Attachment_0026_-_Portable_Dyno_Appendix_B__Dyno_Test_Procedure.pdf

REV N/R

OCTOBER 2006

14584310

PORTABLE DYNO

APPENDIX B

DYNO TEST PROCEDURE

PREPARED and WRITTEN by

PRODUCTION DELIVERY and SUPPORT (PD&S)

SUPPORT SERVICES

CONFIDENTIAL AND PROPRIETARY TRADE SECRET INFORMATION

© Copyright, General Dynamics Land Systems-Canada Corporation. All rights reserved. This is unpublished confidential and proprietary trade secret information of General Dynamics Land Systems-Canada Corporation ( GDLS-CC ) which shall only be used by GDLS-CC and General

Dynamics Land Systems Inc. personnel. This work must not be copied, distributed or disclosed in any form, by any means, to any third party, in whole or in part, without the prior written permission of General Dynamics Land Systems-Canada Corporation.

© Copyright, General Dynamics Land Systems-Canada Corporation

Appendix B Dyno Test Procedure

3.5 POWER PACK ASSEMBLY No. 10651875-011 (W/O A/C)

POWER PACK ASSEMBLY No. 10655490-011 (with A/C)

CATERPILLAR 3126 HEUI

ENGINE TEST CELL PROCEDURE

GDLS-C: ____________________ CHP

Engine Part No. - 10625002 Ser. No. ________________

Engine E.C.M. Part No. - 1608859-01 Ser. No. ________________

Transmission Part No. - 10651486-001 Ser. No. ________________

Transmission E.C.U. Part No. - 10655357-001 Ser. No. ________________

Date Started: ________________

Date Completed: ________________

Special Notes:

FINAL RELEASE

The records attached have been checked, signed off and meet specifications.

Tester(s): ____________________________________________

Date: _______________________

CHECKLIST

1 Place Power Pack on Stand and Perform Visual Check.

1.1 Check Power Pack assembly and note any deficiencies. Check that there are no open deficiencies or shortages.

1.2 Check all hoses and piping for proper routing and for loose fitting.

1.3 Check that all covers and plugs are in.

1.4 Check electrical wiring for proper routing and that all connections are tight.

1.5 Check exhaust system connections.

1.6 Check turbocharger and air intake filter application.

1.7 Check Alternator belt and slack adjuster operation.

1.8 Check Alternator application and pulley alignment (Visual only).

2 Check Oil and Fill Oil Levels

2.1 Engine: Check oil level and fill to proper level if required.

NOTE: Never over fill engine

2.2 Transmission: Check oil level and fill to proper level.

2.3 Fill cooling system with 50/50 Glycol and water and 1.5 liters of Additive (10628273).

2.4 Fill the cases of the following components with hydraulic oil:

CAUTION: Never run engine without pre-filling cases.

2.4.1 Fan hydraulic pump

2.4.2 Auxiliary hydraulic pump

2.4.3 A/C drive motors (QTY: 2)

2.5 Fill main hydraulic reservoir.

2.6 Bleed air out of Steering Pump.

3 Check Line-Up of Power Pack to Dyno and Locked into Run Position

3.1 Hook up drive shaft between Dyno and Power Pack.

3.2 Lower Dyno driveshaft mechanism.

4 Hook Up the Following Items:

4.1 Exhaust system.

4.2 Electrical system (multi-pin plugs and positive and negative cables).

4.3 Fuel lines (QTY: 2).

4.4 Compressor lines (QTY: 2).

4.5 Parking brake (MAXI Brake).

4.6 Install jumper hose from steering pump to oil cooler radiator QD.

4.7 Engine Exhaust Brake.

5 Reconfigure/Confirm CAT ECM for BCT Specifications

5.1 Open Air Inlet Damper.

5.2 Ensure Dyno driveshaft mechanism is at lowest position.

5.3 Turn Cooling/Ventilation Fans.

5.4 Turn System Status Panel Switch ON (Red light will illuminate), wait for the Red light to extinguish and Green light to illuminate.

