1. Manuals
  2. Brands
  3. MD Manuals
  4. Service Equipment
  5. MD-AWD-150
  6. Manual

MD -AWD-150 Manual

Chassis dynamometer
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
MD-AWD-150 S
M
R
. A
ERIES
ANUAL
EV
Mustang Dynamometer
MD-AWD-150
Page 1

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the MD-AWD-150 and is the answer not in the manual?

Questions and answers

Summary of Contents for MD MD-AWD-150

  • Page 1 MD-AWD-150 S ERIES ANUAL Mustang Dynamometer MD-AWD-150 Page 1...
  • Page 2 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 Rev. B May, 2013 Mustang Dynamometer MD-AWD-150 Page 2...
  • Page 3 Keep limbs, hair, jewelry and clothing away from the moving rolls. When operating a vehicle on the machine, remain inside the vehicle until the rolls have stopped, Cover the rolls when the equipment is not in use. Mustang Dynamometer MD-AWD-150 Page 3...
  • Page 4 GANCORP INVESTMENTS INC. dba MUSTANG DYNAMOMETER Mustang Dynamometer MD-AWD-150 Page 4...

  • Page 5: Table Of Contents

      6.2.1 Pillow Block Bearings ..........................36   6.2.2 Gear Toothed Couplings ........................37   6.2.3 Pneumatic Clutch Couplings ........................38   6.2.4 P.A.U (Eddy Currents) ........................... 39   PREVENTATIVE MAINTENANCE TIME TABLE ..................41 Mustang Dynamometer MD-AWD-150 Page 5...
  • Page 6   SECTION 8 – APPENDIX ........................... 45   A – T ......................45 PPENDIX ORQUE PECIFICATIONS   B – R ........................ 48 PPENDIX ECOMMENDED LUIDS   – A ................. 49 PPENDIX C NCHOR NSTALLATION LOORS Mustang Dynamometer MD-AWD-150 Page 6...

  • Page 7: Section 1 - Introduction

    Vehicle Heating & Cooling Systems Engine Performance and Evaluation Drive Train Component Evaluation Transmission Components Tire Testing Track Lap Simulation Road Grade Simulation Trailer Towing Simulation Fuel Efficiency Auxiliary Components Failure Analysis Mustang Dynamometer MD-AWD-150 Page 7...

  • Page 8: About This Manual

    This manual provides you with the information you will need to know when you want to install and perform routine maintenance as well as more complex service on your MD-AWD-150-Series Chassis Dynamometer. The following sections are included in this manual: Section 1 –...

  • Page 9: Boxes

     This is an example of a NOTE box. A NOTE box is generally used to bring to your attention information that should be of particular benefit, information that pertains to a special situation, etc. Mustang Dynamometer MD-AWD-150 Page 9...

  • Page 10: Before You Start

    Before attempting to operate your Dynamometer for normal usage, it is very important that… Your Dynamometer has been properly installed. Your Dynamometer has been properly maintained. Your Dynamometer has been properly calibrated. Please refer to the MD- PowerDyne software manual.

  • Page 11: Section 2 - The System

    Doing so will greatly help you to understand the information that is presented in other sections of this manual. 2.2 M AJOR YSTEM OMPONENTS The Major components of a MD- AWD-150-Series Dynamometer System can be grouped into the following categories, which are discussed below: Dynamometer Control and Monitoring System Software System Mustang Dynamometer...

  • Page 12: Dynamometer

    High power couplings are used to accurately transmit speed and power to instrumentation. Pneumatic High power coupling that is used to disengage the Clutch AWD half of the dynamometer so you can test 2 wheel drive vehicles and Motorcycles. Mustang Dynamometer MD-AWD-150 Page 12...

  • Page 13: Control And Monitoring System

    The rated accuracy of the Load Cell is ± 0.1% Magnetic Pick-up One revolution of the drive line will cause 60 pulses to be generated. By measuring the time between pulses generated, the speed of the rotation can be calculated. Mustang Dynamometer MD-AWD-150 Page 13...

  • Page 14: Control And Monitoring System (Not Attached To Dyne)

    When both torque (from the load cell signal) and speed (from the magnetic pickup signal) are known, horsepower can easily be determined. Mustang Dynamometer MD-AWD-150 Page 14...

  • Page 15: Section 3 - Safety First

    AINTENANCE AFETY SSUES maintenance and service on you dynamometer system. Please be sure to read and follow the directives in all of the safety messages given in this section. Mustang Dynamometer MD-AWD-150 Page 15...

  • Page 16: General Safety Issues

    – The rolls can move freely whenever the roll brake is not applied. Never walk OVER OLLS on the rolls. Cover the rolls when the dynamometer is not in use. – Maintain acute awareness when the dynamometer rolls are in motion. TTENTION Mustang Dynamometer MD-AWD-150 Page 16...

