16-inch socket and extension torque the motormounting 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 tensionmeasurement tool, ESP30402, and a straight edge. Set the large O-ring on the body of thetension tester to 1/4-inch from the end of the body. Set the small O-ring on the plunger againstthe body of the tension tester. Place the straight edge on the belt. With the tension tester in themiddle of the belt and perpendicular to the span, push on the tension tester and deflect the beltuntil the large O-ring is in line with the straight edge. Release pressure and read pounds of forceat 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 longextension to tighten the adjustment screw on the motor pivot plate below the motor. Apply afew drops of Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end


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

METHOD 2 – Check the tension of the motor belt by running a dynamometer calibrationsequence. If the belt slips during the test, tighten it using a 9/16-inch socket and long extensionto tighten the adjustment screw on the motor pivot plate below the motor. Apply a few drops ofLoctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end wrench tightenthe 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 thethumb and index finger. Attempt to twist the belt. Properly adjusted, the belt should easily rotatebetween 90 and 180 degrees. Tighten the belt, if necessary, using a 9/16-inch socket and longextension to tighten the adjustment screw on the motor pivot plate below the motor. Apply afew drops of Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open endwrench tighten the adjustment screw jam nut. Apply a few drops of Loctite 262 to the threads ofthe 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 removethe two (2) 1-1/2-inch pillow block bearing mounting bolts, flat washers, lock washers, and nutsfrom the rear end of the dynamometer. Using a 15/16-inch socket wrench and 15/16-inch openend 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 alltraces of Loctite prior to installation.

FIG 3.3PAU


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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 a9/16-inch wrench. Do not remove both bearing stop screws from any bearing.

REMOVE AND REPLACE PAU ASSEMBLY (CONTINUED)

WARNINGThe PAU assembly is extremely heavy. Be sure the PAUassembly is properly supported when removing it from theframe. Failure to observe these precautions may result indamage to equipment, injury to personnel, or both.

AVERTISSEMENTL’ensemble PAU est extrêmement lourd. S’assurer quel’ensemble PAU soit correctement supporté lors de sadépose du châssis. Ne pas observer ces précautions peutentraîner des dégâts de l’équipement, des blessures dupersonnel, ou les deux.

Using proper lifting equipment remove the PAU. Note and mark the location of any shimslocated under the bearings. The shims must be replaced in the same position when the PAU isreplaced. 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. Thepulley should be loose on the pulley bushing.

To replace the PAU, place the PAU and any shims that were installed under the PAU bearingson top of the frame. Make sure the load cell bracket is facing upward. Apply a few drops ofLoctite 262 to the clean threads of two (2) 5/8-11 x 4-1/2-inch bolts (5/8-11x 5-1/2-inch boltsfor models ESP30184-12 , –13 and -18) and insert them with flat washers into the 1-3/4-inchpillow block bearing mounting holes at the pulley end of the PAU. Apply a few drops of Loctite262 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 formodels ESP30184-12, –13, and -18) and insert them with flat washers into the 1-1/2-inch pillowblock 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 bothends of the PAU and lightly screw in the bolts. Do not torque the bolts at this time. Snug up thebearing 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 theload cell. Do not torque the bolts at this time. Make sure the load cell is vertical on the outboardside 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 flaton top of the inertia weight and on top of rolls #3 and #4. Note the position of the bubble on thelevel. The bubble on the level should be in the same position for all three locations. If thealignment is not level then shim the PAU or roll as necessary by placing shim stock under theroll or PAU bearings.

Refer to Figure 3.4 and verify the alignment of the PAU to the rolls by placing a square betweenthe face of the inertia weight and roll #4. Visually inspect the alignment. If the PAU is notsquare loosen the jam nuts and use the bearing stop screws on the PAU bearings to set thesquare flat to the PAU.

Recheck the PAU alignment using the square. Realign if necessary.