5.5 Turn ON Master Switch at Run-Up Module and wait for System Ready Light (Green) to illuminate.

5.6 Turn Engine Ignition Switch ON.

5.7 Power up VTS.

5.8 Start CAT Electronic Technician Configuration.

5.9 Record ECM Serial No. on Page 1.

5.10 Verify Engine Serial No. matches engine nametag.

5.11 Check/Modify Speed Calibration setting to 58331 PPM (pulses/mile).

5.12 Check/Modify Vehicle Speed Limit setting to 68 mph.

5.13 Check/Modify VSL Protection to 2840 rpm.

5.14 Check/Modify Engine Exhaust Brake Mode setting to Manual.

5.15 Check/Modify Soft Cruise Control setting to NO.

5.16 Check/Modify Fast Idle RPM setting to 1200 rpm.

5.17 Check/Modify Transmission Style setting to Auto w/o 2 Brake Switches.

5.18 Turn Engine Ignition switch OFF or proceed to Step 6.2.

6 Pre-Start-Up Checks

6.1 Turn Ignition Switch ON (Fuel pump should run)

6.2 On Dyno Control Box Check Main (ON/OFF) Switch, ensure it is OFF.

The AUTO

KNOB switch should be on KNOB and the knob should be at minimum (turned completely clockwise).

6.3 Check for leaks, unsafe conditions, loose components, etc.

7 Start-Up Procedure (Do Not Heat Engine Above 170°F)

NOTE: Engine will automatically jump to High Idle if allowed to idle for more than 10 minutes (in NEUTRAL (N) and MAXI Brake ON).

7.1 Place Transmission Selector in Neutral (N) position and MAXI Brake Applied.

7.2 Turn Engine Ignition switch to Start.

7.3 Perform engine Walk-Around noting any leaks, noises or abnormalities.

7.4 Run gearshift selector through all ranges and return to Neutral (N).

7.5 Verify transmission oil level is at full cold.

7.6 Verify alternator voltage output is 29 ± 1 volt.

7.7 Verify all display screen parameters are within operating ranges (Use CAT ET).

7.8 Verify High Idle function (1200 rpm), only with MAXI applied and T/X in Neutral (N).

7.9 Turn OFF Engine Ignition switch.

7.10 Top-up Hydraulic Reservoir as required.

7.11 Top-up Coolant Reservoir as required.

8 Transmission ECU check using Allison Diagnostic Tool (ADT)

8.1 Turn Engine Ignition ON and Start.

8.2 Start Allison Diagnostic Tool software.

8.3 Record ECU serial number from ADT on Page 1 of this procedure.

8.4 Using transmission gear selector, progress through all gears and verify Allison Diagnostic displays the corresponding gears.

8.5 Start Engine and allow idling. Ensure MAXI brake is applied.

8.6 Place Transmission in 6th gear. Turn Dyno Control Box Main (ON/OFF) Switch ON; Place Dyno Control Box AUTO

KNOB switch to KNOB and turn knob CCW to read 2-3A on Amp meter. Release MAXI brake.

8.7 Slowly increase engine throttle and verify on ADT that the transmission shifts through all gears.

NOTE: Transmission lock-up occurs in 2nd gear (ADT status goes from 2C to 2L)

