Bomba Aidco - Serie 900 - Manual de Servicio - Pag-184

AIDCO 900 Series
Transmission and Hydraulic

Component Test Center
Service Manual
Including PowerNet TD Data Acquisition
and Control System
Mitsui Maquinaria
Lima, PERU
Publication Number: 080801

This manual is intended to assist operating personnel in becoming familiar with the machine and as
guidance in ordering necessary parts inclusive of Power Test’s warranty requirements.
Maximum operating efficiency and life of any Power Test machine will be attained through complete
understanding of the instructions and recommendations contained within this manual.
N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

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AIDCO 900 Transmission and
Hydraulic Component Test
Center Service Manual
Includes Preventive Maintenance, Electrical
Schematics and Mechanical Drawings
This manual is intended to assist operating personnel in becoming familiar with the machine and as
guidance in ordering necessary parts inclusive of AIDCO’s warranty requirements.
Maximum operating efficiency and life of any AIDCO machine will be attained through complete
understanding of the instructions and recommendations contained within this manual.
ervices performed beyond preventive maintenance by personnel other

S
! WARNING! than AIDCO Service Technicians on any AIDCO System during the
warranty period may void the warranty.
lease include the job number, model number and serial number of the machine in
P
 Note any correspondence.

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Table of Contents
1.0 Introduction......................................................................................................................1
2.0 Safety Guidelines.............................................................................................................3
3.0 Warranty and Service Statement.....................................................................................5
3.1 Ordering Parts.........................................................................................................5
3.2 Service Calls...........................................................................................................5
4.0 Preventive Maintenance..................................................................................................7
4.1 Oil and Filters..........................................................................................................7
Changing the Oil.....................................................................................................7
Main Reservoir Kidney Loop Filter . .......................................................................7
Main Reservoir Sump Filter ...................................................................................7
Main Reservoir Return to Tank Filters.....................................................................7
Main Reservoir Aux Pump Servo Filter...................................................................8
Hydrostatic Reservoir Filters...................................................................................8
4.2 Electric Motors........................................................................................................8
4.3 Heat Exchangers....................................................................................................8
Closed Water Cooling System................................................................................8
4.4 Relief Valves...........................................................................................................9
5.0 General Information.......................................................................................................11
5.1 Requirements........................................................................................................11
Electricity...............................................................................................................11
Water....................................................................................................................11
Oil..........................................................................................................................11
Adapter Kits..........................................................................................................11
5.2 Primary Hydraulic Systems and Their Functions.................................................. 11
Hydrostatic Drive System......................................................................................12
Oil Flow Out Systems...........................................................................................13
Diagnostic Recirculation Loops.............................................................................14
5.3 Capacities, Dimensions and Weight.....................................................................15
Capacities.............................................................................................................15
Dimensions...........................................................................................................15
Weight...................................................................................................................15
6.0 Installation Instructions..................................................................................................17
6.1 Placement.............................................................................................................17
6.2 Unwrapping the Unit.............................................................................................17
Main Unit...............................................................................................................17
Work Support Sump..............................................................................................17
6.3 Sump Pump, Water and Electrical Connections...................................................17
Sump Pump Connection.......................................................................................17
Water Connections...............................................................................................17
Electrical Connections..........................................................................................18
7.0 Start-Up Procedure........................................................................................................19
7.1 Reservoirs and Fluids...........................................................................................19
Hydrostatic Reservoir............................................................................................19
Main Reservoir......................................................................................................19
7.2 Initial System Check.............................................................................................20

Table of Contents
7.3 Start-Up and Check..............................................................................................20
Main Motor Start Interlocks...................................................................................20
Main Electric Motor Check....................................................................................21
Priming the Hydrostatic System............................................................................22
Pressurizing the Flow Systems.............................................................................22
Heat Exchanger Adjustment.................................................................................23
8.0 Operation.......................................................................................................................25
8.1 Routine Start-Ups ................................................................................................25
8.2 Hydrostatic Drive System......................................................................................25
Directional Control................................................................................................25
Speed and Torque Relationships..........................................................................25
Speed Control and Tachometer............................................................................26
Monitoring Instruments.........................................................................................26
8.3 Oil Flow Out Systems...........................................................................................27
Lube .....................................................................................................................27
High Pressure.......................................................................................................27
8.4 Return Oil to the Main Reservoir...........................................................................28
Return to Tank Ports.............................................................................................28
Sump Return.........................................................................................................28
8.5 Diagnostic Recirculation (Recirc) Loops...............................................................29
FM2 Flowmeter 0-60 GPM....................................................................................29
FM3 Flowmeter 0-150 GPM..................................................................................29
FM4 Flowmeter 0-300 GPM (optional)..................................................................30
FM5 Flowmeter 0-60 GPM....................................................................................30
Low Flowmeters (optional)....................................................................................30
8.6 Transmission Pressure Gauges............................................................................31
8.7 Sump Pump System.............................................................................................31
8.8 Fluid Conditioners, Indicators, etc.........................................................................31
Filters....................................................................................................................31
Heat Exchangers..................................................................................................31
Oil Level Sight Gauges.........................................................................................32
Temperature Controllers.......................................................................................32
Ports and Control Switches...................................................................................32
9.0 Testing...........................................................................................................................33
9.1 Transmission Testing............................................................................................33
Test Stand Functions............................................................................................33
Flow and Pressure Settings..................................................................................33
Mounting a Transmission......................................................................................34
Remote or Direct Mount Transmission..................................................................35
9.2 Pump Testing........................................................................................................36
Normal Recirculation.............................................................................................36
Computing Pump Loss..........................................................................................36
Reduced Tests for Large Pumps...........................................................................37
Pump Mounting.....................................................................................................38
Hose Connections.................................................................................................38

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Table of Contents
Gear and Vane Pump Testing...............................................................................39
Piston Pump Testing.............................................................................................39
9.3 Hydraulic Motor Testing........................................................................................40
9.4 Cylinder Testing....................................................................................................40
Mounting...............................................................................................................40
Hose Connections.................................................................................................40
Test Guidelines.....................................................................................................41
9.5 Valve Testing.........................................................................................................42
Mounting...............................................................................................................42
Adapters and Hose Connections..........................................................................43
Test Guidelines.....................................................................................................43
9.6 Torque Converter Testing......................................................................................44
10.0 Troubleshooting.............................................................................................................45
10.1 Electrical Motors...................................................................................................45
Unusual Noise or Heat..........................................................................................45
Bearing Overheating.............................................................................................45
Damaging Vibrations.............................................................................................45
10.2 Gauges.................................................................................................................45
10.3 Flow Meters..........................................................................................................45
Readings Are Suspect..........................................................................................45
No Reading or Erratic Reading.............................................................................45
10.4 Tachometer...........................................................................................................46
No Reading or Erratic Reading ............................................................................46
10.5 Hydrostatic System...............................................................................................46
Routine Checks.....................................................................................................46
Pressure Tests......................................................................................................46
Hydrostatic System Motor Test.............................................................................47
10.6 Other Checks........................................................................................................48
11.0 Appendix........................................................................................................................49
iii
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Drawing List
JM0054 HYD TEST STAND SYS 900K-300HP 480/60

535463.1 FRAME & COVER PANEL KIT - 900/900C
535462 FLOW-OUT PANEL ASM - 900K
535461 GAUGE PANEL ASM - 900K
535444 WORK TABLE / SUMP ASM 900/900C
535465.1 MOTOR & PUMP ASM-900K-300HP SAUER 180cc
535467.2 HYDRAULIC TANK ASM 300GAL 900K
535468.2 HYDROSTATIC TANK ASM 100GAL 900K (180cc)
535469.2 HYDROSTATIC MOTOR & LIFT ASM 900K SAUER
535470.2 HEAT EX- SUMP & KIDNEY PUMP KIT 900K
535452.1 ELECTRICAL BOX ASM-900K-300HP 380/460/60

535471.2 PNET TD CONTROLLER ADD-ON 900K
535424.12333334 PNET TD CONTROLLER BASE - 900 DAQ

535466 FM4 300GPM FLOW CIRCUIT ADD-ON 900K
535450.2 HOSE INTERCONNECT KIT - 900K
535453.1 TRANS DRIVE GROUP 900/900C (SAUER)

505787 DRIVE SHAFT GUARD WELD 900/900C - SAUER
554034 DRIVE SHAFT FLEXIBLE
22K1974 FITTINGS AND QUICK DISCONNECT 850/900
22S804 TWO-BOLT FLANGE GROUP - 850/900
22S785 TRANSMISSION SUPPORT GROUP 900

272301 HYD SCHEMATIC 900K-300 w/ 300GPM REC
280172 WIRING SCHEMATIC-POWER BOX 900K
280174 WIRING SCHEMATIC-GAUGE PANEL 900K
280177 WIRING SCHEMATIC-PNET TD (900K w FM4)
303051 OUTLINE DRAWING 900/900C/900K

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1.0 Introduction
You have chosen one of the most versatile test stands built for off-highway hydraulics. With the AIDCO
Model 900 Transmission and Hydraulic Component Test Center, you have the capability to test:
▪ Automatic Transmissions
▪ Powershift Transmissions
▪ Hydraulic Pumps
▪ Hydraulic Motors
▪ Hydraulic Cylinders
▪ Hydraulic Valves
▪ Torque Converters
lease read the preventive maintenance procedure and the complete manual in detail
P
 Note prior to operating the test stand and contact AIDCO immediately if you experience
problems to avoid any warranty issues.


