Obd Dyne Manual

MAINTENANCE
AND
SERVICE MANUAL
MODEL MD-OBD-DYNE
SERIES
Revision Release Date Initial

A 09 July 98 KS
B 15 July 98 KS
C 21 September 98 KS
D 30 November 98 KS
E 1 April 99 JH
F 11 June 1999 JH
G 25 October, 1999 DF
H 14 March , 2002 DF
MUSTANG DYNAMOMETER
- 1 -MODEL OBD DYNE MAINTENANCE AND SERVICE

MUSTANG DYNAMOMETER
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  1999
Ganzcorp Investments, Inc. dba Mustang Dynamometer
All rights reserved
Mustang Dynamometer
2300 Pinnacle Parkway
Twinsburg, Ohio 44087 USA
Telephone: (330) 963-5400 * Fax: (330) 425-3310
MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -2-

MUSTANG DYNAMOMETER
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.
AVIS
Ce manuel a été conçu et écrit pour fournir de l’information utile sur
l’équipement et les systèmes Mustang Dynamometer. Toutes les
précautions ont été prises pour rendre ce manuel aussi complet que
possible, mais aucune garantie d’adaptation ni autre n’est implicite.
L’information contenue dans ce manuel est fournie « telle quelle ». Ni

l’auteur de ce manuel ni la direction ni les propriétaires de Mustang
Dynamometer ne seront responsables envers quiconque ni envers
quelque entité que ce soit des pertes ou dommages résultants de
l’information contenue dans ce manuel.

MUSTANG DYNAMOMETER
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
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
Garder les membres, les cheveux, les bijoux et les
vêtements éloignés des rouleaux en mouvement.
Lors de l’utilisation d’un véhicule sur l’équipement,
rester à l’intérieur du véhicule jusqu’à ce que les
rouleaux se soient arrêtés. Couvrir les rouleaux
lorsque l’équipement ne sert pas.
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.
DANGER
Ne pas utiliser l’équipement ni effectuer son
entretien avant d’avoir lu attentivement ce manuel
en entier et d’avoir compris tout le matériel
présenté dans chaque section.

MUSTANG DYNAMOMETER
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.
ATTENTION
Des pratiques d’utilisation non sûres peuvent conduire
à des situations potentiellement dangereuses lors du
fonctionnement de l’équipement.
Seul le personnel responsable et correctement
instruit doit entreprendre d’utiliser cet
équipement.
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.
ATTENTION
Les instructions de dépose et de démontage données
dans ce manuel ont été réduites au minimum pour en
faciliter la lecture.
Seul du personnel d’entretien expérimenté doit
entreprendre d’installer ou de faire des réparations
sur cet équipement.
SECTION
MUSTANG DYNAMOMETER
INTRODUCTION
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 ...........................................................................1-6
1.5 ENVIRONMENTAL DATA .....................................................................................1-7
1.6 INSTALLATION DATA .........................................................................................1-7
1.7 NAMEPLATE DATA ............................................................................................1-7
1.8 IF YOU NEED HELP ...........................................................................................1-7

MUSTANG DYNAMOMETER

MUSTANG DYNAMOMETER
1.1 DESCRIPTION
This manual contains maintenance and service information for Model MD-OBD Series Chassis
Dynamometers. Table 1.1 lists part numbers and descriptions of the dynamometers. Most
maintenance and service procedures are similar for all model dynamometers. Specific
procedures for some model numbers are given.
Table 1.1 ESP/Mustang Dynamometer ASM-97 Series Dynamometers
MD Model Number Description
MD-OBD Low profile
Model MD-OBD Series Chassis Dynamometers are designed for Acceleration Simulation Mode
(ASM) emissions testing and meet or exceed all State design and performance criteria.
Major system components include the dynamometer, and the control system. Major
dynamometer components include the frame, rolls, inertia weight, and Power Absorber Unit
(PAU).
Refer to Figure 3.1 for an illustration of the major components of the MD-OBD Series
Dynamometers.

MUSTANG DYNAMOMETER
1.2 GENERAL SAFETY ISSUES

CONSIGNES GÉNÉRALES DE SÉCURITÉ
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.
Être instruit ... Ne pas essayer d’utiliser, d’entretenir ni de réparer le système dynamométrique
de châssis (banc d’essai) Mustang avant de s’être familiarisé avec l’équipement en lisant les
instructions de ce manuel.
Act Responsibly ... Exercise caution and discretion when operating or performing maintenance
on the dynamometer. Always observe typical, common sense test area precautions.
Agir de manière responsable ... Exercer prudence et bon jugement lors de l’utilisation ou de
l’entretien de ce dynamomètre. Toujours observer les précautions de bon sens de zone d’essai.
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.
Attention aux projectiles ... Les pneus en rotation peuvent projeter des pierres et autres
projectiles. Porter des lunettes de sécurité approuvées à proximité du véhicule en cours d’essai.
Protect Your Ears ... Always wear approved ear protection when working near the
dynamometer.
Protéger les oreilles ... Toujours porter une protection approuvée pour les oreilles lors du travail
près du dynamomètre.
Beware of Being Grabbed ... Keep limbs, hair, jewelry, and clothing away from the moving
dynamometer components.
Attention de ne pas être happé ... Garder les membres, les cheveux, les bijoux et les vêtements
éloignés des composants en mouvement du dynamomètre.
Pay Attention ... Maintain acute awareness when the dynamometer rolls are in motion.
Faire attention ... Faire très attention lorsque les rouleaux du dynamomètre sont en rotation.
1.3 OPERATIONAL SAFETY ISSUES

CONSIGNES DE SÉCURITÉ DE FONCTIONNEMENT
Your dynamometer comes standard with “Drop-In” style Restraints. One is for the left wheel
and the other for the right wheel. The “Drop-In” style restraints are for ASM 50/15 and ASM
25/25 testing ONLY. The maximum speed for the “Drop-In” style restraints are 25 MPH. Prior
to performing an ASM 50/15 or ASM 25/25 test, ensure the “Drop-IN” style restraints are
properly positioned and rubber wheel chocks are placed in the appropriate places of the non-
drive axle.
For ALL other types of testing, use chains, straps, Ratchet binders or strap ratchet binders of
suitable size with floor anchors and wheel chocks 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.
Wheel chocks should be used on the non-drive axle for all testing types.
MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 10 -

MUSTANG DYNAMOMETER
OPERATIONAL SAFETY ISSUES (CONTINUED)

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.
Dégazer les échappements du moteur ... Fournir une aération adéquate de la pièce. Une
concentration élevée de gaz d’échappement du moteur peut être mortelle. Ne pas faire fonctionner
le dynamomètre sans ventilation appropriée. Le système de ventilation doit fournir quatre (4)
renouvellements d’air par heure dans l’atelier et six (6) renouvellements d’air par heure pour la
fosse.
Monitor Carbon Monoxide ... Make sure you have installed a carbon monoxide monitor in the
dynamometer bay.
Contrôler le niveau d’oxyde de carbone ... S’assurer d’avoir installé un contrôleur d’oxyde de
carbone dans la baie du dynamomètre.
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.
Barrières de protections ... Prévoir un marquage au sol et des rails de protection des clients et
des opérateurs. NE JAMAIS faire fonctionner le dynamomètre avec des panneaux de protection
déposés sauf instructions contraires spécifiques ailleurs dans ce manuel.
Keep Clear of Rolls ... Stay away from the rolls when in operation.
Rester éloigné des rouleaux ... Rester éloigné des rouleaux pendant le fonctionnement.
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.
Contrôler les pneus ... Avant de conduire le véhicule d’essai sur le dynamomètre, s’assurer que
les pneus du véhicule soient bien gonflés. Inspecter les pneus en recherchant les signes de
dommages et retirer tout objet incrusté dans la bande de roulement.
Restrain Vehicle Movement ... During dynamometer operation, make sure that the restraints
are in position.
Empêcher le mouvement du véhicule ... Pendant le fonctionnement du dynamomètre, s’assurer
que les dispositifs de blocage soient en place.
Proper Clearance ... Always ensure that there is a clearance of at least four (4) feet to the front,
rear, and sides of the dynamometer.
Assurer un bon dégagement ... Toujours s’assurer qu’il y ait un dégagement d’au moins 1,20
mètres à l’avant, à l’arrière et sur les côtés du dynamomètre.
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.
Rester assis ... Le conducteur du véhicule DOIT rester en permanence assis sur le siège du
conducteur pendant un essai de cycle de conduite. NE PAS essayer de rentrer ni de sortir du
véhicule lorsque les rouleaux du dynamomètre sont en fonctionnement.

MUSTANG DYNAMOMETER
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.
En cas de doute ARRÊTER! ... Arrêter l’équipement immédiatement en cas de doute sur la
sûreté des conditions de fonctionnement du dynamomètre ou sur la validité des procédures
effectuées.
1.4 MAINTENANCE SAFETY ISSUES

CONSIGNES DE SÉCURITÉ D’ENTRETIEN
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.
Risque d’électrocution ... Couper l’alimentation électrique du système avant d’effectuer tout
travail d’entretien. Couper le disjoncteur principal du boîtier de disjoncteurs avant de travailler sur
tout élément relatif au PAU ou au moteur.
No Jewelry ... Remove any jewelry before performing any electrical or mechanical
troubleshooting, repair, etc. on the dynamometer.
Pas de bijou ... Retirer les bijoux avant d’effectuer tout dépannage électrique ou mécanique, toute
réparation, etc. sur le dynamomètre.
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.
Panneaux de protection ... Être très prudent à proximité des mécanismes d’entraînement et des
pièces en mouvement lors de l’utilisation du dynamomètre avec un de ses panneaux de protection
déposé du châssis.
Avoid Straining Yourself ... Be careful when lifting dynamometer cover panels. Be careful
when replacing belts, couplings, or bearings.
Éviter les élongations ... Être prudent lors du levage des panneaux de protection du
dynamomètre. Être prudent lors du remplacement des courroies, des accouplements, ou des
paliers.
Air Pressure ... Make sure that there is no shop air to the dynamometer when working on lift
plates or air bags.
Pression d’air ... S’assurer qu’il n’y ait pas d’alimentation en air sous pression de l’atelier sur le
dynamomètre lors du travail sur les plaques de levage ou les sacs gonflables.
Watch Your Hands ... Never put your hand between the lift plate and roll when shop air supply
is connected to the dynamometer.
Attention aux mains ... Ne jamais mettre les mains entre les plaques de levage et les rouleaux
lorsque l’air sous pression de l’atelier est connecté au dynamomètre.
NEVER, NEVER, NEVER! ... Never pull on the drive belt in order to spin the rolls.
JAMAIS, JAMAIS, JAMAIS! ... Ne jamais tirer sur la courroie d’entraînement pour faire
tourner les rouleaux.
Check Tightness ... Make sure that all bolts on the dynamometer are tight and all couplings are
properly secured.
Vérifier le serrage ... S’assurer que tous les boulons du dynamomètres soient serrés et que tous
les accouplements soient correctement bloqués.

