AW 200 User manual

OPERATORS MANUAL
Dynamometer Models:
Model 2OO, Model 375, NEB 2OO,
NEB 4OO, NEB 600, NEB 8OO
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1. WARRANTY
2. SAFETY
3, COOLING REQUIREMENTS
A. Cooling Systems
B. Water Requirements for Continuous Testing
4. GENERAL DESCRIPTION
5. PRE.INSTALLATIOI\ & OPERATION OF THE DYNAMOMETER
6. INSPECTION/SERVICING BRAKE DRUM UNI;
7. SERVICING THERMAL FUSE
8. TROUBLESHOOTING DYNAMOMETER
9. PARTS
1.0. DECAL REPLACEMENT REORDERING
Pg. 1
Pe.2
Pg. 3
Po6
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Pg. 13
Po 15
Pg.17
P9.20
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SECTTON 1
WARRAl\TY
AW Dynamometer, Inc. warrants its products to be free from defects in material
and workmanship under normal and proper use for a period of one year from the
date of shipment" Any produets purchased from AW Dynamometer, Inc. that upon
inspebtion at AW Dynamometer's factory prove to be defective as a result of
normal use during lhe one year period will be repaired or replaced ( t Aw
Dynamometer's option) without any charge for parts or labor. This limited
warcanty shall be void in regard to (1) any product or part without AW
Dynamometer's previous written eonsent or (2) any product or part thereof that has
been subjeeted to unusual clectrical, physical, or mechanical stress or upon which
the original identifieation marks have been removed or altered. Transportation
charges for shipping any product or part thereof that the bmyer elairns is
covered by this limited warranty shall be paid by the buyer. WITI{ THE
EXPRESS WARR.ANTY SET CUT ABOVE, AW DY}IAMOMETER, INC"
DOES NCT GR.ANT A}dY WARR,ANTIES EIT}IER EXPRESSED OR
IMPLIED, INCLUDING IMFI,IED WARRANTItrS OF MERCHANTAFITITY
CR FIThTESS FCR. USE" The obligations or liabilities of AW Dynamometer, Inc"
specifieally shall not be liable for damages, AW Dynamometer, Ine. speeifieally
shall not be liable for re:instailing any produet or part thereof repaired or replaeed
under the limited warranty set out above. AW Dynamometer, Inc. expressiy
excludes all liability for any indirect or oonsequential damages the buyer may
sustain in conneetion with the delivery, use, or performanee of AW Dynamometer,
Inc" products.
Under no circumstances shall any liability for which AW Dynamometer, Ine" is
held responsible exceed the selling price to the buyer of the AW Dynamometer,
Inc. products that are proven to be defective. This limited warranty applies
exclusively to AW Dynamometer, Inc. m'anufacrured producJs. Warranties for
driveline components, gauges, power computer and printer and other
manufacturer's goods are covered by their warcanty. Any legal aetion for breach
of any AW Dynamometer, Inc. warrarrty must be commenced within one year of
the date on which the breach is or should have been discovered.