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FIG 3.4PAU ALIGNMENT

Using a torque wrench with a 3/4-inch socket and a 3/4-inch open end wrench torque the 1-1/2-inch pillow block bearing mounting bolts at the end of the PAU to 50 foot-pounds. Using atorque wrench with a 15/16-inch socket and a 15/16-inch open end wrench torque the 1-3/4-inchpillow block bearing mounting bolts at the pulley end of the PAU to 70 foot-pounds. Tightenthe bearing stop screws and fully tighten the jam nuts. Apply a few drops of Loctite 262 to thethreads 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 50foot-pounds.

PAU PULLEY INSTALLATIONNOTE

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 holeswith brake cleaner to remove any contaminates that may interfere inthe assembly.

REMARQUENe pas utiliser de lubrifiants dans cette installation. Inspecter l’arbrede PAU, le coussinet et le moyeu apparié. Retirer toutes les encoches,la peinture, la saleté, la graisse, etc. des surfaces de contact. Laver ouessuyer le cône de roulement et les trous taraudés avec un produit denettoyage de frein pour retirer tous les polluants qui peuventinterférer dans l’assemblage.


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FIG 3.5PAU PULLEY INSTALLATION

CAUTIONDo not exceed torque limits. Too much torque to thepulley/bushing assembly will cause damage to theassembly.

ATTENTIONNe pas excéder les limites de couple. Un couple trop élevésur la poulie et le coussinet entraînera des dégâts del’ensemble.

For models ESP30184-1, -6, -7 and -8, apply a few drops of Loctite 262 to the key and installthe key into the keyway in the shaft. Slide the cleaned bushing onto the shaft and key. The smallend of taper must be outboard. Slide the cleaned tapered pulley over the bushing. First, align theshaft key with one of the slots in the mating hub and second, align the drilled holes in themating pulley with the threaded holes in the bushing. Clean the pulley bolts with brake cleanerif necessary to remove any lubricants. Apply a few drops of Loctite 262 to the clean threads ofthe pulley bolts and insert one bolt through each drilled hole in the mating hub and into thethreaded hole of the bushing. Do not use a lockwasher. NOTE: Once the pulley bolt with Loctiteapplied has started to be installed, the process must be completed before the Loctite cures toensure a true torque reading.

Refer to Figure 3.5 and using a straight edge and ruler, align the bushing and pulley so there is a3/16-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 thefirst pulley bolt to 140 inch-pounds. Torque the second pulley bolt and then the third. Repeatthis step two more times. Second, torque the first pulley bolt to 180 inch-pounds. Torque thesecond pulley bolt and then the third. Repeat this step two more times. Finally, torque the firstpulley bolt to 220 inch-pounds. Torque the second pulley bolt and then the third. Repeat thisstep two more times.


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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 keyinto the keyway in the shaft. Slide the cleaned bushing onto the shaft and key. The small end oftaper must be outboard. Slide the cleaned tapered pulley over the bushing. Align the drilledholes in the mating hub with the threaded holes in the bushing. Clean the pulley bolts with brakecleaner if necessary to remove any lubricants. Apply a few drops of Loctite 262 to the cleanthreads of the pulley bolts and insert one bolt and lockwasher through each drilled hole in themating hub and into the threaded hole of the bushing. NOTE: Once the pulley bolt with Loctiteapplied has started to be installed, the process must be completed before the Loctite cures toensure a true torque reading. Slide the bushing on to the shaft so it is flush with the shaft. Usinga torque wrench with a 1/4-inch Allen wrench, tighten all pulley bolts evenly and progressivelyin rotation. First, torque the first pulley bolt to 140 inch-pounds. Torque the second pulley boltand then the third. Repeat this step two more times. Next, torque the first pulley bolt to 180inch-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 thenthe third. Repeat this step two more times.