MUSTANG DYNAMOMETER
1.5 ENVIRONMENTAL DATA

This equipment is rated for the following environmental conditions:
Indoor use only.
Temperature: -10o to 49oC
Maximum Relative Humidity: 95% Noncondensing
Altitude:Up to 2000 meters
Pollution Degree 1 in accordance with IEC 664
1.6 INSTALLATION DATA

The equipment requires the following electrical service:
230 Vac, 30 Amps, Single Phase, 60 Hertz
ESP provides external circuit breaker rated for 230 Vac, 30 Amp service. It is recommended
that the circuit breaker be located in close proximity to the dynamometer, at minimum, within
the same room.
Installation and mounting hardware are provided with every Dynamometer and shall be used
regardless of a Pit or Floor mount installation. Hardware provided is as follows: (4) 5/8 X 4.5”
Thunderstuds (MD# 20013614), (1) 5/8 X 7” Thunderstud (MD# 20008116) and (4) Dog Ears
(MD# 20001704). Anchor stud hole locations can be found on attached drawing, MD# 20014882.
Tools Required: 1 - Hammer Drill with 5/8” concrete or Masonry bit. 1 - Hammer. 1 - 3/4” Open
end wrench. Various sizes flat Steel shim stock. 1 - 4’ level.
Using hammer drill mark and drill holes in concrete a minimum of 4.5” deep for 4.5 thunderstud
and 7” deep for 7” thunderstud per MD DWG # 20014882. Ensure holes are clean of any debris
prior to attempting installation of Thunderstud. Place Dynamometer into pit or onto floor at
installation site. Check level of dynamometer, use flat steel shim stock (customer supplied) as
necessary to level dynamometer to floor. Level dynamometer in two planes; (1) Place level on top
of rolls parallel with a roll and (2) place level across a front roll and rear roll. Shim unit by
positioning shim near all the anchor locations as well as every 12” under the main frame rails.
Additionally, position shim stock, as necessary, under the air bag channel near the PAU end of
dynamometer. The air bag channel must be supported at this location. Using provided anchor
foot, MD # 20001704, drawing attached, insert thunderstud with flat washer and nut attached into
anchor foot and hole previously drilled into concrete. Using hammer, pound thunderstud into hole
until nut is flush with anchor foot. Ensure anchor foot is also in contact with dynamometer frame.
Using ¾” wrench, tighten nut to 50 ft lbs. When pounding 7” thunderstud, ensure frame bearing
support tube is not damaged.
Take care not to over tighten the nuts, as this may cause damage to the frame of the dynamometer,
the thunderstud, or the concrete.
1.7 NAMEPLATE DATA

The nameplate on the dynamometer frame contains valuable information should it be necessary to
contact Mustang. Besides the model number, date manufactured, and revision level data, the
nameplate contains the dynamometer serial number. Have this number handy when contacting
Mustang Dynamometer.
1.8 IF YOU NEED HELP

MUSTANG DYNAMOMETER
Much effort has been extended to make this manual complete and accurate. However, if there
are any questions please contact a Mustang Dynamometer representative at:
Mustang Dynamometer
2300 Pinnacle Parkway
Twinsburg, Ohio 44087USA
Telephone:(330) 963-5400
Fax: (330) 425-3310

MUSTANG DYNAMOMETER
SECTION
PREVENTIVE MAINTENANCE
CONTENTS
2.1 INTRODUCTION .................................................................................................2-3
2.2 PREVENTIVE MAINTENANCE ...............................................................................2-4
2.3 LUBRICATION ...................................................................................................2-5
2.4 INSPECTION ......................................................................................................2-6

MUSTANG DYNAMOMETER

MUSTANG DYNAMOMETER
2.1 INTRODUCTION
This section contains information and procedures for preventive maintenance of the
dynamometer. Refer to Table 2.1 for a list of recommend tools and Table 2.2 for a list of
consumable items necessary for maintenance of the dynamometer. A Preventive Maintenance
Time Table, Table 2.3, provides recommended service intervals. Preventive maintenance
procedures follow.
Table 2.1 LIST OF RECOMMENDED TOOLS

ITEM USE ON
(2) 1-1/8-inch combination Brake Pad replacement
wrenches
15/16-inch socket 1-3/4 and 2-inch Pillow Block Bearing Bolts
15/16-inch wrench PAU Bracket Bolts
Idler Attachment Bolts
3/4-inch socket 1-1/2-inch Pillow Block Bearing Bolts

3/4-inch wrench Large Roll Pulley Bolts
Load Cell Mounting Bolts
9/16-inch socket Motor Mounting Bolts
9/16-inch wrench Air Bag Mounting Bolts (Two)
7/16-inch socket Motor Pulley Bushing Bolts
Small Roll Pulley Bolts
Limit Switch Bracket Bolts
1/8-inch Allen wrench Coupling set screws
9/64-inch Allen wrench Speed sensor
3/32-inch Allen wrench Small Pulley Bushing and Coupling Set Screws
5/32-inch Allen wrench 1-1/2-inch Pillow Block Bearing Set Screws
3/16-inch Allen wrench 1-3/4 and 2-inch Pillow Block Bearing Set Screws
1/4-inch Allen wrench PAU Pulley Bolts (ESP30184-9 and -11)
1/4-inch, 12-point, deep socket PAU Pulley Bolts (ESP30184-1, -6, -7 and -8)
7/32-inch Allen wrench Air Bag Mounting Bolts (Four)
Torque wrench, 0-250 inch-pounds. Torque Measurements
Torque wrench, 0-100 foot-pounds. Torque Measurements
Pipe wrench Brake Pad replacement
Feeler gauges Speed Sensor
Belt Tension Tester Belt Tension
Straight Edge Belt Tension
Digital Multi-Meter Electrical signals and connections
Table 2.2 LIST OF CONSUMABLE ITEMS

Item Mustang Part Number Designation
Coupling Grease 20010651 Mobil Mobilith AW 2

PAU Grease 20010651 Mobil Mobilith AW 2
Bearing Grease 20014314 Polyrex EM
Brake Cleaner 20014315 Brake cleaner
Thread Lock 20010654 Locktite 262
Teflon Tape 20014810 1/4-inch Teflon tape
2.2 PREVENTIVE MAINTENANCE
MUSTANG DYNAMOMETER
The activities listed in Table 2.3, Preventive Maintenance Time Table, should be performed at
the time intervals indicated. Perform initial startup inspections after installation, after 8 hours of
operation, and after the first forty hours of operation. After startup inspections are complete and
the dynamometer is operating satisfactorily, perform the regular preventive maintenance
inspections and lubrications as indicated.
Table 2.3
Preventive Maintenance Time Table
Initial Every Every Every

Maintenance Procedure Startup Three Six Twelve
Inspections Months Months Months
LUBRICATION
Lubricate Pillow Block Bearings •
Lubricate Couplings •
Lubricate PAU •
Lubricate Motor •
INSPECTION
Inspect Bearings • •
Inspect Couplings • •
Inspect Brake Pads • •
Check Motor to Roll Belt Tension • •
Check Roll to PAU Belt Tension • •
Check PAU Bracket Bolts • •
Inspect PAU Pulley Bolts • •
Inspect Roll Pulley Bolts • •
Inspect Motor Mounting Bolts • •
Inspect Motor Pulley Bolts • •
Inspect Idler Assembly • •
Inspect Restraint Assembly • •
Inspect Lift Assembly • •
Inspect Air Bags • •
Inspect Air Lines and Lift Solenoid • •
Inspect PAU Load Cell Assembly • •
Inspect Speed Sensors • •
Inspect Scale (ESP30184-1 AND –7) • •
Inspect and Clean Dynamometer • •
Inspect and Clean Pit • •
2.3 LUBRICATION
CAUTION
MUSTANG DYNAMOMETER
Bearings and couplings must be lubricated with

recommended lubricants. Lubricants must be fresh and
free from contamination. Failure to lubricate or to use
incorrect or contaminated lubricants will result in reduced
life expectancy and/or damage to bearings and couplings.
Too much grease can change parasitic losses of the
dynamometer and will cause overheating of roll and PAU
bearings in high-speed operation of the dynamometer.
ATTENTION
Les paliers et les accouplements doivent être lubrifiés avec des
lubrifiants recommandés. Les lubrifiants doivent être frais et non pollués.
Ne pas lubrifier ou bien utiliser du lubrifiant incorrect ou pollué résulte en
une durée de vie réduite ou en dégâts des paliers et des accouplements.
Trop de graisse peut modifier les pertes parasites du
dynamomètre et causer une surchauffe des paliers de
rouleau et de PAU lors du fonctionnement à haute vitesse
du dynamomètre.
Adequate lubrication is essential for satisfactory operation of the dynamometer. Lubrication of

the dynamometer pillow block bearings, couplings, and PAU should be done as a part of a
planned maintenance schedule. The recommended lubrication intervals in the Preventive
Maintenance Time Table should be used as a guide to establish this schedule. These intervals
are based on 24 hours of actual machine usage per week. For extreme or unusual operating
conditions, lubricate more often. Even if the dynamometer is used less than 24 hours per week,
the lubrication schedule should be followed in order to purge the system of potential
contaminants.
2.3.1 LUBRICATE PILLOW BLOCK BEARINGS

Remove the plug or temperature probe and replace it with a zerk fitting.
Using a hand pump grease gun filled with (Exxon) Andok C grease, insert the gun into the
fitting and add three grams of grease while rotating the dynamometer rolls by hand. Experiment
with your particular grease gun to determine how many pumps equate to three grams of grease.
It should be roughly equivalent to three pumps using a normal grease gun.
Remove the zerk fitting and carefully replace the plug or temperature probe.
Repeat for each of the 10 pillow block bearings on the dynamometer.
When finished with greasing all the pillow block bearings, run the dynamometer with a vehicle
properly restrained at approximately 20 mph for 15 minutes to evenly distribute the grease.
Run warm-up, parasitic, and coastdown tests.