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2.0 Safety Guidelines
Operators and service personnel should read this manual and become familiar with its content before
attempting to operate this machine or to perform service or maintenance to it. Familiarization with
this manual will minimize the possibility of accidents or injuries. Although the procedures covered in
this manual have proven safe in use, AIDCO assumes no responsibility for personal injury or damage
to equipment resulting from its applications. After reading this manual, personnel should review all
instructions concerning company safety procedures provided at the installation location. It is not
possible to cover all safety conditions in this manual; therefore, always be alert and work with caution.
Only qualified machine operators and maintenance personnel should perform the procedures covered
in this manual.
Exercise caution with equipment, as with all working machinery. Moving parts, electrical connectors,
hot oil, high pressure systems and other conditions require sound safety measures implemented on a
regular basis. Pay particular attention to the following:
▪ Read the Operator’s Manual. It contains the information you need to operate the equipment
safely.
▪ Unqualified personnel should never attempt electrical work.
▪ Do not operate the machinery without proper guards in place and securely fastened.
▪ Always make certain that hoses are securely attached to the flow ports and the component
being tested.
▪ Replace any worn hydraulic hoses or fittings.
▪ Keep the work area as free of oil, water and dirt, as possible.
▪ Inspect the coupling between the electrical motor and main pump assembly on a regular basis.
▪ Never operate any equipment when wearing ties, jewelry, or loose clothing.
▪ Always wear safety glasses.
▪ Do not exceed manufacturer’s guidelines.
Contact AIDCO Test Systems if you have any questions about the safe operations of our equipment
and for service and advice.
This manual places safety concerns into three categories, they are:
Indicates an imminent hazard, which, if not properly addressed and

! WARNING! avoided, could result in death and serious personal injury.
Indicates hazards, which, if not avoided, could result in injuries or damage to the
! Caution hydraulic test stand.
Indicates precautions relating to operation or usage of the machine or highlights

 Note important information on a page.


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3.0 Warranty and Service Statement
AIDCO warrants products manufactured by AIDCO against defects in material and workmanship
under normal use and service for a period of 12 months from the time of initial customer operation.
At AIDCO’s request, buyer will make any defective article available for inspection by AIDCO at the
installation site or will return defective article to AIDCO, charges prepaid. AIDCO shall correct any
defect at AIDCO’s discretion, either by repairing or replacing the defective article, or by issuing a credit
for the purchase price. If an outside manufacturer furnishes the article, warranty shall be limited to the
warranty of the respective manufacturer for the article, but not more than twelve months from the date
of initial customer operation. This warranty shall not apply to any product or component that has been
subject to alteration, accident, misuse, abuse, or failure to follow AIDCO’s instructions for operation and
maintenance.
AIDCO accepts no liability hereunder for consequential or contingent damage, secondary charges, or
loss or expense resulting from any alleged defect in said product, failure of said product to operate
properly, or for the negligence of others. AIDCO reserves the right to make design changes or to modify
units previously shipped from AIDCO at any time without obligation to notify past customers.
3.1 Ordering Parts

Repair or replacement parts, spare parts, update kits, and/or adapter kits may be ordered from AIDCO
or one of AIDCO’s current sales representatives. Parts supplied only by AIDCO are covered under
warranty as stated above.
3.2 Service Calls

If the buyer requests field service after the warranty period or during the warranty period if conditions
have invalidated the warranty, the buyer shall pay the time and expenses of the field representative.


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4.0 Preventive Maintenance
The AIDCO Model 900 Transmission and Hydraulic Component Test Center is designed to provide
years of trouble free service with a minimum amount of regular maintenance. This section describes
normal maintenance procedures.
4.1 Oil and Filters

An adequate supply of clean hydraulic fluid must be maintained in the reservoirs at all times. Oil is
needed to keep the test stand's components lubricated. Problems with the operation of the machine are
usually the result of low or dirty oil. Check the oil level daily. The sight level gauge for the main reservoir
is located on the left side of the machine. The sight level gauge for the hydrostatic reservoir is located
on the back of the test stand.
Keep the oil clean. There are several 3-micron and 10-micron filters in the test stand (actual number
depending on options or configuration). As they get contaminated, it becomes more difficult for the oil to
flow through the filters, causing a pressure differential between the inlet and outlet side of the return line
filters to the main reservoir or high vacuum in the suction filter to the hydrostatic reservoir.
Changing the Oil

With continued use of the machine, oil in the main reservoir will need to be changed due to
accumulated dirt, regardless of filter maintenance. The oil change interval depends on frequency of
use, cleanliness of components being tested, and shop and operating conditions. Ideally, oil should
be tested periodically at a laboratory. If this is not possible, clues to oil quality can be found by feeling
for grit and sludge, by visually inspecting the color of the oil as compared to new oil, and by smelling
the oil to detect chemical change or overheating. It is good practice to change the oil in the hydrostatic
reservoir when changing the main reservoir oil.
Main Reservoir Kidney Loop Filter

The Main Reservoir Kidney Loop contains a 3-micron filter. The filter indicator light on the gauge panel
is set to activate when a significant differential pressure between the inlet and outlet sides of the filter
occurs. At higher pressures, oil bypasses the filter and returns directly to the reservoir. Refer to the
Filter Specifications section in the Appendix for more information.
Main Reservoir Sump Filter

The Main Reservoir Sump system is filtered by a 10-micron filter. The filter indicator light on the gauge
panel is set to activate when a significant differential pressure between the inlet and outlet sides of the
filter occurs. Refer to the Filter Specifications section in the Appendix for more information.
Main Reservoir Return to Tank Filters

The two 10-micron filters in the Main Reservoir of the test stand receive a common flow. The filter
indicator lights on the gauge panel are set to activate at approximately 20 PSI differential pressure
(the filter bypasses at 25 PSI) between the inlet and outlet sides of the filters. At higher pressures, oil
bypasses the filters and returns directly to the reservoir. When the indicator light for the corresponding
filter is lit, the filter element requires changing. The filter's condition can also be read on the visual
indicators located on the filters.

Main Reservoir Aux Pump Servo Filter
The Aux Pump Servo is filtered by a 3-micron filter. The filter indicator light on the gauge panel is set to
activate at approximately 20 PSI differential pressure (the filter bypasses at 30 PSI) between the inlet
and outlet sides of the filter.
Hydrostatic Reservoir Filters

The hydrostatic charge and servo filters are located just inside test stand directly above the sump
pump. As the filters become contaminated, the amount of suction required to draw oil through the filter
increases. The filter indicator lights on the gauge panel are set to activate at approximately 8 in. Hg
(eight inches of mercury). Change the filter element by loosening and removing the entire cartridge.
4.2 Electric Motors

Periodically inspect the main electric motor and the sump pump motor for dirt, friction and vibration.
Dust can be blown away from inaccessible locations with compressed air. Keep ventilation openings
clear to allow the free passage of air. Wipe away grease or oil with a rag and petroleum solvent.
he main electric motor is equipped with double-shield ball bearings with sufficient
T
grease to last for 3,500 operating hours under normal conditions. If the test stand is
 Note used in a dirty, wet or corrosive environment, it is advisable to add one-quarter ounce
of grease per bearing every three months. Use a high quality lithium base grease, see
appendix for specifications.
4.3 Heat Exchangers

The heat exchangers can become contaminated from oil, grease, rust and scale. Clean as necessary.
First, drain the tubes completely by blowing them out with compressed air. Then, use a cleaning solvent
to remove oil, sludge and other deposits. Allow the solvent to flow through the heat exchangers in the
direction opposite normal flow for approximately 15 minutes. (The exact length of time depends on the
degree of dirt deposits.) If the heat exchanger is disassembled for cleaning, new gaskets should be
used for re-assembly. During disassembly, care should be taken in handling the tube bundle to protect
the baffle plates and tubes from bending or receiving other damage.
Closed Water Cooling System

If a closed water cooling system is used, a corrosion preventative should be added to the water. This
treatment is effective under normal operating conditions for a period of six months, after which the
system should be drained and filled with new solution. Additionally, if the test stand is installed where
there is a chance of freezing on shutdown, the water circuit should be completely drained or antifreeze
should be added to the system.

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4.4 Relief Valves
The test stand’s primary valves are mounted at various points inside of the main test stand's frame. The
valves were adjusted at the factory and normally do not require re-adjustment. Failure to build pressure
in any of the test stand’s major systems can be the result of long-term decay in valve function or dirt in
the valve control.


