MD MD-AWD-150 User manual

Mustang Dynamometer MD-AWD-150 Page 1
MD-AWD-150 SERIES MANUAL REV.A

Mustang Dynamometer MD-AWD-150 Page 2
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 2012
Ganzcorp Investments, inc. dba Mustang
Dynamometer
All rights reserved
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 and accurate 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
Rev. B May, 2013

Mustang Dynamometer MD-AWD-150 Page 3
LWARNINGL
Do not operate or perform any maintenance on you
equipment until you have carefully read this manual in its
entirety making sure that you understand all of the material
presented in each section.
LWARNINGL
Unsafe operation practices can lead to potentially dangerous
situations when your machine is running.
Only properly trained and responsible personnel should
attempt to operate this machine.
LWARNINGL
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.
LWARNINGL
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 4
WARNING
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 of all Mustang-
related components. Components not manufactured by Mustang will carry the original
manufacture’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 the outside of the 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 then those
fro 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 not limited to, loss of profits, loss of savings or
revenue, loss of use of 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.
GANCORP INVESTMENTS INC. dba MUSTANG DYNAMOMETER

Mustang Dynamometer MD-AWD-150 Page 5
TABLE OF CONTENTS:
SECTION 1 – INTRODUCTION..........................................................................................................................7
1.1WHAT IS ACHASSIS DYNAMOMETER ........................................................................................................7
1.2ABOUT THIS MANUAL................................................................................................................................8
1.3IMPORTANT MESSAGE BOXES ....................................................................................................................9
1.4BEFORE YOU START.................................................................................................................................10
1.5IF YOU NEED HELP ..................................................................................................................................10
SECTION 2 – THE SYSTEM ..............................................................................................................................11
2.1 INTRODUCTION...............................................................................................................................................11
2.2 MAJOR SYSTEM COMPONENTS.......................................................................................................................11
2.2.1 Dynamometer .........................................................................................................................................12
2.2.2a Control and Monitoring System............................................................................................................13
2.2.2b Control and Monitoring System (not attached to Dyne)....................................................................... 14
2.2.3 Software System......................................................................................................................................14
2.3 PRINCIPLES OF OPERATION............................................................................................................................ 14
SECTION 3 – SAFETY FIRST............................................................................................................................15
3.1 INTRODUCTION...............................................................................................................................................15
3.2 GENERAL SAFETY ISSUES...............................................................................................................................16
3.3 OPERATIONAL SAFETY ISSUES .......................................................................................................................17
3.4 MAINTENANCE SAFETY ISSUES ...................................................................................................................... 18
SECTION 4 – INSTALLATION..........................................................................................................................19
4.1 INTRODUCTION...............................................................................................................................................19
4.2 INSPECTION ....................................................................................................................................................19
4.3 TOOLS AND EQUIPMENT NEEDED FOR INSTALLATION ................................................................................... 19
4.4 SHOP LAYOUT AND REQUIREMENTS............................................................................................................... 19
4.4.1 Pit Excavation (Belowground Installation Only) ...................................................................................19
4.4.2 Electrical ................................................................................................................................................20
4.4.3 Pneumatic (air)....................................................................................................................................... 20
4.4.4 Ventilation ..............................................................................................................................................20
4.4.5 Floor Anchors......................................................................................................................................... 20
4.4.6 Clearance ...............................................................................................................................................20
4.5 ABOVE GROUND INSTALLATION .................................................................................................................... 21
4.5.1 Above Ground Installation Procedure.................................................................................................... 21
4.6 BELOW GROUND INSTALLATION ....................................................................................................................27
4.6.1 Below-Ground Installation Procedure ................................................................................................... 27
INSTALLATION ILLUSTRATIONS:........................................................................................................................... 29
4.7 CONTROL INSTALLATION ............................................................................................................................... 29
4.8 PRE-OPERATIONAL INSPECTION......................................................................................................................32
SECTION 5 – OPERATIONAL CHECKOUT..................................................................................................33
5.1 INTRODUCTION...............................................................................................................................................33
5.2 INITIAL START................................................................................................................................................33
SECTION 6 – PREVENTATIVE MAINTENANCE.........................................................................................36
6.1 INTRODUCTION...............................................................................................................................................36
6.2 GENERAL INFORMATION &MAINTENANCE INSPECTION/PROCEDURES.......................................................... 36
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 6
SECTION 7 – TROUBLESHOOTING...............................................................................................................42
7.1 INTRODUCTION...............................................................................................................................................42
7.2 TROUBLESHOOTING GUIDE ............................................................................................................................ 42
SECTION 8 – APPENDIX ...................................................................................................................................45
APPENDIX A–TORQUE SPECIFICATIONS.............................................................................................................. 45
APPENDIX B–RECOMMENDED FLUIDS................................................................................................................ 48
APPENDIX C –ANCHOR POD INSTALLATION-NEW FLOORS.................................................................................49