MUSTANG DYNAMOMETER
2.3.2 LUBRICATE COUPLINGS

Remove the two (2) grease plugs from the coupling sleeves and insert grease fitting into one of
the holes.
Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the grease
fitting and pump the handle until grease comes out of the other hole.
Replace both grease plugs.
Tighten all plugs until they are snug and are approximately 1/16-inch above the surface - DO
NOT OVER-TIGHTEN THE PLUGS. The plugs should not be flush with the coupling sleeves.
If the plug falls below the surface of the coupling sleeve, remove it, wrap the threads with
Teflon tape, and reinstall.
Remove excess grease.
2.3.3 LUBRICATE PAU

The zerk fitting is located on the bottom of the stator frame. Wipe off any dirt or other
contaminates that may be on the grease fitting.
Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the fitting
and add twenty (20) grams of grease while rotating the PAU by hand. Experiment with your
particular grease gun to determine how many pumps equate to twenty grams of grease. It should
be roughly equivalent to twenty pumps using a normal grease gun.
2.3.4 LUBRICATE MOTOR

Wipe off any dirt or other contaminates that may be on the grease fitting.
Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun into the fitting
and add eight grams of grease while rotating the motor by hand. Experiment with your
particular grease gun to determine how many pumps equate to eight grams of grease. It should
be roughly equivalent to eight pumps using a normal grease gun.
2.4 INSPECTION
Table 2.4 Torque Chart
Description Bolt Socket/Key Qt Torque
Size Size y.
1-1/2-inch Pillow Block Bearing 5/16- 5/32 Allen 14 140 inch-pounds.
Set Screws 24
1-3/4-inch and 2-inch Pillow 3/8-24 3/16 Allen 6 250 inch-pounds.
Block Bearing Set Screws
Coupling Set Screws 1/4-28 1/8 Allen 8 75 inch-pounds.
Coupling Set Screws (Models 10-32 3/32 Allen 4 30 inch pounds
ESP30184-12 and –13)
1-1/2-inch Pillow Block Bearing 1/2-13 3/4 14 50 foot-pounds.
Bolts
1-3/4-inch Pillow Block Bearing 5/8-11 15/16 2 70 foot-pounds.
Bolts
2-inch Pillow Block Bearing Bolts 5/8-11 15/16 4 70 foot-pounds.
PAU Bracket Bolts 5/8-11 15/16 4 70 foot-pounds.
PAU Pulley Bolts (Models 5/16- 1/4 Allen 3 220 inch-pounds.
ESP30184-9 and –11) 18 Refer to procedure
for torque method.

MUSTANG DYNAMOMETER
Table 2.4 Torque Chart

Description Bolt Socket/Key Qt Torque
Size Size y.
PAU Pulley Bolts (Models 1/4-20 1/4 12 Point 3 220 inch-pounds.
ESP30184-1, -6, -7, and –8) Refer to procedure
for torque method.
PAU Pulley Set Screws (Models 3/8-24 3/16 Allen 2 250 inch-pounds
ESP30184-12, –13, -18, and
ESP30556-1)
Motor Mounting Bolts 3/8-16 9/16 8 30 foot-pounds.
Motor Pulley Bolts 1/4-20 7/16 2 9 foot-pounds.
Large Roll Pulley Bolts 1/2-13 3/4 3 60 foot-pounds.
Small Roll Pulley Bolts 1/4-20 7/16 3 9 foot-pounds.
Small Pulley Bushing set screw #10-24 3/32 Allen 1 60 inch-pounds.
Idler Attachment Bolts 5/8-11 15/16 2 70 foot pounds.
Restraint Limit Switch Bracket 1/4-20 7/16 2 9 foot-pounds.
Bolts
Air Bag Mounting Bolts (center) 3/8-16 9/16 2 30 foot-pounds.
Air Bag Mounting Bolts 3/8-16 7/32 Allen 4 15 foot-pounds.
(outboard)
Load Cell Bolts 1/2-13 3/4 4 50 foot-pounds.
2.4.1 INSPECT PILLOW BLOCK BEARINGS
NOTE
Three different size pillow block bearings are used. 1-1/2-inch
bearings are used six places on the rolls and one is used on the PAU.
One 1-3/4-inch bearing is used on the other end of the PAU, and two
2-inch bearings are used on the drive end of the rolls.
REMARQUE
Trois différentes dimensions de palier à chapeau sont utilisées. Les
paliers de 1-1/2 pouces sont utilisés en six emplacements sur les
rouleaux et en un sur le PAU. Un palier de 1-3/4 pouce est utilisé sur
l’autre extrémité du PAU et deux paliers de 2 pouces sont utilisés sur
l’extrémité d’entraînement des rouleaux.
Using a torque wrench with a 3/4-inch socket, check that the 1-1/2-inch roll bearing mounting
bolts are torqued to 50 foot-pounds.
If bolts are loose, remove bearing mounting bolts and bearing plate, clean threads with brake
cleaner, apply a few drops of Locktite 262, reassemble plate and bolts and torque to 50 foot-
pounds.
Using a 5/32-inch Allen wrench, check to make sure all bearing set screws are tight.
If set screws are loose, remove, clean with brake cleaner, apply a drop of Locktite 262, insert set
screws, and torque to 140 inch-pounds.
Using a torque wrench with a 15/16-inch socket, check that the 1-3/4-inch and 2-inch pillow
block bearing mounting bolts are torqued to 70 foot-pounds.

MUSTANG DYNAMOMETER
INSPECT PILLOW BLOCK BEARINGS (CONTINUED)

If bolts are loose, remove bearing mounting bolts and bearing plate, clean threads with brake
cleaner, apply a few drops of Locktite 262, reassemble plate and bolts and torque to 70 foot-
pounds.
Using a 3/16-inch Allen wrench, check to make sure all bearing set screws are tight.
Using a 7/16-inch open end wrench, make sure the temperature probes are securely screwed into
the bearing housings.
Check the temperature probe wires to make sure they are secure and do not rub against any
moving parts.
2.4.2 INSPECT CONDITION OF COUPLINGS

For models ESP30184-1, -6, -7, -8 -9 and –11, using a 1/8-inch Allen wrench, check to make
sure both set screws in each coupling assembly are tight (four coupling assemblies).
If set screws are loose, clean with brake cleaner, apply a drop of Locktite 262, insert set screws,
and torque to 75 inch-pounds.
For models ESP30184-12 and –13, using a 1/8-inch Allen wrench, check to make sure the set
screw in each rigid hub is tight. Using a 1/8-inch or 3/32-inch Allen wrench (one or the other
will be present), check to make sure the set screw in each flex hub is tight (four coupling
assemblies).
If set screws are loose, clean with brake cleaner, apply a drop of Locktite 262, insert set screws,
and torque to 75 inch-pounds for the 1/8-inch Allen wrench or 30 inch-pounds for the 3/32-inch
Allen wrench.
2.4.3 INSPECT BRAKE PADS

WARNING
Make sure that the air lift will not be accidentally raised
while performing this inspection. Failure to turn off shop
air after lowering the lift plate may allow the lift plate to
raise and cause injury.
AVERTISSEMENT
S’assurer que le levage pneumatique ne soit pas levé
accidentellement pendant cette inspection. Ne pas couper
l’alimentation pneumatique de l’atelier après avoir abaissé
la plaque de levage peut laisser la plaque de levage monter
et causer des blessures.
Lower the lift plate and disconnect the shop air supply to the dynamometer.
Visually inspect the brake pads for wear.
If the average brake pad thickness is less than 1/8 inch or if any spot is less than 1/16 inch,
replace the brake pad. Refer to the service section of this manual for replacement instructions.
2.4.4 CHECK MOTOR-TO-ROLL BELT TENSION

MUSTANG DYNAMOMETER
Visually inspect the toothed drive belt to ensure that there are no signs of wear, damage, or
deterioration. The belt should have a snug fit, neither too taut nor too loose. Observe the belt
during the dynamometer calibration sequence. The belt should not slip.
If the belt slips, is too loose or too taut, or needs replacement, refer to the service section of this
manual for procedures to service the belt.
2.4.5 CHECK ROLL-TO-PAU BELT TENSION

Visually inspect the drive belt to ensure that there are no signs of wear, damage, or
deterioration. The belt should have a snug fit, neither too taut nor too loose.
If the belt slips, is too loose or too taut, or needs replacement, refer to the service section of this
manual for procedures to service the belt.
2.4.6 INSPECT PAU BRACKET BOLTS

Using a torque wrench with a 15/16-inch socket, check that four (4) PAU bracket bolts are
torqued to 70 foot-pounds.
If bolts are loose, remove bolts, clean with brake cleaner, apply a few drops of Locktite 262,
reassemble bolts and torque to 70 foot-pounds.
2.4.7 INSPECT PAU PULLEY BOLTS (MODEL ESP30184-9 AND -11)