  • Page 17: Operational Safety Issues

    DO NOT attempt to get in or out of the vehicle while the dynamometer rolls are moving. STOP! – Stop the equipment immediately if you have any doubt about the safe OUBT operating condition of the dynamometer and/or the correctness of any procedure that you are performing. Mustang Dynamometer MD-AWD-150 Page 17...

  • Page 18: Maintenance Safety Issues

    – Never pull on the drive belt in order to spin the rolls. NEVER, NEVER, NEVER! – Make sure that all bolts on the Dyne are tight and all couplings are properly HECK IGHTNESS secured. Mustang Dynamometer MD-AWD-150 Page 18...

  • Page 19: Section 4 - Installation

    NSTALLATION 4.1 I NTRODUCTION This section of the manual provides instructions that you should follow when installing your new MD-AWD-150-Series Chassis Dynamometer. These first few steps apply to both above ground and below ground installations. 4.2 I NSPECTION After unloading the dynamometer from the delivery truck and prior to the departure of the truck driver a visual inspection must be made of the dynamometer.

  • Page 20: Electrical

    It is important to have enough room around the dynamometer to allow equipment to be move around the service bay area. At least 18 feet clearance is needed in front of the dynamometer so that the vehicle under test has enough room to pull in the service bay. Mustang Dynamometer MD-AWD-150 Page 20...

  • Page 21: Above Ground Installation

    Remove the dyne’s cover plates, do this by using a 5/16 Allen wrench to remove the button head bolts. Remove the cover or lid above the PAU. Remove the lag bolts that hold the 4 X 4 wood pieces to the feet of the dyne. Mustang Dynamometer MD-AWD-150 Page 21...
  • Page 22 Keep in mind clearance requirements as discussed in 4.4.6, and the fact that there is only 30 feet of cabling shipped with the dynamometer. Mustang Dynamometer MD-AWD-150 Page 22...
  • Page 23 AWD section for a guide then place the smaller half in place leaving about an inch gap from the spacers. Then with a come-along pull the dyne halves together while holding the spacers in place. Mustang Dynamometer MD-AWD-150 Page 23...
  • Page 24 Fig. 4.5 note snap ring is not red just highlighted for clarity in the illustration. Using a small screwdriver or awl remove the snap ring, then slide the sleeve back, a rubber mallet may be needed (Fig. 4.6) Mustang Dynamometer MD-AWD-150 Page 24...
  • Page 25 Tighten the bearing block adjustment bolts so that the bearing slides over and makes contact with the opposite side bearing block bolts (the 2 that you didn’t move)… tighten the jam nut on the bearing block adjustment bolts. Tighten bearing hardware and torque to 50 ft-lbs. Mustang Dynamometer MD-AWD-150 Page 25...
  • Page 26 Re-install the dynamometer’s plates. Torque the button head bolts to 35 ft. lbs. You will still need access to the PAU for calibration; these steps will be explained in the Power Dyne® software manual, located on the software disc sent with your machine. Mustang Dynamometer MD-AWD-150 Page 26...

  • Page 27: Below Ground Installation

    There should be 3 conduits on the bottom of your pit floor, one for the airline, one for the PAU cable and one for the solenoid valve and speed sensor cables. Run these cables now. Make sure that there is enough slack in the cable to make the appropriate Mustang Dynamometer MD-AWD-150 Page 27...
  • Page 28 PAU off. You will still need access to the PAU for calibration; these steps will be explained in the Power Dyne® software manual, located on the software disc sent with your machine. Mustang Dynamometer MD-AWD-150 Page 28...

  • Page 29: Installation Illustrations

    NSTALLATION LLUSTRATIONS 4.7 C ONTROL NSTALLATION Mustang Dynamometer MD-AWD-150 Page 29...
  • Page 30 3. After routing the air line, push the plastic air line into the quick release air fitting on the air solenoid until it is snug. Make sure that the air line will not come into contact with the rolls. Mustang Dynamometer MD-AWD-150 Page 30...
  • Page 31 Make sure there are no personnel near the dyne or lifts before activating the lift override! After test vehicle is removed from the dyne RETURN THIS BYPASS SCREW BACK TO ITS ORIGINAL POSITION! Mustang Dynamometer MD-AWD-150 Page 31...

  • Page 32: Pre - Operational Inspection

    7. Check all cabling and air lines to be sure that they are secured and clearly away from any rotating components. 8. Check the leveling of the dynamometer and ensure it is secured to the floor. 9. Clean up all installation tools in and around the dynamometer frame. Mustang Dynamometer MD-AWD-150 Page 32...

  • Page 33: Section 5 - Operational Checkout

    Place the vehicle in “Park” or “N” with parking brake, then turn the vehicle’s engine off. 9. For the multi roll style dynamometer like the MD-AWD-150 you will need to place in front of the...
  • Page 34 24. If there are any problems, stop the procedure immediately. 25. If no problem occurs, accelerate the vehicle in 10 MPH increments up to 50 MPH for 2 – 3 minutes at each increment. 26. Repeat steps 22, 23, 24 as required. Mustang Dynamometer MD-AWD-150 Page 34...
  • Page 35 32. If You Have Any Questions, Please do not hesitate to call our corporate headquarters at (330) 963-5400 or toll free in the continental united states at 888 4MUSTANG 33. This completes the basic start up rotational test of the equipment. Mustang Dynamometer MD-AWD-150 Page 35...