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5.0 General Information
This section outlines the AIDCO Model 900 Transmission and Hydraulic Component Test Center's
electric, water, and adapter kit requirements; introduces the test stand’s primary systems; presents
specifications concerning your machine; and references the major optional equipment available from
AIDCO.
5.1 Requirements
The test stand is self-contained. In order to use it, you will need only electricity, water, oil and the
appropriate adapter kits.
Electricity
The electric motor has been wired at the factory to match the electrical service requirements specified
by your company or organization. If an electric motor starter was shipped as part of the original
equipment order, it was also pre-wired at the factory. If the motor starter was not provided with the test
stand, consult an electrician.
Water
A clean water supply of 60 GPM at 30 PSI at 85° F is required to operate the test stand’s heat
exchangers at continuous load.
Oil
The test stand is designed run with a variety of hydraulic and transmission oils. Refer to the Oil
Specifications sheet found in the Appendix.
Adapter Kits
The test stand is designed to test a wide range of hydraulic components. Adapter kits are used to
mount test equipment and attach it to the test stand. AIDCO has a large variety of adapters in inventory.
Several categories of adapter kits are available. Contact your AIDCO sales representative for more
details.
5.2 Primary Hydraulic Systems and Their Functions

The primary hydraulic systems of the test stand consist of the Hydrostatic Drive System, the Oil Flow
Out System, and the Diagnostic Recirculation Loops. The systems and their controls and monitoring
instruments are described in detail in the following pages.
11
Hydrostatic Drive System
Functionally, the test stand's Main Drive System acts as a hydrostatic power transmission. The
hydrostatic drive offers greater flexibility and adaptability than other forms of power transmission. The
main drive consists of the electric motor which turns a hydraulic pump, producing a flow of oil under
pressure. The oil is transmitted through hoses to a hydraulic motor and, by turning the motor, creates
mechanical power. The output shaft of the hydraulic motor drives components under test. Controls on
the hydrostatic system enable the test stand operator to vary the output speed from 0 to 3,400 rpm in
either the clockwise or counterclockwise direction of rotation. The drive system is highly reliable and
easily maintained.
900-300 900-400
Direction CCW & CW CCW & CW
Hydrostatic Drive
Max Speed 3,400 RPM 3,400 RPM

Max Torque 1,214 Ft-Lbs 1,214 Ft-Lbs
System
Max Torque Speed Range 0-1,260 RPM 0-1,750 RPM

Max Pressure 6,000 PSI 6,000 PSI
Pump Displacement 180cc 250cc
Motor Displacement 250cc 250cc
Table 5.1

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Oil Flow Out Systems
There are five flow out systems. Oil can be supplied from any or all of these systems to the component
being tested.
900-300 900-400
Flow 0-60 GPM (227 L/min) 0-60 GPM (227 L/min)
Pressure 0-1,000 psi (69 bar) 0-1,000 psi (69 bar)
(FM2)
MAIN
Flowmeter Yes Yes

Gauge 7,500 psi 7,500 psi
Fluid Flowouts

Pressure 0-65 psi (4 bar) 0-65 psi (4 bar)
Lube
Flowmeter No No
Gauge 200 psi 200 psi

High PSI

Flowmeter Yes Yes
Table 5.2
13
Diagnostic Recirculation Loops
There are several oil-monitoring loops which are used to monitor oil flowing from the test component.
These loops require fluid from the component under test. These loops simply monitor the pressure
or flow from the component or the test bench itself. Depending on the system used, the oil passes
through a flow meter or a pressure adjust (load) valve or both and then returns to the component under
test or the main tank. The test stand also has test pressure gauges, which can be used to monitor
various pressures in components under test.
900-300 900-400
Flowmeter 0-60 GPM (227 L/min) 0-60 GPM (227 L/min)
Non-Loadable
Loadable/

60 GPM
(FM2)
Load Valve Yes Yes


Non-Loadable
Loadable/

150 GPM
(FM3)
Load Valve Yes Yes

Diagnostic Recirculation Loops

(optional)
Loadable
300 GPM

(FM4)
Load Valve Yes Yes


60 GPM Closed Circuit
Can not be used Can not be used

Non-Loadable
simultaneously with Main simultaneously with Main

(FM5)
Flow Out Flow Out

Load Valve No No
Flowmeter 0.5-5.0 GPM 0.5-5.0 GPM

(optional)
Low
Flowmeter 0.2-2.0 GPM 0.2-2.0 GPM
Table 5.3

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5.3 Capacities, Dimensions and Weight
Capacities
There is a 300-gallon main reservoir, 100-gallon worktable sump, and a separate 100-gallon hydrostatic
system reservoir.
Dimensions
1. The overall dimensions of the test stand with main unit, motor starter and work support sump in
place are 168.5" wide x 203" deep x 88" high.
2. The dimensions of the work support sump by itself are 67" wide x 144" deep x 12" high.
Weight
The weight of the test stand is approximately 13,000 pounds and the weight of the work support sump
is approximately 2,000 pounds.
15

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6.0 Installation Instructions
This section outlines the placement of the AIDCO Model 900 Transmission and Hydraulic Component
Test Center in the shop environment and describes the sump pump, water and electrical connections
required for installation.
6.1 Placement
The test stand should be installed in an area that allows access to all sides of the machine. The
dimensions for the main unit and worktable sump are discussed in the previous chapter.
6.2 Unwrapping the Unit

The test stand is shipped in two sections. The main unit measures approximately 14' x 7' x 8' (LxWxH)
crated. The work support sump measures approximately 12' x 6' x 3' crated.
Main Unit
Carefully unwrap the main unit and position it in the place reserved for the test stand.

Make certain that the machine is level to ensure proper operation. If needed, resilient
 Note shims should be used to distribute the load evenly.
Work Support Sump

Unwrap the work support sump. Remove all cartons and parts packed with it. The cartons contain
adapter kits for mounting test components or attaching them to the test stand. Set them aside for
unpacking and individual storage.
Position the work support sump by centering the output drive shaft of the main unit between the T-slot
bars of the sump. The sump must fit tight against the front of the main unit under the drip guard. Secure
the work support sump in the same manner that the main unit was secured, making certain that the
sump extension is properly attached and level.
6.3 Sump Pump, Water and Electrical Connections

Sump Pump Connection
Connect the work support sump’s drain hose to the sump pump located inside the bottom right side of
the main unit. Connect the float level switches to the main unit.

All required hoses and hardware for making the sump pump connections are supplied. Once in place,
position the grating in the sump cavity.
Water Connections
There are two primary heat exchangers in the test stand’s main unit. One is for the hydrostatic system;
17
6.0 Installation Instructions
the other is for the main reservoir. The water lines to the heat exchangers are connected together; the
1-¼" inlet and 1-½" outlet are located behind the left rear door of the test stand. Connect a water supply
to the inlet pipe and a drain line to the outlet pipe. Maintain a line size at least as large as the water
lines on the test stand.
The automatic water control valve is designed to remain closed to the cooling water until a specified
temperature level is reached. Then, the valve opens allowing water to pass through the heat exchanger
until the oil temperature drops, at which point the water valve closes. The water control valve on the
hydrostatic system heat exchanger operates in the same way.
The temperature settings for hydrostatic and main reservoir are made from the control panel
Adjustments to the heat exchanger settings, if required, should be made later. (See Heat Exchanger
Adjustment in Section 7). The test stand is designed so that during normal use the heat exchangers
operate only occasionally. If a prolonged test is run on a problem component, the heat exchangers will
operate as necessary to maintain proper oil temperatures.
Electrical Connections
When the electric motor starter is shipped as part of the test stand's original equipment, it is pre-wired
at the factory, making the installation simple. Bring the three wires of the 3-phase electric current to the
proper points in the starter box. Make certain the line voltage and frequencies are the same as those
on the main motor tag.

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7.0 Start-Up Procedure
This section outlines the AIDCO Model 900C Transmission and Hydraulic Component Test Center
oil reservoirs and fluid requirements; describes oil fill and electrical check operations; and details
procedures for checking the direction of rotation of the main electric motor, priming the hydrostatic
system, pressurizing the flow systems and adjusting the heat exchangers.
7.1 Reservoirs and Fluids

Hydrostatic Reservoir
This 100-gallon reservoir is located on the back of the machine; the oil level sight gauge is on the back
of the reservoir. Verify that the hydrostatic reservoir is filled with oil (supplied by the customer). For
initial fill and oil change purposes use hydraulic transmission oil, automatic transmission oil, or fluids
as specified in the specifications section. Satisfactory operation of the hydrostatic system depends on
specific fluid characteristics.
Cleanliness
Ninety percent of failures in a hydraulic system are due to contamination. The hydraulic components in
the test stand require a cleanliness level of ISO 18/15/13 or better.
Antiwear Qualities
The oil must provide antiwear qualities equal to or better than those found in API classifications MS
crankcase oil.
Viscosity
Viscosity should not fall below 60 SUS in the reservoir under the most adverse operating conditions.
The optimum viscosity is 80 to 180 SUS. Viscosity at the lowest expected start-up temperature should
not exceed 1,000 SUS. In the shop environment, the test stand typically is protected from extreme
temperatures.
Inhibitors
The oil must have rust and oxidation inhibitors in order decrease the potential corrosion rate of the
components used in the test stand.
Barium Additives
The oil must not contain any barium additives.
Water
The test stand's hydrostatic system does not contain any water separators. The system should be
run with a good quality mobile hydraulic oil that will absorb any water due to normal condensation or
minimal contamination, as opposed to an oil that displaces water.
Main Reservoir
This 300-gallon main reservoir comprises the upper left quarter of the main unit, directly above the
main electric motor. The oil level sight gauge for this reservoir is on the end of the reservoir. Standard
19
antiwear hydraulic oil or automatic transmission oil (supplied by the customer) is normally used in the
main reservoir.
7.2 Initial System Check

Prior to using the unit, ensure that:
1. The CONTROL POWER key switch is off.