Using a torque wrench with a 1/4-inch Allen wrench, check that three (3) PAU pulley bolts are
torqued to 220 inch-pounds.
If bolts are loose, refer to the service section of this manual for a procedure to torque the bolts.
2.4.8 INSPECT PAU PULLEY BOLTS (MODEL ESP30184-1, -6, -7, AND -8)
Using a torque wrench with a 1/4-inch, 12-point socket, check that three (3) PAU pulley bolts
are torqued to 220 inch-pounds.
If bolts are loose, refer to the service section of this manual for a procedure to torque the bolts.
2.4.9 INSPECT PAU PULLEY SET SCREWS (MODEL ESP30184-12, –13, -18, AND MODEL
ESP30556-1)
Using a torque wrench with a 3/16-inch Allen wrench, check that the two set screws on the PAU
pulley are torqued to 250 inch-pounds.
2.4.10 INSPECT ROLL PULLEY BOLTS

Using a torque wrench with a 3/4-inch socket, check that the three (3) large roll pulley bolts are
Using a torque wrench with a 7/16-inch socket, check that the three (3) small pulley bolts are
INSPECT ROLL PULLEY BOLTS (CONTINUED)

MUSTANG DYNAMOMETER
Using a 3/32-inch Allen wrench, check to make sure all set screws in the small pulley bushing
are tight.
2.4.11 INSPECT MOTOR MOUNTING BOLTS

Using a torque wrench with a 9/16-inch socket, check that the four (4) motor swivel base frame
mounting bolts and the four (4) motor base to motor swivel base bolts are torqued to 30 foot-
pounds.
2.4.12 INSPECT MOTOR PULLEY BOLTS

Using a torque wrench with a 7/16-inch socket, check that two (2) motor pulley bolts are
2.4.13 INSPECT IDLER ATTACHMENT BOLTS

Using a torque wrench with a 15/16-inch socket, check that the two (2) idler attachment bolts
are torqued to 70 foot-pounds.
If bolts are loose, refer to the service section of this manual for idler and belt service
instructions.
2.4.14 INSPECT RESTRAINT LIMIT SWITCH ASSEMBLY

Using a torque wrench with a 7/16-inch socket, check that the two (2) restraint limit switch
bracket bolts are torqued to 9 foot-pounds.
Make sure wire connections are secure and switch is adjusted properly.
2.4.15 INSPECT LIFT ASSEMBLY

Using a torque wrench with a 7/32-inch Allen wrench bit, check that the four outboard air bag-
to-lift plate attachment bolts (two per end) are torqued to 15 foot-pounds.
Using a torque wrench with a 9/16-inch socket, check that the two (2) center air bag attachment
2.4.16 INSPECT AIRBAGS

MUSTANG DYNAMOMETER
Remove the lift plates and visually inspect the airbags for any wear, cracks, or dry rot. If air
bags need replacement, refer to the service section of this manual.
2.4.17 INSPECT AIR LINES AND LIFT SOLENOID

Inspect air lines for leaks. Replace faulty air lines if necessary.
Check all fittings on the lift solenoid to make sure they are secure and there are no air leaks.
Make sure all wire connections are secure.
2.4.18 INSPECT PAU LOAD CELL ASSEMBLY

Place a small level on top of the PAU bracket and make sure the PAU is level. If necessary,
level the PAU using a 3/4-inch wrench to remove the mounting bolt and adjusting the rod end
assembly up or down as necessary. Make sure rod ends do not touch center body of load cell.
Using a torque wrench with a 3/4-inch socket, check that the top PAU load cell mounting bolt is
If the bolt is loose, remove bolt, clean with brake cleaner, apply a few drops of Locktite 262,
reassemble bolt and torque to 50 foot-pounds.
Using a torque wrench with a 3/4-inch socket, check that the bottom PAU load cell eye bolt
(bearing) is torqued to 50 foot-pounds.
If the bolt is loose, remove bolt, clean with brake cleaner, apply a few drops of Locktite 262,
reassemble bolt and torque to 50 foot-pounds.
Using a torque wrench with a 3/4-inch socket, check that the two load cell bracket mounting
reassemble bolts and torque to 50 foot-pounds. It may be necessary to use a 3/4-inch end
wrench on one of the bolts.
Make sure load cell and PAU are not touching each other.
2.4.19 INSPECT SPEED SENSOR ASSEMBLIES

Verify that the primary speed sensor is snug. If it is loose, refer to the service section of this
manual. Note: the notch must face up.
Using feeler gauges verify that the spacing between the primary speed sensor and the top of the
pulley teeth is between 0.020 and 0.030 inches.
Verify that the secondary speed sensor is snug. If it is loose, refer to the service section of this
manual.
Using feeler gauges verify that the spacing between the secondary speed sensor and the top of
the pulley teeth is between 0.020 and 0.030 inches.
2.4.21 INSPECT AND CLEAN THE DYNAMOMETER, FRAME, CONTROL BOX AND PIT
Check to make sure the frame is level and shims and/or anchor bolts have not settled or moved.
Level the dynamometer using steel shim stock as necessary.

MUSTANG DYNAMOMETER
Tighten frame anchor bolts (“Thunderstuds”).

Refer to Table 2.3 and check all torque values listed. If bolts are loose, clean bolts, apply a few
drops of Locktite 262 on the threads, and torque to the specified value.
CAUTION
Do not use pressurized water or compressed air to clean
the dynamometer. Using pressurized cleaning techniques
can force contaminants into bearings and cause bearing
failure.
ATTENTION
Ne pas utiliser d’eau pressurisée ni d’air sous pression
pour nettoyer le dynamomètre. Utiliser des techniques de
nettoyage sous pression peut forcer l’entrée de polluants
dans les paliers et entraîner des défaillances des paliers.
INSPECT AND CLEAN THE DYNAMOMETER, FRAME, CONTROL BOX, AND PIT (CONTINUED)
Clean the dynamometer using a cloth that has been lightly wetted with water or a mild soap
solution.
CAUTION
Pay special attention to the air bags and the area
surrounding them. A build-up of dirt in this area can cause
wear and premature air bag failure.
ATTENTION
Faire particulièrement attention aux sacs gonflables et à la
zone qui les entoure. Une accumulation de saleté dans
cette zone peut entraîner de l’usure et une défaillance
prématurée du sac gonflable.
After cleaning the dynamometer, use an anticorrosive spray on all exposed metal to prevent
damage from rust or corrosion.
Clean the pit of all foreign objects and debris. Use a small paint scraper to loosen any built-up
dirt. Use a small vacuum cleaner to pick up any smaller debris. Wipe clean any excessive grease
thrown from moving parts.
Make sure the drains are clear.
Clean the inside of the control box with a clean rag and small vacuum cleaner.
Check all terminals in the control box for loose wires. Tighten if necessary.
Make sure the motor, PAU, and signal cables are secure. Tighten if necessary.
Make sure the switches on the lid of the control box are secure. Tighten if necessary.

MUSTANG DYNAMOMETER
SECTION
REPAIR MAINTENANCE
CONTENTS
3.1 INTRODUCTION .................................................................................................3-3
3.2 REPAIR M AINTENANCE ......................................................................................3-4

MUSTANG DYNAMOMETER

MUSTANG DYNAMOMETER
3.1 INTRODUCTION
This section contains complete disassembly and repair procedures for the Mustang
Dynamometer OBD Series Chassis Dynamometers. Disassemble the dynamometer only to the
level needed for repair. Most maintenance and service procedures are similar for all model
dynamometers. Specific procedures for some model numbers are given. Refer to Figure 3.1 for
the locations of major components. Refer to Table 3.1 for a list of special tools. Refer to Table
3.2 for a list of consumable items.
TABLE 3.1 LIST OF SPECIAL TOOLS

ITEM USE ON
Belt Tension Testing Tool. Mustang Belt tensioning

part number 20014355
Level PAU alignment
Square PAU alignment
Four point pulley alignment tool, Roll alignment

Mustang part number 20014354
Long straight edge Roll alignment
Torque wrench, 0-100 foot-pounds. Torque Measurements
Feeler gauges Speed Sensor, scale
Straight Edge Belt Tension
TABLE 3.2 LIST OF CONSUMABLE ITEMS

ITEM MUSTANG PART NUMBER DESIGNATION
Coupling Grease 20010651 Mobil Mobilith AW 2
PAU Grease 20010651 Mobil Mobilith AW 2
Bearing Grease 20014314 Polyrex EM
Brake Cleaner 20014315 Brake cleaner
Thread Lock 20010654 Locktite 262
Teflon Tape 20014810 1/4-inch Teflon tape

MUSTANG DYNAMOMETER
3.2 REPAIR MAINTENANCE

3.2.1 REMOVE AND REPLACE COVERS
Remove center cover plate by removing the button head cap screws using a 5/16-inch Allen
wrench. Remove the center cover plate from the dynamometer. Remove PAU/Inertia weight
cover by loosening the hex head cap screws using a 9/16-inch wrench and removing the cover.
Remove bearing cover plate by removing the two (2) button head cap screws using a 5/16-inch
Allen wrench and removing the cover. If necessary, remove the frame endcap plate from the
PAU side by removing the sheet metal screws and plate using a screwdriver. Clean fasteners
with brake cleaner before installation.
To replace covers, locate covers and plates with existing hardware and using a torque wrench
with a 5/16-inch Allen wrench, torque all hardware to 30 foot-pounds.
NOTE
Before replacing covers, inspect and clean the frame and pit and
perform an operational check of the dynamometer.
REMARQUE
Avant de remplacer les panneaux de protection, inspecter et nettoyer
le châssis et la fosse et effectuer un contrôle optionnel du
dynamomètre.
3.2.2 REMOVE AND REPLACE IDLER ASSEMBLY AND DRIVE BELT