  • Page 36: Section 6 - Preventative Maintenance

    These bearings can be identified by a small white metal disk installed under the grease fitting on the bearing’s housing. Non-expansion-type bearings: This type of bearing will have either no disk under the fitting or a small blue metal disk under the fitting. Mustang Dynamometer MD-AWD-150 Page 36...

  • Page 37: Gear Toothed Couplings

    Shell Alvania # 2 grease (or standard Lithium base grease # pump 2 full pumps into each coupling. Wipe excess grease off with a clean rag and replace grease plugs. Mustang Dynamometer MD-AWD-150 Page 37...

  • Page 38: Pneumatic Clutch Couplings

    Using a hand held grease gun pump grease into the zerk (as shown below marked with the red arrow) until the seal “pops” then wipe excess grease from the cam follower. Mustang Dynamometer MD-AWD-150 Page 38...

  • Page 39: Eddy Currents)

    (8) air gaps on each side of the power absorber. The average air gap measurement per side should be between .053" and .057" 2. If the average air gap is out of range, contact a Mustang Dynamometer Service Representative for adjustment instructions. Mustang Dynamometer MD-AWD-150 Page 39...
  • Page 40 Mustang Dynamometer MD-AWD-150 Page 40...

  • Page 41: Preventative Maintenance Time Table

    HIS PREVENTATIVE MAINTENANCE TIME TABLE IS BASED UPON AN AVERAGE OF HOURS OF MACHINE USAGE PER WEEK F YOUR INSTALLATION DIFFERS FROM THIS PLEASE MODIFY THE TIME TABLE ACCORDINGLY ● T HIS REPRESENTS A SPECIAL OPERATION FOR MORE INFORMATION REFER TO THE APPROPRIATE NOTE ABOVE Mustang Dynamometer MD-AWD-150 Page 41...
  • Page 42 Roll is out of balance Check to see if there is a spot were a roll weight has come off, check roll shaft for wear: normally needs new roll or tighten set screws on bearing. Mustang Dynamometer MD-AWD-150 Page 42...
  • Page 43 Inspect and replace any defective tubing, connectors, and/or air bags. Pins at lift points are missing. Replace missing pins Low air pressure Adjust dry, regulated air pressure furnished to dyne to a maximum of 120 psi. Mustang Dynamometer MD-AWD-150 Page 43...
  • Page 44 No Speed Readout Bad electrical connection Check all electrical connections in the system. Incorrect magnetic pickup to Verify that the air gap is set to gear air gap. 0.020” Magnetic pickup failure Replace magnetic pickup. Mustang Dynamometer MD-AWD-150 Page 44...
  • Page 45 150 ft.-lbs. 203.3 Nm M16 1.5 160 ft.-lbs. 216.8 Nm 24mm M20 2.5 295 ft.-lbs. 399.7 Nm M20 1.5 325 ft.-lbs. 440.4 Nm 30mm M24 3 505 ft.-lbs. 684.3 Nm M24 2 555 ft.-lbs. 752 Nm 36mm Mustang Dynamometer MD-AWD-150 Page 45...
  • Page 46 M12 1.75 40 ft.-lbs. 54.2 Nm ORQUE OVER LATE OLTS (ANSI B18.3-1986, B UTTON CREWS PECIFICATIONS ORQUE OCKET 3/8-16 15 ft.-lbs. 20.3 Nm 7/32 1/2-13 35 ft.-lbs. 47.4 Nm 5/16 5/8-11 70 ft.-lbs. 94.9 Nm Mustang Dynamometer MD-AWD-150 Page 46...
  • Page 47 Pole Plate Bolts K-40 to K-160 50 ft.-lbs. 270 Nm K-200 to K-480 85 ft.-lbs. 120 Nm Seal Plate Bolts 85 in.-lbs. 9 Nm Terminal Block Nuts 20 in.-lbs. 1.95 Nm 30 in.-lbs. 3.43 Nm Mustang Dynamometer MD-AWD-150 Page 47...
  • Page 48 B – R PPENDIX ECOMMENDED LUIDS ECOMMENDED LUIDS MD P UMBER ANUFACTURER ESIGNATION ESCRIPTION REASE 20010651 Mobil Mobilith AW2 Used in all general bearings. Multi-purpose, lithium-complex grease; Excellent protection against rust and corrosion, smooth and tacky, green in color 20010653...
  • Page 49 – A PPENDIX C NCHOR NSTALLATION LOORS Mustang Dynamometer MD-AWD-150 Page 49...

Table of Contents