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
^b'"
PoQ
'o'-
Pg. 13
Po 15
Pg.17
P9.20
Po ??

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

SECTION 5
PRE II{STALLATION AND OPERATION OF THE
DYNAMOMETER
dynamometer back about two inches to avoid
end thrust on power shaft.
5. Use a hammer to-force brake locks against
tires to prevent movement of dwamo*Jt.r.
1. Select proper front half splined power shaft:
| 318" - 6 Tooth 540 RPM
I 3/8" -21 Tooth 1000 RpM
I 314" -20 Tooth 1000 RpM
2. Placetransmission shift lever in park or
Neutral. Block tractor's rear wheels for added
safety when on slopes or uneven ground.
3. Attach power shaft to tractor pTO. Alisn
power shaft so that angles of the universal-parts
are straight as possible and on parallel plains.
4. Push dynamometer forward until power
shaft is at minimum length - then puil
6. Jack stand at rear of dynamometer should be
lowered for added stability.

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*:a. ,t 7. Connect dynamometer water discharge hose
and tighten clamp or fitting. There should
neve be a shut off valve on the discharge line.
B. Connect dynamometer water inlet supply.
b{OTE: At thib point it is most impofiant to
eheck water volume. Reference Cooling
Requirements - Section 3.
9. Ifthe end user changes the standard preset
plumbing, they must make sure the water outlet
is larger than or equal to the ineoming wator
supply. This will eliminate any unnecessary
baek pressure inside the tank that would reduee
water seal life.
10. Turn on the water supply to fillthe
dynamometer. In cases of close loop systems,
the end user must check the water level test
valve before operating the dynamometer'
NOTE: For non-ciosed loop systems, the end
user must make sure the water is running out of
the drain hose before operation of the
dynamometer. This will ensure that the water
level inside the top tank is at full capacity.
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i 1' Prior tq starting the test, both the ToP and BoTToM VALVES of the load control valve
must be open. To open both valves, turn counterclockwise.
12. starttractor and allow it to reach normal operating temperature.
13' When the tractor is at proper operating temperature, engage the tractor pTo and advance
speed control level to maximum RpM.
Ij' To begin the dyno test, close thc main bypass valve on the bottom of the manual control
ilow valve.
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15. To apply load to the tractor'
turn the fine tune valve on toP of
the rrranual flow eontrol valve
cloelcwise. Continue to apply load
until the RP1\4 on the 2100S DYno
Fro eomputer reae hes its desjred
rated RPM per the Nebraska test
spees.
16. To stop the dyno test, rotate the fine tune vaive eounter eloekwise and thcn open the main
bypass valve on the bottom of the manual flow eontrol valve.
** If an emergeney oeeurs during the test, the main bypass valve ean be opened to relieve ali
hyclraulie pressure within the brake system'
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17. TfOReUtr RISE: In orcler to find peak torque, the end user will seteet the torque set Lrutton
on the 2100s Alf RATED RpVn. onee the torque set button has been seleeted, the torque %
value on the 2100s soreen will display 100%. The end user will then pull the tractor down to the
reeommcnded speeifieations per the Nebraska test specs' (Example: 50% tor"que risc : 150% on
tho 2100S scroen disPlaY.)
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SECTION 6
INSPECTION/SERVICING BRAKE, DRUM UNIT
The-synthetic oil (Paft#20405 Rml oil) inside the Load unir of the Model 200, Model 375,
NEB 200, NEB 400, NEB 600 and the NEB 800 Ag PTo Dynamometers must be inspected
eveqi25 hours to determine the condition of the oil. Normal coloration of the 405 Synthetic Oil
should be a honey brown color with transparency.
1' Drain the water from the bottom base tank until the water level is below the brake drum.
2. Remove reservoir lid usine two 3/q wrenchs.
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Remove "O" ring plugs from brake drum(s)'
To inspect the 405 Rml oil, rotate the drum(s) until the "o" ring plug holes are atthe l
o,cloet position then quickly rotate the drum assembly back to the 12 o'clock position.
During thiu pro..uu, tlr... should be a residual amount of oil on the load unit assembly'
If the Synthetic Oil is a honey brown color, then the fluid is satisfactory and does not need
to be drzined or replaced. *** If the 405 oil is black due to overheating of the drums
eaused by lack of water or exceeding the torque limitation, then fol1ow procedure #6
below.
To drain aii of the 405 oil, rotate the drums until the "O" ring holes are on bottom at the 6
o'clock position. Continue to drain for 5-10 minutes'
Rotate the loacl unit until the "O" ring holes arc atthe 12 o'clock position'
g. Replenish 1 pint (.241) of 16 ounses of 405 Rml synthetic oil per drum.
J.
7.
6.
L4

9. Insert and tighten the plugs.
10' Attach the dynamometer to the PTo of the tracior. Before engaging the tractor, make sure
the operator has an electronic heat gun to detect the heat inside the drum. Do not exceed.
140 degree F inside the drum.
Il" NOTE: No water is used during flushing eycle.
12. start the tractor and spin the pro @ 500-600 Rpm,s for 5-10 minutes.
13. Disengage PTO and stop the traetor engine.
14. Begin to drain the oil from the brake drum(s). (5-10) minutes.
NOTE: If oi1 appears extremely dirty or dark, asecond flushing is recommende6. Dark oil
indioates extreme heat due to laek of water or passing the torque limitation on the dyno.
15' If the oil appears transparent and-.has a honey brown color it is suecessful and you can
eontinue the draining of the brake drum 5-10 minutes. Replenish each individual brake
drum with 6-8 ounces of new Rml405. Fasten ,,o,,ring hole snug tight.
16' Replaee the reservoil lid and fill with water. *** Make sure the tightening of the top lid
was hand tight and not performed with an air ratchet. Over tighteriing the lid gasket wiil
eause it to split and will not seal properly.
SECTION 7
SERVICII{G THERMAL FUSE
15
1. Remove the water inside the top tank.