Note and mark the location of any shims if they are present. To remove the drive belt, remove
the idler assembly bolts using a 15/16-inch socket wrench. Remove the idler assembly.
Disconnect the three air line connections at the PAU end of the dynamometer by pushing in the
green hub on the press lock fittings and pulling out the air line. Slide the belt off the PAU pulley
and gently slide the belt over the flanges on the roll pulleys. Clean idler assembly bolts with
brake cleaner.
TABLE 3.3
DRIVE
BELTS
ESP PART NUMBER MUSTANG PART NUMBER
ESP30184-1, -6, -7 20013412
ESP30184-9, -11 20013999
ESP30184-12, -13, -18 20014659

ESP30556-1
Refer to Table 3.3 for replacement drive belt part numbers. To replace the drive belt slide the
belt over the flanges of the roll pulleys and then gently slide it over the flanges of the PAU
pulley. Push belt in the slack area so it is snug around the pulleys. Confirm that the belt is

MUSTANG DYNAMOMETER
properly engaged on the three pulleys. The belt must not come in contact with any of the frame
parts or interfere with the air lines.
Apply a few drops of Loctite 262 to the clean threads of the two (2) idler attachment bolts, and
install the idler assembly and bolts using a 15/16-inch socket wrench. Replace any shims that
were present. Using a torque wrench with a 15/16-inch socket, torque the bolts to 70 foot-
pounds.
REMOVE AND REPLACE IDLER ASSEMBLY AND DRIVE BELT (CONTINUED)

CAUTION
The drive belt must be correctly aligned before operation of the
dynamometer. Improper alignment of the drive belt can result in
damage to the belt, pulleys, and bearings.
ATTENTION
La courroie d’entraînement doit être correctement alignée avant la
mise en fonctionnement du dynamomètre. Un mauvais alignement
de la courroie d’entraînement peut entraîner des dégâts de la
courroie, des poulies et des paliers.
Rotate the belt by moving the rolls by hand. Inspect the belt for damage and insure belt does not
ride on the edges of the pulleys. The belt may walk from side to side and may change direction
when rotated in the opposite direction. If the belt rides excessively on one edge of the pulley
flanges, shim the idler arm as necessary to align the belt. If the belt moves toward the flange in
one direction and toward the other flange when rotated in the other direction but does not ride
on either flange, do not shim the idler arm.
To shim the idler arm, loosen the idler arm and place the shims half way between the idler arm
and the frame. Always install the same number of shims on both sides of the arm. Put shims on
the top of the idler arm to move the belt away from the PAU. Put shims on the bottom to move
the belt toward the PAU.
Reconnect the air lines by sliding the air line into the fitting. To check for air leaks turn on the
shop air to the dynamometer and listen for leaks.
DRIVE BELT TENSIONING

Refer to Figure 3.2 and check the tension of the belt using belt tension measurement tool, Mustang
part number 20014355 (ESP30402-1), and Dynamometer Drive Belt Adjustment Bar, ESP10644-
1.
Lower the lift plate so the dynamometer rolls are free to turn. The lift must be lowered to obtain
the correct belt tension measurements.
WARNING
Make sure the dynamometer cannot be operated
while the belt tension is being adjusted. Severe
injury can occur if the power is applied to the
dynamometer during this procedure.
AVERTISSEMENT

MUSTANG DYNAMOMETER
S’assurer que le dynamomètre ne puisse pas être

utilisé pendant que la tension de la courroie est
réglée. Des blessures graves peuvent se produire si
l’alimentation est appliquée sur le dynamomètre
pendant cette procédure.
Turn the dynamometer power to OFF. Remove the belt drive access cover if not already
removed.
FIG 3.2
DRIVE BELT TENSIONING

For models ESP30184-1, -6, -7, and –8, set the large O-ring on the body of the tension tester to
the “25” mark on the body of the tool (about 3/8-inch from the end of the tool). Set the small O-
ring on the plunger against the body of the tension tester.
For models ESP30184-9, -11, -12, -13, -18, and ESP30556-1 set the large O-ring on the body of
the tension tester to the “15” mark on the body of the tool (about 1/4-inch from the end of the
tool). Set the small O-ring on the plunger against the body of the tension tester.
Place the alignment bar over the upper pulley as shown and center the bar across the width of
the belt. With the tension tester positioned in the correct alignment tool hole and perpendicular
to the alignment bar, push on the tension tester and deflect the belt until the large O-ring just
contacts the alignment bar. Release pressure and read pounds of force at the O-ring on the
plunger. Refer to Table 3.4 for proper drive belt tension.
TABLE 3.4 DRIVE BELT TENSION

MUSTANG DYNAMOMETER
DYNAMOMETER FORCE READING

ESP30184-1, -6, -7, -8 25 Pounds
ESP30184-9, -11, -12, -13, -18 15 Pounds

ESP30556-1, OBD DYNES
DRIVE BELT TENSIONING (CONTINUED)
CAUTION
Do not apply too much tension to the drive belt. Too
much tension on the drive belt can result in damage
to the belt, pulleys, and bearings.
ATTENTION
Ne pas appliquer trop de tension sur la courroie
d’entraînement. Trop de tension sur la courroie
d’entraînement peut entraîner des dégâts de la
courroie, des poulies et des paliers.
Tighten the belt by loosening the two idler bolts using a 15/16-inch wrench, loosening the
adjustment stop bolt, and tightening the adjustment nut. Be sure to torque the idler mounting
bolts to 70 foot-pounds. Apply a few drops of Loctite 262 to the threads of the stop nut.
3.2.3 REMOVE AND REPLACE MOTOR ASSEMBLY AND MOTOR BELT

To remove the motor belt use a 9/16-inch socket with long extension and loosen the adjustment
screw on the motor pivot plate to give slack to the belt. Remove the belt.
Swivel the motor for access to the bolts and using a 9/16-inch socket wrench with long
extension remove the four (4) motor mounting bolts, flat washers, and lock washers. Clean
hardware with brake cleaner prior to installation.
To replace the motor assembly place the motor on the motor support plate. Apply a few drops of
Loctite 262 to the threads of the four (4) motor mounting bolts and insert them with flat washers
and lock washers into the motor and motor mounting plate. Swivel the motor for access to the
bolts and using a torque wrench with a 9/16-inch socket and extension torque the motor
mounting bolts to 30 foot-pounds.
To replace the motor belt place the belt over the pulleys.
MOTOR BELT TENSIONING

M ETHOD 1 – Refer to Figure 3.2 and check the tension of the belt using belt tension
measurement tool, ESP30402, and a straight edge. Set the large O-ring on the body of the
tension tester to 1/4-inch from the end of the body. Set the small O-ring on the plunger against
the body of the tension tester. Place the straight edge on the belt. With the tension tester in the
middle of the belt and perpendicular to the span, push on the tension tester and deflect the belt
until the large O-ring is in line with the straight edge. Release pressure and read pounds of force
at the O-ring on the plunger. For all models, the belt should deflect 1/4-inch when fifteen (15)
pounds of force is applied. Tighten the belt, if necessary, using a 9/16-inch socket and long
extension to tighten the adjustment screw on the motor pivot plate below the motor. Apply a
few drops of Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end
MUSTANG DYNAMOMETER
wrench tighten the adjustment screw jam nut. Apply a few drops of Loctite 262 to the threads of
the jam nut.
M ETHOD 2 – Check the tension of the motor belt by running a dynamometer calibration
sequence. If the belt slips during the test, tighten it using a 9/16-inch socket and long extension
to tighten the adjustment screw on the motor pivot plate below the motor. Apply a few drops of
Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end wrench tighten
the adjustment screw jam nut. Apply a few drops of Loctite 262 to the threads of the jam nut.
MOTOR BELT TENSIONING (CONTINUED)

M ETHOD 3 – The belt tension may be checked by grasping the belt at mid span between the
thumb and index finger. Attempt to twist the belt. Properly adjusted, the belt should easily rotate
between 90 and 180 degrees. Tighten the belt, if necessary, using a 9/16-inch socket and long
extension to tighten the adjustment screw on the motor pivot plate below the motor. Apply a
few drops of Loctite 262 to the threads of the adjustment screw. Using a 9/16-inch open end
wrench tighten the adjustment screw jam nut. Apply a few drops of Loctite 262 to the threads of
the nut.
3.2.4 REMOVE AND REPLACE PAU ASSEMBLY

Release the tension of the drive belt. Refer to Remove and Replace Idler Assembly.
Refer to Figure 3.3, and using a 3/4-inch socket wrench and 3/4-inch open end wrench remove
the two (2) 1-1/2-inch pillow block bearing mounting bolts, flat washers, lock washers, and nuts
from the rear end of the dynamometer. Using a 15/16-inch socket wrench and 15/16-inch open
end wrench remove the two (2) 1-3/4-inch pillow block bearing mounting bolts, flat washers,
lock washers, and nuts at the pulley end. Clean hardware using brake cleaner and remove all
traces of Loctite prior to installation.
FIG 3.3
PAU