Mustang Dynamometer MD-AWD-150 Page 7
SECTION 1–INTRODUCTION
1.1 WHAT IS ACHASSIS DYNAMOMETER
Today and in the future, automobiles and trucks will be required to meet increasingly stringent
emission and safety standards, In many cases, dynamic testing – either on-highway or with a
chassis dynamometer is the only way to adequately measure vehicle performance or emissions.
As Mustang Chassis Dynamometer (sometimes referred to as a “dyne” or “dyno”) is a rugged
piece of equipment which is used to apply a load to a test vehicle. The Mustang Chassis Dyne is
an integrated assembly of mechanical, electromechanical, and electrical/electronic sub-systems
which function together to provide you with the ability to simulate actual road loads while the
vehicle is being tested remains in the safe and controlled confines of a test center. In addition
during a test, this capability will also enable you to connect test instruments and diagnostic
equipment to the test vehicle’s engine to monitor specific engine performance characteristics.
As the torque from the test vehicle’s drive wheels cause the rolls of the Dyne to rotate, Mustang’s
air-cooled electrical eddy current Power Absorbing Unit (PAU) opposes this force by converting
the vehicle’s kinetic energy into heat. A microcomputer-based control unit, using closed-loop
feedback control, regulates the amount of power that is absorbed by the PAU and, as a result, the
amount of load that is imposed on the test vehicle.
The Chassis Dynamometer has emerged as a major asset in the areas of Emissions Testing,
Fault Diagnosis, Performance Engineering, and Test Engineering throughout the world. Chassis
Dynamometer can be used to perform a wide variety of test on vehicles; some examples of these
tests deal with…
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 8
1.2 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 – Introduction This is the section you are currently reading.
Section 2 – The Systems This section presents a description of the MD-
AWD-150-Series Chassis Dynamometer
System to familiarize you with its major
components. In addition, the principles of
dynamometer operation are discussed.
Section 3 – Safety First A number of very important safety tips are
presented in this section. Be sure to study
this section carefully!
Section 4 – Installation A step-by-step procedure is given in this
section to help ensure that your dyne is
installed properly.
Section 5 – Operational Checkout A sequence of operational checks is provided
in this section to verify that your system is
operating properly.
Section 6 – Preventative Maintenance General maintenance and lubrication
instructions are presented in this section.
Section 7 – Troubleshooting Some basic troubleshooting hints are
contained in this section.
Section 8 – Appendices The appendices contain reference information
that you can easily access when you need it.

Mustang Dynamometer MD-AWD-150 Page 9
1.3 IMPORTANT MESSAGE BOXES
When you read this manual, and operate/maintain your Mustang Dynamometer System, BE SURE
TO OBSERVE ALL DANGER, WARNING AND CAUTION ADVISORIES!
These advisories point out potentially hazardous procedures and conditions. As can be seen
below, all three types of advisories are enclosed in a box to call attention to them.
l DANGER
This is an example of a DANGER message. A DANGER message alerts a
person that sever bodily injury or loss of life could occur if procedures are not
followed.
v DANGER
This is an example of an electrical DANGER message. An electrical DANGER
message alerts a person that, as a result of electrical shock, severe bodily injury
or loss of life could occur if procedures are not followed.
l WARNING
This is an example of a WARNING message. A WARNING message alerts a
person to potential bodily injury if procedures are not followed.


CAUTION
This is an example of a CAUTION message. A CAUTION message alerts a
person that if procedures are not followed, damage to, or destruction of the
equipment could result.


NOTE
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 10
1.4 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.
All personnel who will be performing maintenance and service on your Dynamometer
have read this manual in its entirety and understand all of the information presented.
1.5 IF YOU NEED HELP
Much effort has been extended to make this manual easy to work with as well as complete and
accurate. However, if there is something that you do not understand or something that you have a
question about, please feel free to contact a Mustang Representative at...
MUSTANG DYNAMOMETER
2300 PINNACLE PKWY.
TWINSBURG,OHIO 44087 USA
PH:[phone]
FAX:[phone]
[e-mail]