2. The SPEED AUTO/MANUAL switch is set to Manual.
3. The SPEED ADJUST, MAIN FLOW ADJUST and the MAIN pressure ADJUST are turned
all the way out (counterclockwise).
4. The five pressure adjust valves on the gauge panel, High psi flowout pressure
adjust, fm2 load valve adjust, fm3 load valve adjust, fm4 load
valve adjust and main flowout pressure adjust are turned all the way out
(counterclockwise).
5. The flow adjust valve on the flow out panel, high pressure flow adjust is turned all the
way out (counterclockwise).
6. The flow adjust valve on the flow out panel LUBE FLOW adjust is turned all the way in
(clockwise).
7. The 2" supply and 4" supply on the flow out panel are in the closed (vertical) position.
8. All switches on the gauge panel are turned to the off position.
9. Make certain that there is no drive shaft connected to the hydrostatic motor and the gib locking
bolts are tight.
7.3 Start-Up and Check

Connect 1” hoses between ports listed below:
1. main flowout to fm3 150gpm load in.

2. fm3 150gpm out to fm2 50gpm load in.
3. fm2 50gpm out to either return to tank port.
Prior to turning on the Control Power key switch, ensure that all ball valves

! Caution inside of the test stand are in the open position.
Main Motor Start Interlocks

Turn on the CONTROL POWER key switch. Turn on the Kidney Loop off/on switch. Once turned
on, the Kidney Loop switch will remain engaged, even if power to the test stand is shut off. The Main
Electric Motor will not start if the Kidney Loop switch is not engaged. If an attempt is made to start the
Main Electric Motor without the Kidney Loop switch engaged, the Kidney Loop Indicator will light,
alerting the operator to turn on the Kidney Loop pump switch.
In addition, the MAIN FLow Adjust and SPeed Adjust must turned all the way counter-clockwise.
If either of these are not turned all the way counterclockwise, the Main Motor will not start.

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Main Electric Motor Check
All electric motors will rotate in the same direction as supplied by the factory. Follow these instructions
to determine proper rotation:
Operating the test stand components in the improper direction of rotation will

! Caution result in damage to the equipment.
1. Determine if the main electric motor is rotating in the proper direction. Jog the main electric
motor by pushing the MOTOR START and MOTOR STOP switches on the gauge panel. The
motor’s shaft should rotate as indicated by the directional arrows on the pumps supplied.
2. If the shaft of the main electric motor is not rotating properly, you must switch any two of the
three wires on the incoming 3-phase current at the main electric motor starter.
High-Pressure System Checks

Check each of the following:
1. Turn High Pressure adjust in (clockwise) until high pressure flowout on the
gauge panel displays 2,000 psi.
2. After the High-Pressure system has been checked, return the pressure to 0 psi and resume
start-up procedure.
21
Priming the Hydrostatic System

Prior to starting the Hydrostatic System motor, ensure that there is no drive
shaft connected and that the gib bolts have been securely tightened.
! WARNING! Failure to do so will result in damage to the equipment and injury to
personnel.

1. Ensure that the DLS OFF/On switch is in the off position.
2. Jog the main electric motor by pushing the MOTOR START and MOTOR STOP switches on
the gauge panel. Pay attention to the sound of the hydrostatic system pumps. They will make
various noises as air is forced out of the system. Continue jogging the main motor until there is
a noticeable difference in the sound of the pumps.
3. After the air is purged from the system, the test stand is primed and ready to operate. Press the
MOTOR start switch and let the motor come up to speed.
High-Pressure System Checks

Check each of the following:

1. The hydrostatic CHARGE on the gauge panel should rise to a nominal 290 PSI; slightly
more or less is acceptable.
2. Begin turning the SPEED adjust slowly to the right (clockwise). The output shaft of the
hydraulic motor, which drives components under test, will begin to rotate, recording a reading on
the tachometer. Adjust the speed until 1000 rpm is reached. Hold this speed for approximately
10 minutes.
3. Drop the speed back to zero and proceed to pressurizing the flow systems.
Pressurizing the Flow Systems
1. Turn the main flowout pressure adjust on the gauge panel clockwise approx. half
way.
2. Increase the Main Flow by turning the main FLOW adjust on the flow out panel clockwise
to approx. 40 GPM. FM2 Flowmeter 2, FM3 Flowmeter 3 and FM4 Flowmeter 4
should all display similar readings.
3. FM2, FM3 and FM4 can all be simultaneously pressurized. Turn the fm4 load valve
adjust on the gauge panel in (clockwise) until FM4 LOAD VALVE indicates 1500 PSI.
main flowout, fm3 flow valve, and fm3 load valve should all display similar
readings.
4. Turn fm4 load valve adjust on the gauge panel out (counterclockwise) until FM4
LOAD VALVE indicates 0 PSI.
5. Turn the fm3 load valve adjust on the gauge panel in (clockwise) until FM3 LOAD
VALVE indicates 1500 PSI. main flowout and fm3 load valve should display similar
readings.

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6. Turn fm3 load valve adjust on the gauge panel out (counterclockwise) until FM3 LOAD
VALVE indicates 0 PSI. main flowout, fm3 flow valve, and fm3 load valve should
all display similar readings.
Heat Exchanger Adjustment

The heat exchangers can be verified and adjusted now or during the first component test. There
are two digital temperature controllers on the gauge panel, one for the main reservoir and one
for the hydrostatic system. Observe the displays during operation of the test stand. The operating
temperatures of the heat exchangers can be adjusted from the digital controls on the left side of the
gauge panel. These controllers were set during factory run-out, but due to differences in water flow and
temperature, readjustments may be required. The red display indicates the actual temperature and the
green display indicates the set point at which the tank is to cool or heat the fluid within.
23

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8.0 Operation
8.1 Routine Start-Ups
To start the AIDCO Model 900 Transmission and Hydraulic Component Test Center for day-to-day
operation:
Prior to turning on the Control Power key switch, ensure that all ball valves

! Caution inside of the test stand are in the open position.
1. Turn the CONTROL POWER key switch to the on position. This supplies 110-volt power to the
control circuit.
2. Ensure the SPEED AUTO/MANUAL switch is set to Manual.
3. Verify that all valves and other controls are ready for testing, preferably in the off or closed
positions. Also, make certain that hoses are secure and that ports not in use are capped.
4. Turn on the Kidney Loop off/on switch.
5. Turn main flowout adjust and SPeed Adjust all the way counter-clockwise.
6. Push the MOTOR start switch to start the main electric motor.
Prior to starting the Hydrostatic System motor, ensure that there is no drive
shaft connected and that the gib bolts have been securely tightened.
! WARNING! Failure to do so will result in damage to the equipment and injury to
personnel.
8.2 Hydrostatic Drive System

This system consists of the main electric motor, hydraulic pump, hydraulic motor, hydrostatic reservoir,
system controls and fluid conditioners. By operating the controls, you will be able to control the output
speed of the hydraulic motor anywhere within its range.
Directional Control
Select the desired direction of rotation for the hydraulic motor’s output shaft. This is accomplished by
turning the DIRECTION CW/CCW switch on the gauge panel clockwise or counterclockwise.
irection of rotation is the direction of the output shaft as viewed from the front of the
D
 Note machine.
Speed and Torque Relationships

Understanding the relationship of speed and torque is important to proper use of the test stand’s speed
controls. Refer to table 5.1 in Chapter 5 for more information.
s speed increases, maximum torque available remains fairly constant through the
A
 Note low speed range and drops off in the high range.
25
8.0 Operation
Speed Control and Tachometer
Both the hydraulic pump and hydraulic motor are variable displacement piston components. The speed
of the hydraulic motor’s output shaft can be adjusted to a maximum on the SPEED ADJUST as per the
specifications in Chapter 5.
Speed Control
The hydraulic motor turns when operating the SPEED ADJUST, causing oil to flow to the motor,
increasing the displacement of the hydraulic pump. As the motor receives the flow, it begins to turn in
relation to the quantity of oil being pumped into it. When the pump reaches maximum displacement,
the motor begins to decrease in displacement, increasing the speed, but reducing the torque of the
Hydrostatic Drive System.
Tachometer
This instrument measures the test stand’s output speed (the speed of the hydraulic motor’s output
shaft).
Monitoring Instruments
Monitoring instruments for the hydrostatic system:
Hydrostatic Charge
This gauge registers the internal charge pressure of the hydrostatic system. A charge pressure of 290
PSI above case pressure is normal, which translates to a reading of approximately 280 to 340 PSI on
the gauge. Radical drop in charge pressure, if it occurs, will be accompanied by impaired hydrostatic
function.
Hydrostatic System
This gauge registers the pressure at which the hydrostatic system is working. Higher pressures indicate
that higher torque is required to turn the component being tested. Maximum system pressure is 6,000
PSI. At this pressure, internal relief valves activate.
Oil and Filter Indicators

Indicators for the Hydrostatic System are located on the gauge panel.
Hydrostatic Tank Cool

This digital temperature controller displays the temperature and cooling set point of oil in the
hydrostatic reservoir and allow the user to create a set point for cooling.
Hydrostatic Tank Low Level

When lit, indicates the 100 gallon hydrostatic reservoir is low on oil.
Hydrostatic Servo and Hydrostatic Charge

When lit, clean or replace the hydrostatic system filter(s) as previously instructed.