MUSTANG DYNAMOMETER
Using a 3/4-inch open end wrench, remove the load cell from the load cell bracket.
Loosen one bearing stop screw from the outboard side of each pillow block bearing using a
9/16-inch wrench. Do not remove both bearing stop screws from any bearing.
REMOVE AND REPLACE PAU ASSEMBLY (CONTINUED)
WARNING
The PAU assembly is extremely heavy. Be sure the PAU
assembly is properly supported when removing it from the
frame. Failure to observe these precautions may result in
damage to equipment, injury to personnel, or both.
AVERTISSEMENT
L’ensemble PAU est extrêmement lourd. S’assurer que
l’ensemble PAU soit correctement supporté lors de sa
dépose du châssis. Ne pas observer ces précautions peut
entraîner des dégâts de l’équipement, des blessures du
personnel, ou les deux.
Using proper lifting equipment remove the PAU. Note and mark the location of any shims
located under the bearings. The shims must be replaced in the same position when the PAU is
replaced. Do not attempt to service the PAU. Consult the factory for repair.
Before replacing the PAU, inspect the pulley for dings on the flange or burrs on the cutouts. The
pulley should be loose on the pulley bushing.
To replace the PAU, place the PAU and any shims that were installed under the PAU bearings
on top of the frame. Make sure the load cell bracket is facing upward. Apply a few drops of
Loctite 262 to the clean threads of two (2) 5/8-11 x 4-1/2-inch bolts (5/8-11x 5-1/2-inch bolts
for models ESP30184-12 , –13 and -18) and insert them with flat washers into the 1-3/4-inch
pillow block bearing mounting holes at the pulley end of the PAU. Apply a few drops of Loctite
262 to the clean threads of two (2) 1/2-13 x 4-1/2-inch bolts (1/2-13 x 5-1/2-inch bolts for
models ESP30184-12, –13, and -18) and insert them with flat washers into the 1-1/2-inch pillow
block bearings mounting holes at the rear end of the PAU.
Place the bearing bolt nuts, flat washers, and lock washers under the bearing supports at both
ends of the PAU and lightly screw in the bolts. Do not torque the bolts at this time. Snug up the
bearing stop screws. Do not tighten the jam nut.
Apply a few drops of Loctite 262 to the threads of the load cell mounting bolts and install the
load cell. Do not torque the bolts at this time. Make sure the load cell is vertical on the outboard
side of the PAU and there is clearance between the PAU and the motor.
PAU ALIGNMENT
Verify the horizontal alignment of the PAU to the rolls using a small level. Place the level flat
on top of the inertia weight and on top of rolls #3 and #4. Note the position of the bubble on the
level. The bubble on the level should be in the same position for all three locations. If the
alignment is not level then shim the PAU or roll as necessary by placing shim stock under the
roll or PAU bearings.
Refer to Figure 3.4 and verify the alignment of the PAU to the rolls by placing a square between
the face of the inertia weight and roll #4. Visually inspect the alignment. If the PAU is not
square loosen the jam nuts and use the bearing stop screws on the PAU bearings to set the
square flat to the PAU.
Recheck the PAU alignment using the square. Realign if necessary.

MUSTANG DYNAMOMETER
FIG 3.4
PAU ALIGNMENT
Using a torque wrench with a 3/4-inch socket and a 3/4-inch open end wrench torque the 1-1/2-
inch pillow block bearing mounting bolts at the end of the PAU to 50 foot-pounds. Using a
torque wrench with a 15/16-inch socket and a 15/16-inch open end wrench torque the 1-3/4-inch
pillow block bearing mounting bolts at the pulley end of the PAU to 70 foot-pounds. Tighten
the bearing stop screws and fully tighten the jam nuts. Apply a few drops of Loctite 262 to the
threads of the bearing stop screws and jam nuts.
Recheck the PAU alignment using the square. Realign if necessary.
Using a torque wrench with a 3/4-inch socket, torque the PAU load cell mounting bolts to 50
foot-pounds.
PAU PULLEY INSTALLATION

NOTE
Do not use lubricants in this installation Inspect the PAU shaft,
bushing, and mating hub. Remove all nicks, paint, dirt, grease, etc.
from mating surfaces. Wash or wipe bushing taper and tapped holes
with brake cleaner to remove any contaminates that may interfere in
the assembly.
REMARQUE
Ne pas utiliser de lubrifiants dans cette installation. Inspecter l’arbre
de PAU, le coussinet et le moyeu apparié. Retirer toutes les encoches,
la peinture, la saleté, la graisse, etc. des surfaces de contact. Laver ou
essuyer le cône de roulement et les trous taraudés avec un produit de
nettoyage de frein pour retirer tous les polluants qui peuvent
interférer dans l’assemblage.

MUSTANG DYNAMOMETER
FIG 3.5
PAU PULLEY INSTALLATION
CAUTION
Do not exceed torque limits. Too much torque to the
pulley/bushing assembly will cause damage to the
assembly.
ATTENTION
Ne pas excéder les limites de couple. Un couple trop élevé
sur la poulie et le coussinet entraînera des dégâts de
l’ensemble.
For models ESP30184-1, -6, -7 and -8, apply a few drops of Loctite 262 to the key and install
the key into the keyway in the shaft. Slide the cleaned bushing onto the shaft and key. The small
end of taper must be outboard. Slide the cleaned tapered pulley over the bushing. First, align the
shaft key with one of the slots in the mating hub and second, align the drilled holes in the
mating pulley with the threaded holes in the bushing. Clean the pulley bolts with brake cleaner
if necessary to remove any lubricants. Apply a few drops of Loctite 262 to the clean threads of
the pulley bolts and insert one bolt through each drilled hole in the mating hub and into the
threaded hole of the bushing. Do not use a lockwasher. NOTE: Once the pulley bolt with Loctite
applied has started to be installed, the process must be completed before the Loctite cures to
ensure a true torque reading.
Refer to Figure 3.5 and using a straight edge and ruler, align the bushing and pulley so there is a
3/16-inch offset from the roll pulley to the PAU pulley. Using a torque wrench with a 1/4-inch,
12-point socket, tighten all pulley bolts evenly and progressively in rotation. First, torque the
first pulley bolt to 140 inch-pounds. Torque the second pulley bolt and then the third. Repeat
this step two more times. Second, torque the first pulley bolt to 180 inch-pounds. Torque the
second pulley bolt and then the third. Repeat this step two more times. Finally, torque the first
pulley bolt to 220 inch-pounds. Torque the second pulley bolt and then the third. Repeat this
step two more times.

MUSTANG DYNAMOMETER
PAU PULLEY INSTALLATION (CONTINUED)

For models ESP30184-9 and -11, apply a few drops of Loctite 262 to the key and install the key
into the keyway in the shaft. Slide the cleaned bushing onto the shaft and key. The small end of
taper must be outboard. Slide the cleaned tapered pulley over the bushing. Align the drilled
holes in the mating hub with the threaded holes in the bushing. Clean the pulley bolts with brake
cleaner if necessary to remove any lubricants. Apply a few drops of Loctite 262 to the clean
threads of the pulley bolts and insert one bolt and lockwasher through each drilled hole in the
mating hub and into the threaded hole of the bushing. NOTE: Once the pulley bolt with Loctite
applied has started to be installed, the process must be completed before the Loctite cures to
ensure a true torque reading. Slide the bushing on to the shaft so it is flush with the shaft. Using
a torque wrench with a 1/4-inch Allen wrench, tighten all pulley bolts evenly and progressively
in rotation. First, torque the first pulley bolt to 140 inch-pounds. Torque the second pulley bolt
and then the third. Repeat this step two more times. Next, torque the first pulley bolt to 180
inch-pounds. Torque the second pulley bolt and then the third. Repeat this step two more times.
Finally, torque the first pulley bolt to 220 inch-pounds. Torque the second pulley bolt and then
the third. Repeat this step two more times.
For models ESP30184-12, -13, -18, and ESP30556-1 no bushing is used. Apply a few drops of
Loctite 262 to the key and install the key into the keyway in the shaft. Slide the PAU pulley
over the shaft and key and using a square or straight edge, align the PAU pulley with the roll
pulley. Apply a few drops of Loctite 262 to the threads of the two set screws and using a torque
wrench with a 3/16-inch Allen wrench, tighten the set screws to 250 inch-pounds.
3.2.5 REMOVE AND REPLACE SPEED SENSORS (SEE FIGURE 3.6)
PRIMARY SPEED SENSOR REMOVAL

Using a 9/64-inch Allen wrench loosen the screw on the clamp that holds the sensor in place
and remove the primary speed sensor.
SECONDARY SPEED SENSOR REMOVAL

Using two 3/4-inch wrenches disassemble the jam nuts and remove the secondary speed sensor.
PRIMARY SPEED SENSOR INSTALLATION

To install the primary speed sensor apply a drop of Loctite 262 to the threads of the clamp
screw and slide the sensor through the clamp. Secure it using a 9/64-inch Allen wrench. Using
feeler gauges set the spacing between the primary speed sensor and the top of the pulley teeth to
between 0.020 and 0.030 inches. Ensure notch on body of sensor faces upward.
SECONDARY SPEED SENSOR INSTALLATION

To install the secondary speed sensor apply a few drops of Loctite 262 to the threads of the jam
nuts, slide the sensor through the bracket, and secure it using two 3/4-inch wrenches to set the
jam nuts. Using feeler gauges set the spacing between the secondary speed sensor and the top of
the pulley teeth to between 0.020 and 0.030 inches
FIG 3.6

MUSTANG DYNAMOMETER
SPEED SENSORS
Fig 3.7
COUPLING DETAILS
(ESP30184-1, -6, -7, -8, -9, -10, -11, -18, AND ESP30556-1)

MUSTANG DYNAMOMETER
Fig 3.8
COUPLING DETAILS
(ESP30184-12, -13)
3.2.5 REMOVE AND REPLACE INNER SHAFTS (SEE FIGURES 3.7 AND 3.8)
REMOVAL
Using a 3/16-inch Allen wrench remove both grease plugs from each coupling sleeve. Using a
small flat edged screwdriver insert the screwdriver in the notch of the steel snap ring and gently
pry the end of the ring out of the ring groove. Continue removing the ring from the sleeve using
a spiral motion.
Slide sleeve off flex hub toward the center of the inner shaft. Repeat this procedure to remove
the other coupling sleeve. Remove inner shaft.
REPLACEMENT
To install the inner shafts inspect the shaft, sleeve and hub for nicks, dirt, grease, etc. Clean
with brake cleaner to remove any contaminates. Make sure each coupling hub has a rubber ring
(Seal for Models ESP30184-12 and –13) on it. If the rubber ring or seal is not present, install it.
Hold the inner shaft between the rolls and slide the coupling sleeves over the coupling hubs on
both ends. Install the snap ring between the roll rigid hub and the sleeve.
Remove the two (2) grease plugs from the coupling sleeves and insert a grease fitting into one
of the holes. Using a hand pump grease gun filled with Mobilith AW 2 grease, insert the gun
into the grease fitting and pump the handle until grease comes out the other hole. Make sure that
no grease seeps out through the O-rings or seals. If grease runs through the O-rings or seals
replace the O-rings or seals.
Remove the grease fitting and replace both grease plugs. Tighten the plugs until they are snug
and are approximately 1/16-inch above the surface. DO NOT OVER TIGHTEN THE PLUGS.
If any plug is flush or below the surface remove it, wrap it with Teflon tape, and reinstall.