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SECTION 2
SAFETY
This safety alert symbol indicates important safety messages in.this operator's manual.
When you see this symbol, be alert to the possibility of personal rnjury and carefully read
the message that follows.
1. Stay clear of the rotating driveline and adapter assernbly during opeqat-ion. Do not
stand or strqddle the driveline while it is in use. A11 driveline shields must be in place
prior to oper:bting the test and inspected prior to each test for damage or defects.
Replace as required
Z. Driveline and adapters require inspection prior to each test by visual inspection. Once
ayear all driveline components must be magnafluxed for stress cracks and replaced if
found defective.
fiff 3. prolonged exposure to loud noise can cause impailment or loss of hearing. Wear
;ffi suitable hearing protective device such as ear muffs or ear plqs to protect against
G objectionable or uncomfortable loud noises
Caution: Water and electrictty are lethal. Anf spillage or ieakage of water from the
cooling system or dynamometer does create ahazardous condition to the operator'
Any exposure of water leakage in the test area must be corrected before any test is
conducted. The water system should be inspected for leakage prior to each test.
Water leakage during the test should result in the operator aborting the test and
correcting the leakage problem prior to proceeding.
Ali driveline shields. chain shields and sheet metal covers must be on the machine
during operation.
6. At a minimum of once per year the internal lubrication must be inspected as to its
quality and quantity
ffi 7 . Replace all safety and maintenance decals if they become worn and unledgeable or
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r- mlsslns. Refer to Section 10.
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SECTION 3
COOLING REQUIREMENTS
The most important part or requirement is water for cooling the dynamometer. Through the
conversion of mechanical energy into heat energy by the dynamometer tremendous amounts of
heat is created.
The unit of quantity of this thermal energy is ealled British Thermal Units or B,T.U.s. One
B'T.U. is the amount of heat (thermal energy required to raise the temperature of 1 pound of
water), 10F in 1 minutb of time.
778 isthe number of foot pounds of meehanical energy equivalent to 1 B.T.U. and is called the
mechanical energy. It takes 33,000 ft lbs of work in 1 minute to produce t horsepower.,
33,000 divided by 778:42.6 B.T.U, per horsepower.
Let's say we. are testing a 100 H.p. tractor on a dynamometer.
100 H'P. X 42'6: 4260 B.T.U. per minute of eooling. If we are to load test t hour we have a
totalquantityofheat of 4260 B,TU. @minuteX60:255,600B.T.u.perhour. Thisisequaito
a furnace roughly heating 2 Yzhouses with the thennostat eompletely u.? on high for one hour. trt
is this heat whish must be removed from the dynamometer in order io keep it coal. Without
proper cooling your test periods would be short and the dynamometer life will have short
intervals befwoen major overhauls. Installations with an insufficient supply of water must follow
Inspection/Servicing Brake Drum Unit in Section 6 very closely to prevenidamage to the
equipment or injury to personnel.
The following charl shows several types of cooling systems that have been used down throush
the years.

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In most applications fresh tap water is used for cooling. Free flowing{ap water requirements for
the dynamometer are based on the ineoming water temperatur e md, imiximum rut", discharge
temperature of 1400F. The chart provided shows the frish water requirements based on
incoming temperature versus increments of 100 H.p.
Enclosed systems require higher volumes of water flow to decrease the amount of temperature
rise between the inlet and outlet. This is very important on systems which have no supplemental
cooling and only rely on the holding tank as ahea|sink or storage systems without some source
for cooling the hot water and will suffer short tests and more maintenanee on the- dynamometer.
SECTION 38
WATER REQUIREMENTS FOR
COI\TII{UOUS TESTING
Incoming
'Water
Temperature
0F -Gallons Per Minute
400 510 15 20 25 30 35 40 45
500 612 18 24 30 36 42 4B 54
600 a14 21 28 35 42 49 56 63
700 816 24 32 40 48 56 64 72
900 918 27 36 45 54 63 72 81
900 10 20 30 40 50 60 70 80 90
't000 13 26 39 52 65 78 91 104 117
1 100 17 34 51 6B 85 142 119 136 153
Horsepower 100 204 300 400 500 600 700 800 900
: 60'F
Exawple: water requires 7 gpm to test 100 H.p.
Gravity feed systems are not recommended due io fo* pressure creatid by them, reducing the
required volume for cooling
several areas of caution should be used when plumbing the system.
1. Retum lines from the dynamometer back to the cooling system or drain must be of the correct
size as not to create more than 8-10 P.S.I of back pressure on the dynamometer's tank.
NOTE: The rotor on the dynamometer will not pump water. Water must be forced through the
system for proper cooling. It is intended to create a pressure drop from the incoming watJr 30-
60 P.S.I down to a maximum of 8-19 lbs on the outlet. Pressures greater than 8-10 lbs. on the
dynamometer tank will reduce water seal life.

SECTION 4
GENERAL DESCRIPTION
L. Horsepower ComPuter
2. 'Load Control Valve
3. Water TemPerature Guage
4. Dead Weight Test Ban
5. FTO Shaft
6. Therrnal Fuse
7" Water Level Check
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1. 21005 Computer
3" Waten Ternperatl.rre Gauge
2. toad Control Valve
5" PTG Shaft (see diagram 0n page G)

6. Thermal Fuse
7. Water Check Valve