For models ESP30184-12, -13, -18, and ESP30556-1 no bushing is used. Apply a few drops ofLoctite 262 to the key and install the key into the keyway in the shaft. Slide the PAU pulleyover the shaft and key and using a square or straight edge, align the PAU pulley with the rollpulley. Apply a few drops of Loctite 262 to the threads of the two set screws and using a torquewrench 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 placeand 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 clampscrew and slide the sensor through the clamp. Secure it using a 9/64-inch Allen wrench. Usingfeeler gauges set the spacing between the primary speed sensor and the top of the pulley teeth tobetween 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 jamnuts, slide the sensor through the bracket, and secure it using two 3/4-inch wrenches to set thejam nuts. Using feeler gauges set the spacing between the secondary speed sensor and the top ofthe pulley teeth to between 0.020 and 0.030 inches

FIG 3.6


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SPEED SENSORS

Fig 3.7COUPLING DETAILS(ESP30184-1, -6, -7, -8, -9, -10, -11, -18, AND ESP30556-1)


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Fig 3.8COUPLING 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 asmall flat edged screwdriver insert the screwdriver in the notch of the steel snap ring and gentlypry the end of the ring out of the ring groove. Continue removing the ring from the sleeve usinga spiral motion.

Slide sleeve off flex hub toward the center of the inner shaft. Repeat this procedure to removethe other coupling sleeve. Remove inner shaft.

REPLACEMENT

To install the inner shafts inspect the shaft, sleeve and hub for nicks, dirt, grease, etc. Cleanwith 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 onboth 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 oneof the holes. Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the guninto the grease fitting and pump the handle until grease comes out the other hole. Make sure thatno grease seeps out through the O-rings or seals. If grease runs through the O-rings or sealsreplace the O-rings or seals.

Remove the grease fitting and replace both grease plugs. Tighten the plugs until they are snugand 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 couplingsleeves and using a torque wrench with a 1/8-inch Allen wrench torque the set screws to 75inch-pounds.

3.2.6 REMOVE, REPLACE, AND ALIGN ROLLS

NOTE: Rolls are aligned and bearing stops are set at the factory. Do not remove or replace rollsunnecessarily. Remove only those components necessary for service. When replacing rolls, donot loosen any bearing stop screws unless specifically instructed to do so.

WARNINGThe roll assemblies are extremely heavy. Be sure the rollassemblies are properly supported when removing themfrom the frame. Failure to observe these precautions mayresult in damage to equipment, injury to personnel, orboth.

AVERTISSEMENTLes rouleaux sont extrêmement lourds. S’assurer que lesrouleaux soient correctement supportés lors de leurdépose du châssis. Ne pas observer ces précautions peutentraîner des dégâts de l’équipement, des blessures dupersonnel, ou les deux.

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

ATTENTIONLes rouleaux doivent être correctement alignés pour lefonctionnement à haute vitesse. Un mauvais alignementdes rouleaux peut entraîner une mauvaise performance del’équipement ainsi qu’une défaillance prématurée descomposants.

Remove idler assembly and drive belt. Refer to Remove and Replace Drive Belt and IdlerAssembly. Remove speed sensors. Refer to Remove and replace Speed Sensors. Remove innershafts. Refer to the Remove and Replace Inner Shafts. Remove motor belt if necessary. Refer tothe 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 ofthe dynamometer, away from the restraint tubes. All alignment measurements are made withreference to roll #3.


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FIG 3.9ROLL 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 the2-inch pillow block located between the two bearings using a 9/16-inch open end wrench. Usinga 3/4-inch socket wrench remove the bearing mounting bolts, lock washers, flat washers, andbearing 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, andbearing 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 ofLoctite using a 1/2-13 die for the 1-1/2-inch bearings or a 5/8-11 die for the 2-inch bearings.

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

AVERTISSEMENTLes rouleaux sont extrêmement lourds. S’assurer que lesrouleaux soient correctement supportés lors de leurdépose du châssis. Ne pas observer ces précautions peutentraîner des dégâts de l’équipement, des blessures dupersonnel, ou les deux.

Using suitable lifting equipment remove the roll(s) from the frame.