8.8 Bring Engine to idle. Apply MAXI brake. Shift transmission into Reverse.

8.9 Releases MAXI brake and verify transmission functions in reverse.

8.10 Verify Dyno output speed is approx. 517 rpm in Reverse gear when the engine is at 2600 rpm.

8.11 Bring Engine to idle, Apply MAXI brake, and then Shift transmission into 1st gear.

8.12 Release MAXI brake and verify Dyno output speed is approx. 746 rpm in 1st gear, when engine is at 2600 rpm.

8.13 Engage transmission into 2nd gear and verify Dyno output speed is approx. 1395 rpm when engine is at 2600 rpm.

8.14 Engage transmission into 3rd gear and verify Dyno output speed is approx. 1845 rpm when engine is at 2600 rpm.

8.15 Engage transmission into 4th gear and verify Dyno output speed is approx. 2600 rpm when engine is at 2600 rpm.

8.16 Engage transmission into 5th gear and verify Dyno output speed is approx. 3467 rpm when engine is at 2600 rpm.

8.17 Engage transmission into 6th gear and verify Dyno output speed is approx. 4000 rpm when engine is at 2600 rpm.

8.18 Switch ON Engine Exhaust Brake (Pack Brake).

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8.19 Quickly throttle back engine from 2600 rpm to idle. Exhaust Brake should activate and assist to bring engine to idle. Observe that Exhaust Brake mechanism is engaging.

8.20 Run throttle back up to 2600 rpm in 6th gear and repeat Step 8.19 once.

8.21 Bring Engine to idle and switch OFF Exhaust Brake.

8.22 Shift Transmission to Neutral (N).

8.23 Turn Dyno Control Box Main (ON/OFF) Switch to OFF.

8.24 Shoot down Engine.

9 Full Engine Load Test (Do not run under load for more than 6 minutes)

9.1 CLOSE valve at Thermal Manifold QD. (This will place the cooling fan in full load condition).

9.2 Start DynoMax 2000 software.

9.3 Check Dyno Control Box Main (ON/ OFF) Switch is OFF and the AUTO

KNOB switch is set to AUTO .

9.4 Turn Engine Ignition ON and Start Engine, push Zero button on DynoMax 2000 Pro software and start CAT ET and Allison Diagnostic software s.

9.5 On Allison Diagnostic software select Action Request, Clutch Test Enable, and click OK.

9.6 Shift Transmission gear selector into 4th gear.

9.7 Release MAXI Brake (Parking Brake).

9.8 Start Recording by pressing Record button on DynoMax 2000 software.

9.9 Turn Dyno Control Box Main (ON/OFF) Switch to ON. Slowly bring the Engine to full throttle. Dyno should hold the engine @ 2600 rpm for 5 - 6 minutes.

9.10 Return Engine to idle; Turn Dyno Control Box Main (ON/OFF) Switch to OFF, position AUTO KNOB switch to KNOB ; Stop recording by pressing Pause button on

DynoMax 2000 Software; and Save the Run.

9.11 Press F5 to view Graph on the most recent saved run. Print graph and attach to Test Procedure. Get HP and Torque readings at about 4 - 5 minutes into the run and record them on Page 6.

9.12 During Load Test, monitor CAT ET and note any abnormalities.

9.13 Let Engine run at idle for 3 minutes in 4th gear to stabilize internal engine temperature and cool down Dyno.

9.14 Stop Engine.

9.15 Review test data of FULL ENGINE LOAD TEST (9.11). Perform corrective action and re-test if require (9.1 - 9.13). Wait at least one (1) hour before re-testing.

10 When Engine has cooled, check Coolant, Engine Oil, and Hydraulic Oil Levels and Adjust as Required.

11 Disconnect Engine from Dyno.

HORSEPOWER STANDARDIZATION

Engine Model: CAT 3126 HEUI

Engine Serial No: ________________

Transmission Serial No: ________________

At about 4-5 minutes into the Full Load Test, record the following from the DynoMax 2000 Pro software screen:

Torque @ 2600 rpm: _____________ ft/lbs.

Horsepower @ 2600 rpm: _____________ HP (1)

AUXILIARY HORSEPOWER LOSSES

Fan Pump, Motor and PTO 50.0 HP

Auxiliary Pump (A/C OFF) and PTO 2.0 HP

Steering Pump 2.0 HP

Alternator 5.0 HP

Transmission Loss (4th Gear Lock-Up) 12.0 HP

Total Auxiliary Losses 71.0 HP (2)

Total Corrected Horsepower: (1) + (2) _____ CHP.

Accepted limit: Minimum 330 CHP.