MUSTANG DYNAMOMETER
REMOVE AND REPLACE INNER SHAFTS (CONTINUED)

Apply a drop of Loctite 262 to the threads of the set screws, insert set screws into the coupling
sleeves and using a torque wrench with a 1/8-inch Allen wrench torque the set screws to 75
inch-pounds.
3.2.6 REMOVE, REPLACE, AND ALIGN ROLLS

NOTE: Rolls are aligned and bearing stops are set at the factory. Do not remove or replace rolls
unnecessarily. Remove only those components necessary for service. When replacing rolls, do
not loosen any bearing stop screws unless specifically instructed to do so.
WARNING
The roll assemblies are extremely heavy. Be sure the roll
assemblies are properly supported when removing them
from the frame. Failure to observe these precautions may
result in damage to equipment, injury to personnel, or
both.
AVERTISSEMENT
Les rouleaux sont extrêmement lourds. S’assurer que les
rouleaux soient correctement supportés lors de leur
CAUTION
Rolls must be properly aligned for high-speed operation.
Roll misalignment can lead to poor machine performance
as well as premature component failure.
ATTENTION
Les rouleaux doivent être correctement alignés pour le
fonctionnement à haute vitesse. Un mauvais alignement
des rouleaux peut entraîner une mauvaise performance de
l’équipement ainsi qu’une défaillance prématurée des
composants.
Remove idler assembly and drive belt. Refer to Remove and Replace Drive Belt and Idler
Assembly. Remove speed sensors. Refer to Remove and replace Speed Sensors. Remove inner
shafts. Refer to the Remove and Replace Inner Shafts. Remove motor belt if necessary. Refer to
the Remove and Replace Motor and Belt.
Refer to Figure 3.9 for roll positions and bearing locations. Roll #3 is located on the flat side of
the dynamometer, away from the restraint tubes. All alignment measurements are made with
reference to roll #3.

MUSTANG DYNAMOMETER
FIG 3.9
ROLL AND BEARING POSITIONS
ROLL REMOVAL (ROLLS #3 AND #4)

To remove rolls #3 and #4 refer to Figure 3.10 and loosen the two bearing stop screws from the
2-inch pillow block located between the two bearings using a 9/16-inch open end wrench. Using
a 3/4-inch socket wrench remove the bearing mounting bolts, lock washers, flat washers, and
bearing plates located under the bearing support tube from the 1-1/2-inch pillow block bearings.
Using a 15/16-inch socket wrench remove the mounting bolts lock washers, flat washers, and
bearing plates located under the bearing support tube from the 2-inch pillow block bearings.
Clean all hardware with brake cleaner and chase threads if necessary to remove all traces of
Loctite using a 1/2-13 die for the 1-1/2-inch bearings or a 5/8-11 die for the 2-inch bearings.
WARNING
The rolls are extremely heavy. Be sure the rolls are
properly supported when removing them from the frame.
Failure to observe these precautions may result in damage
to equipment, injury to personnel, or both.
AVERTISSEMENT
Les rouleaux sont extrêmement lourds. S’assurer que les
rouleaux soient correctement supportés lors de leur
Using suitable lifting equipment remove the roll(s) from the frame.
ROLL REMOVAL (ROLLS #1 AND #2)

MUSTANG DYNAMOMETER
Remove rolls #1 and #2 using a 3/4-inch socket wrench to remove the bearing mounting bolts,
lock washers, flat washers, and bearing plates located under the bearing support tubes from the
1-1/2-inch pillow block bearings. Clean all hardware with brake cleaner and chase threads if
necessary to remove all traces of Loctite using a 1/2-13 die for the 1-1/2-inch bearings.
Using suitable lifting equipment remove the roll(s) from the frame.
FIG 3.10
BEARING STOPS
ROLL REPLACEMENT (ROLLS #1 AND #2)

Using suitable lifting equipment set both rear rolls, roll #1 and roll #2 in place with the coupling
hubs facing the center of the dynamometer. Apply a few drops of Loctite 262 to the clean
threads of two (2) 1/2-13 x 3-inch bolts and insert them with lock washers and flat washers into
each pillow block bearing. Hold the bearing plates under the bearing support tubes and start the
bolts in the bearing plates. Snug up the bolts but do not torque them. Verify that the rubber O-
ring is on the coupling rigid hub and the steel snap ring is between the coupling hub and the
bearing.
ROLL REPLACEMENT (ROLLS #3 AND #4)

Using suitable lifting equipment set roll #3 and #4 in place with the coupling hubs facing the
center and the pulleys towards the PAU. Apply a few drops of Loctite 262 to the clean threads
of two (2) 1/2-13 x 3-inch bolts and insert them with lock washers and flat washers into the 1-
1/2–inch bearings located in the center of the dynamometer. Apply a few drops of Loctite 262 to
the clean threads of two (2) 5/8-11 x 3-inch bolts and insert them with lock washers and flat
washers into the 2–inch bearings at the PAU end. The bearing plate under the 2-inch bearing is
not symmetrical. The short end of the plate should be oriented near to frame. Hold the bearing
plates under the bearing support tubes and start the bolts in the bearing plates. Snug up the bolts
but do not torque them. Verify that the rubber O-ring is on the coupling rigid hub and the steel
snap ring is between the coupling hub and the bearing.

MUSTANG DYNAMOMETER

MUSTANG DYNAMOMETER
ROLL ALIGNMENT
Rolls are aligned at the factory. When replacing rolls extensive realignment may not be
necessary. Verify the alignment of the rolls before attempting any alignment procedure.
Alignment between roll #3 and the inner wall, between rolls #3, and #4, (four point), between
rolls #4 and #2, and between rolls #3 and #1 (straight edge), and between the PAU and rolls
(square) is critical and must be checked.
Refer to Figure 3.11 and verify the position of roll #3 using a tape measure. The center of the
shaft should be 5-1/2-inches from the inner wall of the frame at both ends of the roll. If
necessary align roll using the bearing stop bolts to move the roll bearings.
Refer to Figure 3.12 and using a small pry bar set the distance between the pulley and the front
of the bearing support. For models ESP30184-1, -6, -7, and –8 set the distance to between 1/16
and 1/8 inches. For models ESP30184-9, –11, -12, and -13 set the distance to between 3/4 and
1-inch. Snug up the bearing mounting bolts. Do not torque the bolts or set the jam nut now.
Verify the position of roll #4 using a tape measure. The center-to-center distance between the
roll shafts should be 17 inches at both ends of the roll. If necessary align roll using the bearing
stop bolts to move the roll bearings.
FIG 3.12
ROLL PULLEY LOCATION
Note: On ESP30184-18 and ESP30556-1 the roll sprocket bushing is mounted onto the roll first.

MUSTANG DYNAMOMETER
ROLL ALIGNMENT (CONTINUED)

Refer to Figure 3.13 and verify the alignment of the roll pulleys on rolls #3 and #4 by placing
the four point pulley alignment tool, Mustang part number 20014354 (see Appendix), across the
pulley hub faces. The tool has a cutout that should be located around the flanges of the pulleys.
The tool should touch the faces of the hubs at four points. If two points touch on the same roll
and none on the other roll, adjust one of the rolls using a small pry bar so that all four points
touch. If three points touch, adjust roll #4 using the bearing stop screws to move the roll so all
four points touch.
Using a torque wrench with a 3/4-inch socket torque the 1-1/2-inch pillow block bearing
mounting bolts to 50 foot-pounds on rolls #3 and #4. Using a torque wrench with a 15/16-inch
socket torque the 2-inch pillow block bearing mounting bolts to 70 foot-pounds. Recheck the
four-point alignment. Realign if necessary. Set the jam nuts on the bearing stops. Apply a few
drops of Loctite 262 to the threads of the bearing stop screws.
The distance between the inner coupling hubs of roll #2 and roll #4 and between the inner
coupling hubs of roll #1 and roll #3 should be 19-1/2 to 19-5/8 inches. Adjust roll #2 or roll #1
if necessary using a small pry bar.
FIG 3.13
FOUR POINT ALIGNMENT

MUSTANG DYNAMOMETER
FIG 3.14
ROLL ALIGNMENT
Refer to Figure 3.14 and check the alignment of roll #2 to roll #4 and of roll #1 to roll #3 by
placing a straight edge across the rolls. If the rolls are not aligned, align the rolls using the
bearing stop screws on roll #1 or Roll #2. Do not move rolls #3 or #4. Apply a few drops of
Loctite 262 to the threads of the bearing stop screws if they were moved.
Using a torque wrench with a 3/4-inch socket torque the 1-1/2-inch pillow block bearing
mounting bolts to 50 foot-pounds on rolls #1 and #2.
Verify the alignment of the rolls. Realign if necessary.
Replace inner shafts, idler assembly, belts, and speed sensors. Refer to the procedures in this
section.
3.2.8 REMOVE AND REPLACE BRAKE PADS, AIR BAGS, AND LIFT PLATE ASSEMBLY
NOTE
The lift plate assembly does not have to be removed for brake shoe
replacement.
REMARQUE
Il n’est pas nécessaire de déposer la plaque de levage pour le
remplacement des freins.
Remove the brake pads using two 1-1/8-inch crescent wrenches. After one nut is loosened, use a
13-mm open-end wrench to hold the pin while removing the other nut. Remove the brake pads.
Clean the hardware with brake cleaner.
Note: when replacing the brake pads coat the back of the pads with Mobilith AW 2 grease.
To replace brake pads apply a few drops of Loctite 262 to the threads of the brake pad pin and
install the brake pads, flat washers, and nuts onto the pin. Using two 1-1/8-inch crescent
wrenches tighten the nuts.
REMOVE AND REPLACE BRAKE PADS, AIR BAGS, AND LIFT PLATE ASSEMBLY (CONTINUED)