ROLL REMOVAL (ROLLS #1 AND #2)


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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 the1-1/2-inch pillow block bearings. Clean all hardware with brake cleaner and chase threads ifnecessary 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 3.10BEARING STOPS

ROLL REPLACEMENT (ROLLS #1 AND #2)Using suitable lifting equipment set both rear rolls, roll #1 and roll #2 in place with the couplinghubs facing the center of the dynamometer. Apply a few drops of Loctite 262 to the cleanthreads of two (2) 1/2-13 x 3-inch bolts and insert them with lock washers and flat washers intoeach pillow block bearing. Hold the bearing plates under the bearing support tubes and start thebolts 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 thebearing.

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


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ROLL ALIGNMENT

Rolls are aligned at the factory. When replacing rolls extensive realignment may not benecessary. 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), betweenrolls #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 theshaft should be 5-1/2-inches from the inner wall of the frame at both ends of the roll. Ifnecessary 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 frontof the bearing support. For models ESP30184-1, -6, -7, and –8 set the distance to between 1/16and 1/8 inches. For models ESP30184-9, –11, -12, and -13 set the distance to between 3/4 and1-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 theroll shafts should be 17 inches at both ends of the roll. If necessary align roll using the bearingstop bolts to move the roll bearings.

FIG 3.12ROLL 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 placingthe four point pulley alignment tool, Mustang part number 20014354 (see Appendix), across thepulley 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 rolland none on the other roll, adjust one of the rolls using a small pry bar so that all four pointstouch. If three points touch, adjust roll #4 using the bearing stop screws to move the roll so allfour points touch.

Using a torque wrench with a 3/4-inch socket torque the 1-1/2-inch pillow block bearingmounting bolts to 50 foot-pounds on rolls #3 and #4. Using a torque wrench with a 15/16-inchsocket torque the 2-inch pillow block bearing mounting bolts to 70 foot-pounds. Recheck thefour-point alignment. Realign if necessary. Set the jam nuts on the bearing stops. Apply a fewdrops 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 innercoupling hubs of roll #1 and roll #3 should be 19-1/2 to 19-5/8 inches. Adjust roll #2 or roll #1if necessary using a small pry bar.

FIG 3.13FOUR POINT ALIGNMENT


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FIG 3.14ROLL ALIGNMENT

Refer to Figure 3.14 and check the alignment of roll #2 to roll #4 and of roll #1 to roll #3 byplacing a straight edge across the rolls. If the rolls are not aligned, align the rolls using thebearing stop screws on roll #1 or Roll #2. Do not move rolls #3 or #4. Apply a few drops ofLoctite 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 bearingmounting 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 thissection.

3.2.8 REMOVE AND REPLACE BRAKE PADS, AIR BAGS, AND LIFT PLATE ASSEMBLY

NOTEThe lift plate assembly does not have to be removed for brake shoereplacement.

REMARQUEIl n’est pas nécessaire de déposer la plaque de levage pour leremplacement des freins.

Remove the brake pads using two 1-1/8-inch crescent wrenches. After one nut is loosened, use a13-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 andinstall the brake pads, flat washers, and nuts onto the pin. Using two 1-1/8-inch crescentwrenches tighten the nuts.

REMOVE AND REPLACE BRAKE PADS, AIR BAGS, AND LIFT PLATE ASSEMBLY (CONTINUED)


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Using a 7/32-inch Allen wrench remove the bolts from the two outboard air bags. Using a 9/16-inch socket wrench remove the bolts from the center air bag. Raise the lift plate and slide it overthe 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 thereplacement air bag press the air line into the fitting and place the air bag on the center support.

NOTEWhen replacing the lift plate coat the ends of the plate that slide in theframe guides with Mobilith AW 2 grease.

REMARQUELors du remplacement de la plaque de levage, enduire les extrémitésde plaque qui coulissent dans les guides du châssis avec de la graisseMobilith AW 2.