2. Remove the three bolts from thermal
back into housing. Remove the existing
thermal fuse assemblY.
fuse flange. Push thermal fuse hydraulie release plunger
1/, of theblown fuse and instali the new fuse onto the
I{OTE: Do not over-tighten fuse or fuse may fail prematurely, Reinstall flange onto roservoir
and use a silieone sealei around the new flange gasket. Use thread sealing compound on bolt
threads. If the thcrmal fusc has blown, it is a necessity to inspeet/sorvice the dynamometer's
load unit. see Inspeetiorvservicing Brake Drum Unit - section 6'
\fi cAurIoN:
/ , :_,' lo6o6. suehDo not substitute thermal fuse with any device other than recommended fuse No'
a substitution will result in damage to brakle drurn and void warranty'
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SECTION 8
1. Vibration
2. Will not load
3. Will not unload
4. Low power reading
5. High power readiqg
6. Erraticloading
7. Overheating
8. Shearing pins
9. Damage to water seals, bellows or lid sasket
10. Smoke or vapor
11. Unstable torque and power reading
TROUBLESHOOTII{G DYI\AMOMETER
Possible Cduse:
1. Vibration
A. Misalignment
B. Adapter hookup
C, Lose shear pins
D. Damaged U-Joint
E. Damaged Driveline
F. Dynamic bearing problerm
G. Power absorption module problem
H. Resonant vibration
Possible Renaedy:
A. Realign drive shaft
B. Check assembly for corroct fit and
run out
C. Properly tighten shear pins and use a
lock nut
D. Replace U-Joint
E. Replace drive-line
F. Determine cause and correct
G. Change the rotation mass of the
prime mover or dynamometer or
install a resilient coupling
Possible Cause:
2. Will Not Load
A. Low on hydraulic oil
B. Thermal fuse release
C. Hydraulic pressure shut off valve
closed
D. Damaged hydraulic line
E. Defective chain or sprocket
F. Hydraulic directional valve in wrons
position
G. Defective hydraulic pump
Possible Remedv:
A. Fill to proper level with 10 weieht
hydraulic oil
Replace thermal fuse Section 13.
Refer to Section 4
Open hydraulic valve
Replace hydraulic line with original
equipment. If unable to determine
cause, consult factory for seryice
Replace with new eomponents
Position bi-directional valve to
proper direction
G. Replace hydraulic pump
Possible Cuuse:
3. Dynamometer will not unload
A. Defective control valve
B. Defective dynamic bearing
C. Restricted hydraulic return line
D. Defective power absorption module
Possible Remedy;
A. Remove valve stem and clean as
required
B. Determine cause and correct
C. Find restriction and correct as
required
D, Reference to SectionIl,12 in
operator manual. If unable to
B.
D.
E.
F.
I/

determine cause, consuit factory for
service
Possible Cuuse:
4. Low Power Reading
A. Torque meter out of calibration
B. Cradle restriction of load ce1l
movement
C. RPM PickuP imProPerlY gappgd
D. Improper weight values used during
calibration
E. Improper engine fuel specification
F. Improper engine RPM specifieation
Fossilsle RenaeclY:
A. Calibrate torque meter (See Section
9 for analog read-out Seetion 10A
for Power ComPuter)
B. Remove restriction as requiied
C, Adjust air gaP to '010 - 015
O. Caiibrate torque meter with properly
known weights (See Section.00)'
Obtain the correet welght usmg a
very reliabie scale
E. Adjust to proper OEM specifications
F. Adjust to proper OEM specifications
Possible Cawse:
5" High Power Reading
A. Torque meter out of calibration
B. Outside force aPPlYing load on
cradle movement
C. Improper weight values used during
calibration
D. Improper specs being used on test
E,. Exsessive over-fueiing
Possible RewnedY:
A. Calibration torque meter (See
Section 9 for analog readout and
Section 10A for Power ComPuter)
B. Remove force and re-balance torque
metet
C. Calibrato torque meter with properly
known weights (see Section 118)
D. Refer to tractor manual for correet
sPocification
E. Reduce to OEM sPeeification
Possible Cause:
6" Erratic ioading (loads and unloads)
A. Operator making rapid load valve
adjustments
B. Low on hYdraulic oil
C. Defeetive 'chain and sProcket
D. Defective power absorption module
E. Incorrect operation of control valve
F. Fuei injector Problems
G. P.T.O' in tractor sliPPing
Fossible RemedY:
A. Make gradual adjustments (See
Section 7 for ProPer Procedure)
B. Refill resetvoir to proper level with
10 weight hydraulic oil (one-ha1f to
two-thirds tull)
C, RePlaee with new comPonents as
required
D. Refer to Section 17,12' If unable to
cletermine causs consult factory for
Ser",tice.
. E,, Make gradual adjustments.
' F. Detennine cause and reParr as
required
G. Delermine cause and rePair as
required
Possible Csuse:
7" Overheating
A. Inadequate water suPPlY
Possible R.emedY:
A. Refer to Seetion 4, Cooling
Requirements
Possible Cuase:
8" Shearing driveline Pins
, A. Exsessive torque load
B. Incorreet shear Pin
C. Resonant vibration
D, Defective driveline
E. Load control valve closed during
sYstem start uP
F. I]efective power absorption module
1B