MUSTANG DYNAMOMETER
Using a 7/32-inch Allen wrench remove the bolts from the two outboard air bags. Using a 9/16-
inch socket wrench remove the bolts from the center air bag. Raise the lift plate and slide it over
the rolls placing a board under the lift plate to prevent damage to the rolls.
To replace air bags, remove the air bag and gently pull the air line from the fitting. On the
replacement air bag press the air line into the fitting and place the air bag on the center support.
NOTE
When replacing the lift plate coat the ends of the plate that slide in the
frame guides with Mobilith AW 2 grease.
REMARQUE
Lors du remplacement de la plaque de levage, enduire les extrémités
de plaque qui coulissent dans les guides du châssis avec de la graisse
Mobilith AW 2.
To replace the lift plate slide the lift plate onto the airbags. Apply a few drops of Loctite 262 to
the threads of the four (4) outboard air bag attachment bolts and using a torque wrench with a
7/32-inch Allen wrench torque the bolts to 15 foot-pounds. Apply a few drops of Loctite 262 to
the threads of the two (2) center air bag attachment bolts and using a torque wrench with a 9/16-
inch socket torque the bolts to 30 foot-pounds.
3.2.9 REMOVE AND REPLACE LIMIT SWITCH TRIP ARMS

Remove limit switch trip arm by removing the spring and the cotter pin from the pin. When
replacing the limit switch trip arm coat the pin with Mobilith AW 2 grease. Make sure the
spring is facing upward and the arm pivots freely.
3.2.10 PAU GROUND SHORT CHECK/REPAIR

The twelve PAU Coils, designated 1N through 12S, are wired in series as shown in the wiring
diagram in Figure 3.15. Shorts to ground can be due to a faulty coil, jumper wire, or terminal
block in the PAU.
To find a shorted coil, disconnect the PAU from the power supply.
Using an ohmmeter, check the PAU coils for shorts to ground at the PAU cable connector.
Resistance should be at least one Megohm.
If a shorted coil is suspected, systematically check half of the coils at a time as follows:
Remove the blue lead of coil 7N to divide the coils into two groups of six, 1N through 6S, and 7N
through 12S.
Connect one lead of the ohmmeter to the PAU ground and the other lead to the first group of six
coils and then to the other group of coils to determine which group of six coils has the short.
Divide the shorted group into two groups of three coils each and use the ohmmeter to check which
group has the short. Keep separating and isolating coils until the short is located.
If the short is in a coil, disconnect both leads of the coil from the terminal block and install a
jumper wire across the terminals. Up to three coils can be disconnected without adversely
affecting PAU performance.
If the short is in the terminal block, replace the terminal block.

MUSTANG DYNAMOMETER
If the short is in a jumper wire, either replace the wire or wrap insulation tape over the wire.
Check the resistance of the PAU by connecting one lead of an ohmmeter to the main red terminal
and one to the blue terminal. Resistance should be approximately 3 Ohms.
Reconnect all wires and recheck for shorts. After all shorts have been eliminated, reconnect the.

MUSTANG DYNAMOMETER
SECTION
TROUBLESHOOTING
CONTENTS
4.1 INTRODUCTION ..................................................................................................... 4-3
4.2 TROUBLESHOOTING GUIDE ................................................................................... 4-3

MUSTANG DYNAMOMETER

MUSTANG DYNAMOMETER
4.1 INTRODUCTION
This section contains information and procedures for isolating and correcting problems with the
dynamometer. Table 4.1, the Troubleshooting Guide, lists problems, possible causes, and
recommended corrections. Refer to the Repair section of this manual for repair instructions for
major components of the dynamometer.
4.2 TROUBLESHOOTING GUIDE
TABLE 4.1 TROUBLESHOOTING GUIDE

Problem Possible Cause Correction
Vibration and/or Noise Structural frame of dynamometer is Check anchor bolts on dynamometer
not secured to pit floor. frame and tighten to proper
specification.
Dynamometer is not level to the floor. Level dynamometer and be sure shims
are in place under frame where
needed.
Roll coupling is out of tolerance or Repair or realign couplings.

alignment.
Coupling between rolls is worn. Replace coupling.
Roll pillow block bearings not secured Tighten bolts to proper specification.
to the frame.
Bearing failure on rolls. Replace bearings.
Bearing Failure on PAU. Replace bearing.
Roll has spun on bearing and is worn. Check roller shaft for wear. Tighten
setscrews to proper specification or
replace roll.
Roll is out of balance. Check for loose weights on roll.

Replace roll if necessary.
Lift Fails to Lower Lift Override switch is in “UP” position. Turn Lift Override switch to ”DOWN”
position.
Lift override module on lift solenoid is Turn screw on override module to the
in the vertical position horizontal position.
No lubrication Coat the ends of the plate that slide in the

Lift Fails to Raise Air supply to dynamometer has not Turn on air supply. Dry air, regulated
been turned on. to a MAXIMUM of 80 psi must be
supplied to the dynamometer.
Air lift solenoid coil has failed. Check for +12 VDC across pins 8 and
9 of the I/O board in the Control Unit.
Replace coil if necessary.
Air lift valve has failed. Replace valve.

MUSTANG DYNAMOMETER
TABLE 4.1 TROUBLESHOOTING GUIDE

Problem Possible Cause Correction
Lift Fails to Raise (Continued) Power supply failing to operate Check all connections in both control
properly. unit and solenoid valve cable. Repair
or replace defective components if
necessary.
Air bag has ruptured. Replace air bag.
No lubrication Coat the ends of the plate that slide in the

Roll speed other than zero is being Troubleshoot speed sensor and wiring.
displayed. Perform zero calibration in control box
and EIS system cabinet.
Low air pressure. Adjust dry, regulated air pressure

supplied to dynamometer to a
maximum of 80 psi.
Defective or improperly wired air Verify correct wiring and test opening
pressure switch. and closing of pressure switch
contacts.
Defective cable or wiring. Inspect all electrical wiring and replace

any defective cables and/or contacts.
“Digital Enable” signal from host Troubleshoot software system.

computer not present. Troubleshoot dynamometer control
unit.
Rolls Do Not Lock Brake pads are worn. Replace brake pads.
Air leak in pneumatic system. Inspect and replace any defective

tubing, connectors, and/or air bags.
Low air pressure Adjust dry, regulated air pressure

supplied to dynamometer to a
maximum of 80 psi.
Display Values Not Stable (Floating, Loose interface connection. Make sure all cable connections are
Fluctuating, etc.) properly seated. Verify all connections
inside the control box are secure.
Bad load cell connection. Check all load cell connection. Repair
if necessary.
No Speed Readout Bad electrical connection. Check all electrical connections in the
system.
Incorrect Magnetic Pickup-to-gear air Verify that the air gap is set to 0.020 to
gap. 0.030 inches.
Magnetic Pickup failure. Replace Magnetic Pickup.

No Torque Readout Bad electrical connections. Check all electrical connections in the
system.

MUSTANG DYNAMOMETER

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MAINTENANCE

Revision Release Date Initial

- 1 -MODEL OBD DYNE MAINTENANCE AND SERVICE

Information in this document is subject to change without notice. No

Telephone: (330) 963-5400 * Fax: (330) 425-3310

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -2-

The information contained in this manual is provided on an “as is” basis.

L’information contenue dans ce manuel est fournie « telle quelle ». Ni

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -3-

GANZCORP INVESTMENTS INC. dba MUSTANG DYNAMOMETER

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -4-

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -5-

1.1 DESCRIPTION ...................................................................................................1-3

1.2 GENERAL SAFETY ISSUES..................................................................................1-4

1.3 OPERATIONAL SAFETY ISSUES ...........................................................................1-4

1.4 MAINTENANCE SAFETY ISSUES ...........................................................................1-6

1.5 ENVIRONMENTAL DATA .....................................................................................1-7

1.6 INSTALLATION DATA .........................................................................................1-7

1.7 NAMEPLATE DATA ............................................................................................1-7

1.8 IF YOU NEED HELP ...........................................................................................1-7

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -7-

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -8-

Table 1.1 ESP/Mustang Dynamometer ASM-97 Series Dynamometers

MD Model Number Description

MD-OBD Low profile

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE -9-

1.2 GENERAL SAFETY ISSUES

1.3 OPERATIONAL SAFETY ISSUES

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 10 -

OPERATIONAL SAFETY ISSUES (CONTINUED)

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 11 -

1.4 MAINTENANCE SAFETY ISSUES

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 12 -

1.5 ENVIRONMENTAL DATA

1.6 INSTALLATION DATA

1.7 NAMEPLATE DATA

1.8 IF YOU NEED HELP

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 14 -

2.1 INTRODUCTION .................................................................................................2-3

2.2 PREVENTIVE MAINTENANCE ...............................................................................2-4

2.3 LUBRICATION ...................................................................................................2-5

2.4 INSPECTION ......................................................................................................2-6

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 15 -

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 16 -

Table 2.1 LIST OF RECOMMENDED TOOLS

3/4-inch socket 1-1/2-inch Pillow Block Bearing Bolts

Table 2.2 LIST OF CONSUMABLE ITEMS

Coupling Grease 20010651 Mobil Mobilith AW 2

Initial Every Every Every

Bearings and couplings must be lubricated with

Adequate lubrication is essential for satisfactory operation of the dynamometer. Lubrication of

2.3.1 LUBRICATE PILLOW BLOCK BEARINGS

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 19 -

2.3.2 LUBRICATE COUPLINGS

2.3.3 LUBRICATE PAU

2.3.4 LUBRICATE MOTOR

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 20 -

Table 2.4 Torque Chart

2.4.1 INSPECT PILLOW BLOCK BEARINGS

MODEL MD-OBD-DYNE MAINTENANCE AND SERVICE - 21 -

INSPECT PILLOW BLOCK BEARINGS (CONTINUED)

2.4.2 INSPECT CONDITION OF COUPLINGS

2.4.3 INSPECT BRAKE PADS