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8.0 Operation
8.3 Oil Flow Out Systems
There are five systems which provide oil from the test stand to components under test. They are the
Main Supply - main flowout, Lube Supply - Lube, High Pressure - High Pressure flowout,
2" Supply and 4" Supply.
Main
The Main pump consists of a variable displacement open-loop piston pump that provides approximately
0-60 GPM up to 1,000 PSI for providing oil to components under test.
Flow Control
Oil comes out the main flowout port on the flow port panel when the main flow ADJUST is
turned clockwise. The rate of flow registers on the system’s FM5 flow meter 5 display.
Pressure Control
The maximum pressure provided can be adjusted using the main flowout pressure adjust on
the gauge panel. Pressure is read on the main flowout gauge.
Operations
The system can supply approximately 60 GPM at up to 1,000 PSI. An example of its use is as follows: a
hydraulic motor requires an oil supply of 40 GPM at 300 PSI. Normally, a remote pump supplies the oil.
Connect a hose from the main flowout port to the hydraulic motor inlet. Increase the main FLOW
ADJUST to establish a flow to the hydraulic motor. Pressurize the oil to 300 PSI, using the main
flowout PRESSURe adjust. Then set the required flow by adjusting the main FLOW ADJUST.
Lube
Using flow from the Supercharge pump, this system provides a low flow, low pressure, 0-8 GPM at
up to 65 PSI oil supply for lubrication of bearings and bushings in the component under test or tooling
used during testing.
Flow Control
Oil comes out the lUBE flowout port. Flow is controlled with the lUBE FLOW ADJUST valve.
Operations
The system can supply 0-30 GPM at up to 65 PSI. An example of its use is as follows: certain
components and tooling require a separate source for low flow, low pressure lubrication. The Lube
Supply is connected to the component under test or tooling used during testing.
High Pressure
The high pressure pump is a fixed displacement check ball pump that provides approximately 0-24
GPM at up to 7,200 PSI for testing hydraulic cylinders or relief valves. This pump does not require the
Main Electric Motor to be turned on.
27
8.0 Operation
Flow Control
Oil comes out the high pressure flowout. Flow is controlled by the high pressure flow
adjust valve.
Pressure Control
The maximum pressure provided can be adjusted using the high psi flowout pressure
ADJUST on the control panel. Pressure is read on the high psi flowout gauge.
Operations
The system can supply 0-24 GPM at up to 7200 PSI. An example of its use is as follows: a relief with
a 6500 PSI setting can be tested by connecting the component to the high pressure flowout.
Turn the high psi flowout pressure ADJUST until the relief valve opens, comparing the
pressure at which the valve opened to the component specifications.
Pump Suction
This system provides approximately six feet (6') of positive suction head for hydraulic pumps from the 3"
supply and 4" supply.
Flow Control
Oil comes out the 2" supply and 4" supply. Flow can be turned on/off using the butterfly valves on
the flow panel. This system does not have a method of flow measurement.
Pressure Control
This system does not have a method of pressure control. Vacuum is read on the 4" supply gauge.
Operations
An example of its use is as follows: an open loop variable displacement piston pump has a max flow
rating of 75 GPM at 1200 RPM. Connect a hose from the 2" supply or 4" supply to the pump
suction inlet of the component under test.
8.4 Return Oil to the Main Reservoir

There are two methods for returning oil to the main reservoir. The preferred method is to use the Return
to Tank ports, which keep the system closed and therefore the oil clean. If necessary, oil can also be
retuned to the Main Reservoir by using the Work Table Sump.
Return to Tank Ports

This system consists of two return to tank ports. The ports are used anytime there is a need to return
oil to the main reservoir. Oil entering through either rETURN TO TANK in port is combined before the
filters into one line inside of the machine and are routed through the return filters before returning to the
Main Reservoir.
Sump Return
Oil from the Work Table Sump is pumped from the Sump by a centrifugal pump and is routed through

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8.0 Operation
the Sump Filter before returning to the Main Reservoir. The Sump Pump is controlled by high and low
level float switches. The Sump Pump remains under power even if the Control Power Key Switch is in
the off position. The Sump Pump can be disabled by either disconnecting main power to the machine or
by switching the circuit breaker inside the control power box on the side of the machine.
he Sump Pump is limited to a maximum 85 GPM. Care should be taken not to

T
 Note return more oil to the Work Table Sump than the pump can handle.
8.5 Diagnostic Recirculation (Recirc) Loops

There are up to 5 circuits capable of monitoring oil flowing from a component under test. Depending
on the system used, the oil passes through a flow meter, flow control valve, pressure relief (load) valve
or any combination of the preceding and is then returned to the component under test or the Main
Reservoir.
FM2 Flowmeter 0-60 GPM

The FM2 Flowmeter 2 can monitor flow and pressure and/or apply an adjustable load of up to 6,500
PSI to flows up to 60 GPM.
Flow and Pressure

The FM2 Flowmeter 2 0-60 gpm circuit is used by putting oil into the test stand through the fm2
load valve in port. Connect the fm2 out port to the component under test or to either of the ports
marked RETURN TO TANK.
The system can be pressurized with the fm2 load valve adjust. Pressure is displayed on the
fm2 load valve gauge and flow is displayed on the fm2 flowmeter 2.
Flow Only
To measure flow only, connect a hose to the fm2 in from the component under test. To measure flow,
connect the fm2 ouT to the component under test or to either of the ports marked RETURN TO TANK.
Flow is displayed on the fm2 flowmeter 2.

This system is similar to FM2 Flowmeter 0-60 GPM with the exception of a higher flow capacity. It
can monitor flow and pressure and/or apply an adjustable load of up to 6,000 psi to flows up to 150
GPM.
Flow and Pressure

29
8.0 Operation
Flow Only
To measure flow only, connect a hose to the fm3 in from the component under test. To measure flow,
connect the fm3 ouT to the component under test or to either of the ports marked RETURN TO TANK.
Flow is displayed on the fm3 flowmeter 3.
FM4 Flowmeter 0-300 GPM (optional)

The FM4 Flowmeter 4 can monitor flow and pressure and/or apply an adjustable load of up 5,000
PSI to flows up to 300 GPM.
Flow and Pressure


The FM5 Flowmeter 5 can monitor flow and pressure up to 1,000 PSI to flows up to 60 GPM if the
MAIN FLOWOUT is not being used.
The FM5 Flowmeter 5 0-60 gpm circuit can not be used when the Main Flowout
 Note is in use.
Flow and Pressure

The FM5 Flowmeter 5 0-60 gpm circuit is used by putting oil into the test stand through the fm5 in
port. Connect the MAIN FLOWout port to the component under test or to either of the ports marked
RETURN TO TANK.
This circuit can only be pressurized with the use of an external valve or restriction. Pressure is
displayed on the main flowout gauge and flow is displayed on the fm5 flowmeter 5.
Low Flowmeters (optional)

The low flowmeters located on the flow out panel are typically used for measuring case drain and other
low volume flows.
Flow Only
To measure flow only connect the component under test to the flow meter. Oil from the Low Flowmeter
returns to sump.

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8.0 Operation
ll pressures should be measured directly from the component under test using
A
 Note the pressure taps. Gauges integrated into the test stand circuits should be used for
reference only.
8.6 Transmission Pressure Gauges

There are numerous small gauges of varying pressure capacities on the right side of the gauge panel.
The gauges range from 100 to 7500 PSI. They can be connected to taps in the component under test
to monitor clutch pack pressures, lube pressure, etc. Use gauges of sufficient capacity for your test
purposes, or else the gauge tube can deform or rupture as a result of over-pressurization or the gauge
itself can be damaged.
A
reference only.
8.7 Sump Pump System

The sump pump returns oil from the work support sump to the main reservoir. The sump pump operates
automatically whenever the system is under power. The sump pump override is used to evacuate
the sump reservoir beyond the limit of the low level float switch.
vacuating the sump beyond the limit of the low level float switch can introduce air
E
 Note into the circuit, resulting in damage to the pump. Bleed the pump each time the sump
is drained.
The SUMP FILTER indicator light indicates if the system's filter needs to be changed.
8.8 Fluid Conditioners, Indicators, etc.

