MD MD-800 SERPENTINE Manual

MAINTENANCE
AND
SERVICE MANUAL
MODEL MD-800 SERPENTINE
CHASSIS
DYNAMOMETERS
MUSTANG DYNAMOMETER
Revision Release Date Initial
A 21 SEPT 18 NK

MODEL MD-800 SERPENTINE DYNAMOMETER SERVICE MANUAL
ii MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE
Information in this document is subject to change without notice. No
part of this document may be reproduced or transmitted in any form
or by any means, electrical or mechanical, for any purpose, without
the express written permission of Mustang Dynamometer.
Copyright 2018
Ganzcorp Investments, Inc. dba Mustang Dynamometer
All rights reserved
Mustang Dynamometer
2300 Pinnacle Parkway
Twinsburg, Ohio 44087 USA
Telephone: [phone] * Fax: [phone]

MUSTANG DYNAMOMETER
MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE iii
NOTICE
This manual has been designed and written to provide useful information
about Mustang Dynamometer equipment and systems. Every effort has
been made to make this manual as complete as possible, but no
warranty or fitness is implied.
The information contained in this manual is provided on an “as is” basis.
Neither the author of this manual nor the management and owners of
Mustang Dynamometer shall have either liability or responsibility to any
person or entity with respect to any loss or damages arising from the
information contained in this manual.

MODEL MD-800 SERPENTINE DYNAMOMETER SERVICE MANUAL
iv MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE
WARRANTY
LIMIT OF LIABILITY
Mustang warrants that the product(s) that is the subject of this sale is free from defects in
material. The duration of this warranty is one year from date of shipment on all Mustang-related
components. Components not manufactured by Mustang will carry the original manufacturer’s
warranty, typically 90 days for all electronic-related components. All warranty claims must be
processed through Mustang.
If a problem arises within the applicable warranty period, it is the responsibility of the purchaser
to (a) promptly notify Mustang in writing (b) obtain a RMA Number from Mustang (c) return to
Mustang the component(s) that are claimed to be defective (transportation charges must be
prepaid by the purchaser). RMA Number must be clearly marked on outside of package(s).
Within a reasonable time after such notification, Mustang will correct any defect(s) in
component(s). If Mustang is unable to repair the component after a reasonable number of
attempts, or if Mustang determines at any time the repair is impracticable, Mustang will provide
a replacement with like or similar component(s). The purchaser is responsible for all
transportation expenses to and from Mustang and all labor expenses associated with removal and
replacement of the component(s) as well as labor involved to repair component(s). Mustang will
bear the expense of parts only. These remedies are the Purchaser’s sole remedies for breach of
warranty.
The expiration of the warranty period, use of the product for purposes other than those for which
it is designed, other abuse or misuse, unauthorized attachments, modifications, or disassembly,
or mishandling of the product during shipping, shall end all liability of Mustang.
In no case shall Mustang be liable for any special, incidental, or consequential damages based
upon breach of warranty, breach of contract, negligence, strict tort, or any other legal theory.
Such damages include but are not limited to, loss of profits, loss of savings or revenue, loss of
use of the product or any associated equipment, cost of capital, cost of any substitute equipment,
facilities or services, downtime, the claims of third parties including customers, and injury to
property.
Unless modified in writing and signed by officers of both parties, this agreement is understood to
be the complete and exclusive agreement between the parties, superseding all prior agreements,
oral or written and all other communications between the parties relating to the subject matter of
the agreement.
GANZCORP INVESTMENTS INC. dba MUSTANG DYNAMOMETER

MUSTANG DYNAMOMETER
MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE v
DANGER
Keep limbs, hair, jewelry and clothing away from
the moving rolls. When operating a vehicle on the
machine, remain inside vehicle until the rolls have
stopped. Cover the rolls when the equipment is not
in use.
DANGER
Do not operate or perform any maintenance on your
equipment until you have carefully read this manual
in its entirety making sure that you understand all
of the material presented in each section.
CAUTION
Unsafe operating practices can lead to potentially
dangerous situations when your machine is running.
Only properly trained and responsible personnel
should attempt to operate this machine.
CAUTION
Removal and disassembly instructions in this manual
have been reduced to a minimum for ease of
readability.
Only experienced maintenance personnel should
attempt to install and/or make repairs to this
machine.

MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE 1-1
SECTION
INTRODUCTION 1
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 .......................................................................... 1-5
1.5 ENVIRONMENTAL DATA ..................................................................................... 1-6
1.6 INSTALLATION DATA ......................................................................................... 1-6
1.7 NAMEPLATE DATA............................................................................................ 1-6
1.8 IF YOU NEED HELP........................................................................................... 1-6

MODEL MD-800 SERPENTINE DYNAMOMETER SERVICE MANUAL
1-2 MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE

SECTION 1-INTRODUCTION MUSTANG DYNAMOMETER
MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE 1-3
1.1 DESCRIPTION
This manual contains maintenance and service information for Model MD-800-SE-DR
Serpentine Chassis Dynamometers. Most maintenance and service procedures are similar for all
model dynamometers.
Major system components include the dynamometer, and the control system. Major
dynamometer components include the frame, rolls, wheelbase adjustment system, drive belt and
Power Absorber Unit (PAU).
Refer to Figure 2.1 for an illustration of the major components of the MD-800 Serpentine
Dynamometer.

MODEL MD-800 SERPENTINE DYNAMOMETER SERVICE MANUAL
1-4 MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE
1.2 GENERAL SAFETY ISSUES
Be Knowledgeable ... Do not attempt to operate, maintain or service your Mustang Chassis
Dynamometer System until you have familiarized yourself with the equipment by reading the
instructions in this manual.
Act Responsibly ... Exercise caution and discretion when operating or performing maintenance
on the dynamometer. Always observe typical, common sense test area precautions.
Beware of Projectiles ... Tires that are rotating can throw off stones and other projectiles. Wear
approved safety glasses when in the vicinity of the vehicle being tested.
Protect Your Ears ... Always wear approved ear protection when working near the
dynamometer.
Beware of Being Grabbed ... Keep limbs, hair, jewelry, and clothing away from the moving
dynamometer components.
Pay Attention ... Maintain acute awareness when the dynamometer rolls are in motion.
1.3 OPERATIONAL SAFETY ISSUES
For ALL
Vent Engine Exhaust ... Provide adequate room ventilation. High concentrations of engine
exhaust can be deadly. Do not operate your dynamometer without proper ventilation. The
ventilation system should provide four (4) air changes an hour in the shop and six (6) air
changes an hour for the pit.
types of testing, use chains, straps, Ratchet binders or strap ratchet binders of suitable
size with floor anchors 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 of 3/8” diameter chain with
3/8” Ratchet binders. For front wheel drive vehicles, two chains and binders should be used to
restrain the front axle and a minimum of one chain/binder for the rear axle. For rear wheel drive
vehicles, 2 chains/binders should be used to secure the rear axle.
Monitor Carbon Monoxide ... Make sure you have installed a carbon monoxide monitor in the
dynamometer bay.
Guarding ... Provide floor markings and protective guard railings for customer/operator
protection. NEVER operate the dynamometer with any cover panels removed unless specifically
directed to do so elsewhere in this manual.
Keep Clear of Rolls ... Stay away from the rolls when in operation.
Check Tires ... Before driving the test vehicle onto the dynamometer, be sure to check the
vehicle’s tires for proper inflation. Inspect the tires for any signs of damage and remove any
embedded objects from the tread.
Restrain Vehicle Movement ... During dynamometer operation, make sure that the restraints
are in position.
Proper Clearance ... Always ensure that there is a clearance of at least four (4) feet to the
front, rear, and sides of the dynamometer.
Stay Seated ... The vehicle operator MUST remain in the driver’s seat at all times during a
drive-cycle test. Do NOT attempt to get in or out of the vehicle when the dynamometer rolls are
moving.
If in Doubt, STOP! ... Stop the equipment immediately if you have any doubt about the safe
operating condition of the dynamometer and/or the correctness of any procedures that you are
performing.

SECTION 1-INTRODUCTION MUSTANG DYNAMOMETER
MODEL MD-800 SERPENTINE MAINTENANCE AND SERVICE 1-5
1.4 MAINTENANCE SAFETY ISSUES
Electrical Shock Hazard ... Turn off electrical service to the system before performing any
maintenance activity. Turn off the main breaker in your breaker box before working on anything
related to the PAU or motor.
No Jewelry ... Remove any jewelry before performing any electrical or mechanical
troubleshooting, repair, etc. on the dynamometer.
Cover Panels ... Use extreme caution around drive mechanisms and moving parts when
operating the dynamometer with any of its cover panels removed from the chassis assembly.
Avoid Straining Yourself ... Be careful when lifting dynamometer cover panels. Be careful
when replacing belts, couplings, or bearings.
Air Pressure ... Make sure that there is no shop air to the dynamometer when working on lift
plates or air bags.
Watch Your Hands ... Never put your hand between the lift plate and roll when shop air supply
is connected to the dynamometer.
NEVER, NEVER, NEVER! ... Never pull on the drive belt in order to spin the rolls.
Check Tightness ... Make sure that all bolts on the dynamometer are tight and all couplings are
properly secured.