To replace the lift plate slide the lift plate onto the airbags. Apply a few drops of Loctite 262 tothe threads of the four (4) outboard air bag attachment bolts and using a torque wrench with a7/32-inch Allen wrench torque the bolts to 15 foot-pounds. Apply a few drops of Loctite 262 tothe threads of the two (2) center air bag attachment bolts and using a torque wrench with a 9/16-inch 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. Whenreplacing the limit switch trip arm coat the pin with Mobilith AW 2 grease. Make sure thespring 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 wiringdiagram in Figure 3.15. Shorts to ground can be due to a faulty coil, jumper wire, or terminalblock 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 7Nthrough 12S.

Connect one lead of the ohmmeter to the PAU ground and the other lead to the first group of sixcoils 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 whichgroup 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 ajumper wire across the terminals. Up to three coils can be disconnected without adverselyaffecting PAU performance.

If the short is in the terminal block, replace the terminal block.


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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 terminaland 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

CONTENTS

4.1 INTRODUCTION.....................................................................................................4-3

4.2 TROUBLESHOOTING GUIDE ...................................................................................4-3


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4.1 INTRODUCTION

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

4.2 TROUBLESHOOTING GUIDE

TABLE 4.1 TROUBLESHOOTING GUIDE

Problem Possible Cause Correction

Vibration and/or Noise Structural frame of dynamometer isnot secured to pit floor.

Check anchor bolts on dynamometerframe and tighten to properspecification.

Dynamometer is not level to the floor. Level dynamometer and be sure shimsare in place under frame whereneeded.

Roll coupling is out of tolerance oralignment.

Repair or realign couplings.

Coupling between rolls is worn. Replace coupling.

Roll pillow block bearings not securedto 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. Tightensetscrews to proper specification orreplace roll.

Roll is out of balance. Check for loose weights on roll.Replace roll if necessary.

Lift Fails to Lower Lift Override switch is in “UP” position. Turn Lift Override switch to ”DOWN”position.

Lift override module on lift solenoid isin the vertical position

Turn screw on override module to thehorizontal position.

No lubrication Coat the ends of the plate that slide in theframe guides with Mobilith AW 2 grease.

Lift Fails to Raise Air supply to dynamometer has notbeen turned on.

Turn on air supply. Dry air, regulatedto a MAXIMUM of 80 psi must besupplied to the dynamometer.

Air lift solenoid coil has failed. Check for +12 VDC across pins 8 and9 of the I/O board in the Control Unit.Replace coil if necessary.

Air lift valve has failed. Replace valve.


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TABLE 4.1 TROUBLESHOOTING GUIDE

Problem Possible Cause Correction

Lift Fails to Raise (Continued) Power supply failing to operateproperly.

Check all connections in both controlunit and solenoid valve cable. Repairor replace defective components ifnecessary.

Air bag has ruptured. Replace air bag.

No lubrication Coat the ends of the plate that slide in theframe guides with Mobilith AW 2 grease.

Roll speed other than zero is beingdisplayed.

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

Low air pressure. Adjust dry, regulated air pressuresupplied to dynamometer to amaximum of 80 psi.

Defective or improperly wired airpressure switch.

Verify correct wiring and test openingand closing of pressure switchcontacts.

Defective cable or wiring. Inspect all electrical wiring and replaceany defective cables and/or contacts.

“Digital Enable” signal from hostcomputer not present.

Troubleshoot software system.Troubleshoot dynamometer controlunit.

Rolls Do Not Lock Brake pads are worn. Replace brake pads.

Air leak in pneumatic system. Inspect and replace any defectivetubing, connectors, and/or air bags.

Low air pressure Adjust dry, regulated air pressuresupplied to dynamometer to amaximum of 80 psi.

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

Loose interface connection. Make sure all cable connections areproperly seated. Verify all connectionsinside the control box are secure.

Bad load cell connection. Check all load cell connection. Repairif necessary.

No Speed Readout Bad electrical connection. Check all electrical connections in thesystem.

Incorrect Magnetic Pickup-to-gear airgap.

Verify that the air gap is set to 0.020 to0.030 inches.

Magnetic Pickup failure. Replace Magnetic Pickup.No Torque Readout Bad electrical connections. Check all electrical connections in the

system.


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