Fluid conditioners on the test stand include oil filters and heat exchangers. Since the conditioners
operate automatically, attention to them is not normally required except during regular maintenance.
However, their operation is vital to the performance of the test stand and should be understood.
Filters
90% of all hydraulic system failures are due to contamination. Clean filters are essential to the proper
operation of the test stand. Specifications and quantities of filters are provided in the Filter Specification
section found in the Appendix.
Heat Exchangers
The test stand includes two oil-to-water heat exchangers, one for the main reservoir and one for the
hydrostatic system. The effectiveness of the heat exchangers depends on the temperature of the
water being used for cooling and the condition of the heat exchanger itself. These units cool hot oil by
31
8.0 Operation
passing water through the tubes in the oil.
Oil Level Sight Gauges

The oil level sight gauge for the main reservoir is on the left side of the main unit. The level sight gauge
for the hydrostatic system is on the back of the main unit. These gauges should be checked daily. Add
oil as necessary to keep the oil level well within the sight gauge. Do not operate the test stand if oil
cannot be seen in the sight gauge.
Temperature Controllers
Oil temperature controllers for the HYDROSTATIC TANK COOL and MAIN TANK HEAT (optional)/
COOL are located on the gauge panel. Once the predetermined set point has been reached, these
units will enable the heat exchangers to cool the system.
Ports and Control Switches

It is good practice when not using the test stand to cap all flow ports and turn all valves, controls and
switches to their off or closed positions.

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9.0 Testing
This section outlines general testing guidelines for use in conjunction with the AIDCO Model 900
Transmission and Hydraulic Component Test Center. Instructions and specifications for specific test
must be obtained from the component or equipment manufacturer.
9.1 Transmission Testing

The purpose of transmission testing is to ensure that serviced or rebuilt components function properly
before they are returned to service in a vehicle. The basic test involves rotating the transmission as if
an engine was driving it. By rotating the transmission, you can adjust pressure settings, set shift points,
check flows and identify unacceptable operating conditions, such as excessive noise vibration and
leakage.
Test Stand Functions

he stand is capable of producing conditions which simulate vehicle operation. Basically, the test stand
T
performs the following functions:
1. The Hydrostatic Drive System is used to rotate the transmission in the required direction at the
required speed.
2. Both the Supercharge and the Aux supply provide a regulated flows of oil under pressure to the
transmission’s valve and clutch package. For oil flowouts to 0-30 GPM up to 65 PSI use the
Lube supply. For oil flowouts to 0-60 GPM up to 6000 PSI use the Main Flowout supply. This
system takes the place of the vehicle’s charge pump when this pump is not an integral part of
the transmission.
3. The flow meters provide a way to monitor the amount of flow and detect leakage in the
transmission system.
4. Pressure gauges can be connected to taps in the transmission to check various internal
pressures.
A
reference only.
As the transmission is rotated and provided with the correct oil supply it will be possible to determine
clutch pack pressures. Also, relief valve settings and valve function within the transmission can be
checked.
Flow and Pressure Settings

Valid test results depend on accurate initial flow and pressure settings.
The supply must be adjusted to the exact flow that the transmission receives in the vehicle. This does
not mean that a transmission from a vehicle with a 50 GPM pump should receive a flow of 50 GPM.
Normally, the pump supplies oil to other functions as well as to the transmission. The exact flow to the
transmission should be obtained from the vehicle under test or it will be impossible to determine clutch
pack leakage and false test results will be obtained.
33
9.0 Testing
If a transmission to be tested has a relief valve as an integral part of the component, the supply
pressure must be established at 100-PSI minimum above the relief valve setting. If not, it will be
impossible to determine whether the relief valve in the transmission or the relief valve in the test stand
is controlling pressure. If the transmission does not include a relief valve, the supply pressure must be
set appropriately to protect the transmission.
Mounting a Transmission
There are three steps to mounting a transmission for testing on the test stand:
Positioning
Position the component so that the transmission’s input shaft and the test stand’s output shaft line up
as closely as possible. The output shaft can be adjusted vertically using the power lift assembly.
Leveling
Establish a secure, level base with universal mounting adapters from the Transmission Support Group
and adapters for the specific component if required. Position one support bar forward and one as far
back as possible under the transmission. Place the spacers in the slots of the support bar so that the
transmission rests securely on a flat base or is supported by clevis adapters. The transmission is not
bolted down. Connect the drive shaft at this time.
Securing
Two cables with load binders are provided with the Transmission Support Group to secure the
transmission to the work support sump. The cables can be attached to the eyebolts that ride in slotted
rails on the sump. Pass the cables across the transmission, loop them around the lifting eyes and
take up the slack with the load binders. The load binders should be placed on opposite sides of the
transmission to keep the mounting snug and secure and to prevent the transmission case from rotating
during shift events. Re-check alignment of the drive shaft and close and lock the drive shaft guard.
Figure 9.1

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9.0 Testing
Remote or Direct Mount Transmission
There are two drive configurations for transmission:
Remote Mount
In most cases, a remote mounted transmission is connected to the engine with a drive shaft. Therefore,
it is only necessary to connect the transmission to the test stand’s output shaft, using the drive shaft
and suitable flanges from the Transmission Drive Group.
Figure 9.2
Direct Mount
On transmissions with torque converters that bolt directly to the engine, it is necessary to attach the
proper bell-housing adapter to drive and support the torque converter. When this is accomplished,
the transmission is connected to the test stand’s output shaft in the same manner as remote mount
components.
Transmission adapter kits supplied by AIDCO include all required mounting, drive and accessory
hardware to perform testing of many types of transmissions. For a list of available adapter kits, contact
an AIDCO sales representative.
35
9.0 Testing
Figure 9.3
9.2 Pump Testing

Rebuilt pumps can be tested to ensure that the direction of rotation is correct and that pumping capacity
is at an acceptable level. Testing under loaded conditions is necessary to assure that the re-assembly
has been made properly and that there are no shaft seal or cover leaks. Pump condition (pumping
efficiency) is determined by observing the amount of oil recirculation that occurs within the unit.
Normal Recirculation
Some recirculation takes place in all new pumps from the high-pressure side to the low-pressure side of
the pump.
Vane Pumps
The amount of recirculation depends on the clearance between the rotor slots and vanes, between the
end plates and rotor vanes and on the condition of contact between the vane tips and the ring surface.
Gear Pumps
Recirculation depends on gear match or clearance between gears, the fit of the gears to the side plates
and on the fit of the gears to the housing.
Piston Pumps
Recirculation occurs between the pistons and piston barrel, the piston barrel and port plates and
between the port plates and housing.
Computing Pump Loss

It is standard practice to compare pump flow at 100 PSI to pump flow at 1000 PSI while maintaining
constant speed. Since pump losses from recirculation are directly affected by pressure, this method is
useful in determining pump condition.
Test Guidelines
The pump is normally rotated at a given speed (usually 1200 or 1800 rpm) at 100-PSI back pressure

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9.0 Testing
on the pressure port. The resulting flow is the pump’s performance base. After recording the base flow,
the pressure is increased to 1000 PSI while the speed is maintained. The decreased flow at the higher
pressure expressed as a percentage of loss indicates the pump’s efficiency:
% loss = (flow rate @ 100 PSI)(flow rate @ 1000 PSI) X 100

(flow rate @ 100 PSI)
For example, a pump that pumps 50 GPM at 100 PSI and 48 GPM at 1000 PSI shows a loss of 4%
4% = (50)(48) X 100
(50)
Acceptable Losses
Acceptable losses vary widely among different types and sizes of pumps and from one manufacturer to
another. For example, piston pumps are generally more efficient than either vane or gear pumps. Also,
small pumps exhibit a greater percentage of loss than do large pumps. Every effort should be made to
obtain performance information from the pump manufacturer. If specifications are not available, a rule
of thumb is that a piston pump that loses no more than 10% of base flow at 1000 PSI and a gear or
vane pump that loses no more than 20% are acceptable for return to service.
Application
Consideration should be given to the type of machine or application in which the pump will work.
For example, a high production or high cycling machine probably requires a pump with a low
percentage of loss; a machine that works intermittently probably can tolerate higher losses.
Operating Temperature
Consideration also should be given to the temperature at which the pump normally operates.
Pumping losses increase with rising temperature due to the change in oil viscosity. As oil becomes
thinner, it recirculates easier within the pump. This change of flow rate is expressed by another rule
of thumb: pump capacity decreases approximately 0.5 GPM for every 10º F. of temperature rise
from 120º F. to 180º F. The resulting value should be doubled when flow from two sections of a
pump are combined.
Reduced Tests for Large Pumps

It is possible to run a reduced test on some very large pumps which cannot be tested at their high
pressures and high flows due to horsepower limitation of the test stand. The reduced test is valid
because flow losses are directly related to pressure; therefore, they increase proportionately as
pressure increases.
37
9.0 Testing
Pump Mounting
A quick-change mounting bracket kit for pumps and motors is available for use with the test stand. Bolt
the bracket to the rails of the work support sump, using the bolts and square nuts provided in the kit.
The mounting bracket will slide along the rails. (A typical pump mounting is illustrated in the drawing
below).
Figure 9.4
Bolt the pump to the appropriate mounting plate, making sure that the boss on the face of the pump
fits snugly into the large center hole of the plate. Lower the mounting plate into the mounting bracket
and lock it in place with the retaining pins. Attach the pump shaft adapter holder to the drive shaft, fit
the appropriate pump shaft adapter to the holder and mate the adapter through the center hole of the
mounting plate to the shaft of the pump itself. Adjust alignment.
Hose Connections
Typical pump connections consist of a hose from the 2" supply or 4" supply on the test stand to the
pump inlet and from the pump outlet to one or more of the Diagnostic Recirculation (Recirc) Loops. The
suction hose should always be connected at the lowest possible point. A piston pump normally requires
a case drain line and a pressure tap line in addition to the other hoses.

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9.0 Testing
Figure 9.5
Gear and Vane Pump Testing

To test a typical gear or vane pump:
1. With a hose connected from the 2" supply or 4" supply port to the pump inlet, open the
corresponding valve.
2. Direct the hose from the pump’s outlet port to the work support sump while priming the pump
and checking its direction of rotation. Some oil should flow through the pump at this point,
providing pre-lubrication.
3. Jog the pump with the SPEED Control until it is primed. Be sure the direction of rotation is
correct.
4. When the pump is primed and oil flows form the loose pump outlet line, connect the line to the
fm3 load valve in and a second line from fm3 out to RETURN TO TANK. For a two-
stage pump, also connect a line from the second pump outlet port to fm2 load valve in and
a second line from fm2 out to RETURN TO TANK.
5. Now proceed according to the pump or vehicle manufacturer’s test specifications.
Piston Pump Testing

Testing a typical piston pump requires a different priming procedure than vane or gear pumps. The
reason is that piston pumps cannot produce a vacuum. Test stand owners who have standard hydraulic
oil in the main reservoir should use the procedure outlined below for testing.
1. Connect a hose form the pump’s outlet port to the main flowout port on the flow port panel.
Be sure that the case drain plug is removed from the pump.
2. With a hose connected from the 2" supply or 4" supply to the pump inlet, turn the valve on
the port to the open position.
39
9.0 Testing
3. Start the test stand. Use the main flowout port and main flowout valve to supply oil
to the pump’s outlet port at the pressure prescribed by the pump or vehicle manufacturer’s test
specifications. The main flowout pressure adjust should be increased slowly until the
pump begins to turn as a motor. Normally, the pressure is 300 PSI or less; do not exceed 500
PSI.
4. With the drive shaft disconnected at the pump, let the pump turn four or five revolutions. At this
point, there must be oil flowing out of the case drain.
5. Decrease the main flowout pressure adjust and the main FLOW ADJUST,
disconnect the hose from the main flowout port and let it lay loose on the work support
sump.
6. Connect the drive shaft; select the proper direction of rotation and start rotating the pump at 100
to 200 rpm until the pump is primed and oil is flowing out the discharge port. Stop rotation as
soon as the pump is primed.
7. Connect pressure hoses from the pump’s outlet port to the fm3 load valve in port.
8. If required, connect the case drain to either low flowmeter.
9.3 Hydraulic Motor Testing

To test a hydraulic motor, set up and connect the motor in the same manner as described under
pump testing. Testing should proceed according to the hydraulic motor or vehicle manufacturer’s test
specifications and procedures. A variation to the test procedure is to supply oil under pressure to the
motor in order to prevent cavitation damage.
9.4 Cylinder Testing

Cylinders can be tested on the test stand to determine if they operate acceptably after repair and re-
assembly. Specifically, you can check for leakage, binding and rod drifting. The cylinder test manifold
and cylinder hold down and mounting bracket kit facilitate testing of these components.
Mounting
Use the cylinder hold down and mounting bracket to provide a solid base on which the component can
be placed. In positioning the cylinder, be careful to ensure that when the rod is fully extended, it will not
be damaged or cause damage to the test stand. Secure the component with load binders.
Hose Connections
Attach appropriate fittings to the cylinder’s inlet and outlet ports.
1. Depending on the size of the cylinder and the pressure required, connect a pressure hose from
the main flowout port or the high pressure flowout port to the cylinder test block
inlet.
2. Connect pressure hoses from the cylinder test block to the component to be tested.

phone: (262) 252-5030 Ι fax: (262) 246-0436
40 www.aidcots.com
9.0 Testing
Figure 9.6
Test Guidelines
Cylinder testing consists of alternately directing a flow of oil under pressure to one cylinder port while
venting the other in order to check rod extension and retraction. During travel, the corresponding
pressure gauges should be observed to determine if the cylinder has any tight spots. With steady oil
flow into the cylinder, there should be no appreciable change in pressure.
A second test consists of blocking one cylinder port and pressurizing the other, thus trapping pressure
in the cylinder. Since the pressure in the rod end is higher than in the head end of the cylinder due to
differences in effective piston area, poor piston sealing can be determined by the drift rate of the rod.
Oil from the higher-pressure side of the cylinder will try to leak past the seals and reach the head end of
the cylinder. Any leakage of oil from the rod end to the head end allows the rod to extend.
The general procedure for cylinder testing is as follows:
1. Begin with all four valves closed on the cylinder test manifold.
2. Start the test stand.
3. Use the corresponding valve to provide a small amount of oil flow to the cylinder test manifold.
4. Use the corresponding pressure adjust (valve) to pressurize the system. Start with low pressure
and gradually increase pressure according to the cylinder manufacturer’s test specifications.
5. Open an inlet valve and an outlet valve on the cylinder test manifold to fully extend the cylinder
rod. Reverse the procedure to retract the rod. Repeat this process at least twice to expel all air
from the system. As the cylinder is cycled, observe the high pressure flowout gauge in
the high pressure flowout system to determine tight spots.
6. With the rod fully extended and all valves on the cylinder test manifold closed, open the inlet
valve to the rod end of the cylinder. Then open the outlet valve to the head end and the cylinder
will retract. When it has retracted approximately one quarter of its total traverse, close the outlet
valve. This will cause pressure to build in the rod end of the cylinder. Oil will attempt to leak past
the seal to the head end, causing rod drift. Mark the rod and observe the rate of drift.
7. Repeat the drift rate test at approximately one-half and three-quarters of full rod extension.
8. During these tests, inspect all welds and seals for leakage.
41
9.0 Testing
Rod drift is predictable in a good cylinder. Cylinder manufacturers have released specifications on drift
rates that are considered acceptable.
Refer to the particular cylinder or vehicle manufacturer for exact test specifications. There may be
variations to the general test guidelines outlined above. For example, some cylinders should be held in
a vertical position instead of lying horizontally on the work support sump.
he valves on the cylinder test manifold are precision zero leak valves of the soft-seat
T
 Note variety. They should be tightened to “snug” only. Over tightening may cause damage
to the pliable valve seats.
9.5 Valve Testing

The purpose of valve testing is to determine whether the valve is functional and that it is adjusted
as required for its application. Test valves to identify internal leakage and observe them for external
leakage.
Mounting
It is generally not necessary to secure the valve to the work support sump. Valves are usually small;
they do not jump from forces acting on them. Placing them on the sump is usually sufficient.
Figure 9.7

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9.0 Testing
Figure 9.8
Adapters and Hose Connections

There are three basic types of valve connections: sub-plate mount, flange connection and pipe port.
Flange connection and pipe port valves require appropriate adapters from the Fittings and Quick-
Disconnects group available from AIDCO. Sub-plate mount valves require a plate or manifold, which
converts the valves to the flange connection variety. These items are generally simple in nature and
easily fabricated at small expense.
Test Guidelines
There are many types of valves and design configurations; however, the test procedure is similar for
most valves.
Directional Control Valve

Use the Main Flowout supply to direct oil to the valve and use both the FM2 Load Valve In port and
fm3 load valve in port to check the flow division function. Hoses from the fm2 out and fm3 out
ports to the RETURN TO TANK ports also are required.
Relief and Check Valves

Depending on the flow rate use the main or the HIGH PRESSURE supply to supply oil to the valve
and the main flowout gauge or the high psi flowout gauge as necessary to test the pressure
setting.
43
9.0 Testing
It is important to obtain test procedures and specifications from the valve or vehicle
 Note manufacturer. Due to the diversity of valve types, it is possible only to describe
general mounting and connections.
9.6 Torque Converter Testing

Torque converters are usually tested in the static condition; they are not rotated during the test process.
This type of testing requires only that oil be supplied to the torque converter’s main housing and
then gradually pressurized until operating pressure is reached. The torque converter can be visually
inspected for seal leakage. However, with the correct adapters, torque converters can be tested
dynamically.
Although it is possible to rotate torque converters for testing on the test stand, most manufacturers do
not release specifications for this purpose. As a result, a valid procedure for checking flow, pressures
and temperatures is not firmly established.

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44 www.aidcots.com
10.0 Troubleshooting
This section outlines basic procedures to follow if the AIDCO Model 900 Transmission and Hydraulic
Component Test Center does not function properly. In most cases, simple adjustment can solve
problems if any occur.
10.1 Electrical Motors

Unusual Noise or Heat
Clean the motor as per the manufacturer's recommendations.
Bearing Overheating
Check for excessive friction resulting from a bent shaft, poor alignment or too much end thrust or side
thrust from the flexible coupling.
Damaging Vibrations
Check for loose motor mountings, misalignment or a faulty hydraulic pump.
10.2 Gauges
Will not return to zero. If the gauge was over-pressurized or struck, it should be checked against an
accurate test gauge. Repair or replace if found to be defective.
10.3 Flow Meters

Readings Are Suspect
To determine whether a flow meter is operating correctly, check the flow meters against each other. This
is accomplished by routing a single supply of oil through all three flow meters:
1. Connect 1” hoses between the main flowout to fm2 load valve in the fm2 out to
fm3 load valve in, and the fm3 out to either return to tank ports.
2. The two pressure adjust valves on the gauge panel fm2 load valve adjust and fm3
load valve adjust are turned all the way out (counter-clockwise).
3. The main flow adjust valve on the flow out panel is turned all the way in (clockwise).
4. Establish an oil flow using the main flow adjust supply.
5. Compare the three flow meter readings.
or several reasons, the flow meters will not register the exact same flow. The
F
 Note accuracy of the instruments themselves (+ or 1% of full scale), leakage and valve pilot
bleed-off can account for minor differences.
No Reading or Erratic Reading

Check all connections to be sure they are secure. If a flow still does not register, connect the flow meter
to a different flow block. This will indicate whether the problem is in the flow meter or the flow block.
45
1. If the problem is in the flow meter, contact AIDCO. Repair parts can usually be identified and
sent immediately.
2. If the problem is in the flow block, remove and inspect the unit to see if contaminants are
keeping the turbine from turning. If the turbine cannot be freed, the flow block should be
replaced.
10.4 Tachometer
No Reading or Erratic Reading

Check all connections to make sure they are secure. Check the magnetic pickup on the drive shaft to
be sure it is secure in its mount with clearance of .010 to .015 inches. If the tachometer still does not
operate, contact AIDCO. Repair parts can usually be identified and sent immediately.
10.5 Hydrostatic System

Routine Checks
If the pump or motor will not operate, performance is sluggish or the drive system is not responsive to
controls, perform the following checks:
Hydrostatic Charge Pressure

The hydrostatic charge gauge on the gauge panel should register at least 200 PSI when the
test stand is running at idle. (See Pressure Tests below).
Pump Coupling
Check the pump drive coupling to make sure it is connected. Make sure the coupling’s rubber insert is
in good condition.
Pressure Tests
If the trouble is not resolved with the Routine Checks above, connect pressure gauges to the pump and
motor and check charge pump inlet pressure, case pressure and charge pressure.
Case Pressure
Case Pressure of the pump or motor should not exceed 40 PSIG at normal operating temperatures.
During cold starts, this limit can be exceeded.
Charge Pressure
Minimum charge pressure, as measured on the hydrostatic charge gauge on the gauge panel,
must be at least 150 PSI above pump case pressure when the motor shaft is loaded. With the variable
pump at neutral and the electric motor at idle speed, the minimum charge pressure must be at least
190 PSI above pump case pressure.

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46 www.aidcots.com
Pressure Test Troubleshooting
Use the results of the pressure tests as follows:
1. If charge pressure, inlet vacuum and case pressure are normal, but the pump control lever
moves freely with no resistance when disconnected from the control cable, remove the control
valve and check for broken or missing parts. Repair or replace the control valve. The unit must
be disassembled and flushed to remove missing or broken parts. If the pump lever moves with
resistance and does not return to center. Clean or replace the orifice.
2. If the charge pressure is very low or registers zero and the system is low on oil, repair leaks and
replace fluid to proper operating level in the hydrostatic reservoir. If the system is not low on oil,
there is a faulty valve in the charge pump or composite valve block. The charge pump is faulty
if charge pressure is low at neutral. The valve block is faulty if charge pressure is low when the
system is operated.
3. If charge pressure is zero, check the charge pump to see if the drive shaft or key is broken. If so,
replace the charge pump.
4. If the charge pressure is low or zero and pieces or flakes of brass are found in the filter and
reservoir, the pump and/or motor are damaged and need replacement. Contamination has
occurred and has spread throughout the system. It is good practice to repair and/or replace the
pump and motor together.
harge pressure also may fluctuate rapidly or fall to or near zero when attempting to
C
 Note operate operating at low speed. The pump and motor may be noisy as well.
Hydrostatic System Motor Test

Hydrostatic drive power will decline if the settings on the high-pressure relief valves decrease in the
hydraulic motor. The reliefs are set at 5800 to 6000 PSI at the factory. Lower settings will keep the
system from working at rated power.
Figure 10.1
1. Position the hydraulic motor at a low point so that the output shaft is level with or lower than the
PUMP SUCTION PORT.
2. Disconnect the drive shaft and bolt the torque arm on to the drive adapter flange so that it
47
extends out to the right as viewed from the front of the work support sump.
3. Place the end of the torque arm to the right of the test stand and let it rest on any firm
foundation. If the hydraulic pump and motor are in good condition, there will be a maximum of
1232 lb-ft of force on the end of the torque arm.
4. Turn on the CONTROL POWER off/on key switch and MOTOR START switches.
5. Turn the DLS OFF/ON to off.
6. Set the Direction ccw/cw to CW (clockwise).
7. Very carefully turn the SPEED CONTROL out until system pressure starts to build.
8. Continue turning the speed control out. System pressure will build rapidly. Observe on the g2
hydrostatic system gauge the point where the relief valve opens. The system pressure
should be 5800-6000 PSI.
9. Stop the test.
10. To run the test in the counterclockwise direction, remove the torque arm and re-install it so that it
extends out to the left and rests on the PUMP SUCTION PORT. Re-run the test in this direction
by switching the direction ccw/cw to cw for reverse (counterclockwise) direction of
rotation.
11. Repeat steps six through 8.
10. Replace a worn relief valve and shim the new valve as necessary to achieve a pressure setting
of 5800 to 6000 PSI.
10.6 Other Checks

The troubleshooting check outlined above cover the main problems likely to be encountered. The
possibility of malfunction of various small parts also should be considered. A faulty valve seating, a
ruptured fitting, a loose connection, a burned out electric switch are a few of the many possibilities that
should be checked.

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11.0 Appendix
The following pages contain information specific to the AIDCO Model 900C Transmission and Hydraulic
Component Test Center. As specifications and part numbers change, these documents will be updated
to reflect the equipment and requirements for your machine at the time of shipment. Contact your
AIDCO sales representative for further information.
49

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50 www.aidcots.com
11.0 Appendix
Fluid Recommendations
The following fluids are recommended for proper operation of the AIDCO Model 900 Transmission and
Hydraulic Component Test Center.
HYDROSTATIC RESERVOIR (100 gallons required),

The following are acceptable:
10W AW Class Hydraulic Oil, Mobil DTE-24 or equivalent

ATF-Automatic Transmission Fluid Dexron III Mercon or equivalent
10W Engine Oils API CD, CE, and CF
Oil must be filtered to an ISO level of 22/18/13 or better while filling the hydrostatic
 Note
reservoir.
MAIN RESERVOIR (350 gallons required),

The following are acceptable:
10W Through SAE 30 AW Class Hydraulic Oil, Mobil DTE-24 or equivalent

ATF-Automatic Transmission Fluid Dexron III Mercon or equivalent
10W Through SAE 30 Engine Oils API CD, CE, and CF
Oil must filtered to an ISO level of 20/18/15 or better while filling the main oil
 Note
reservoir.


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11.0 Appendix
Filter Specifications
There are several 3-micron and 10-micron filters in the test stand (actual number depending on options
or configuration). As they get contaminated, it becomes more difficult for the oil to flow through the
filters, causing a pressure differential between the inlet and outlet side of the return line filters to the
main reservoir or high vacuum in the suction filter to the hydrostatic reservoir.
The following filters can be purchased from Caterpillar using the part numbers listed below, or directly
from AIDCO Test Sytems. Contact your AIDCO sales representative for more details.
Sump Pump Filter (long red filter bowl, located nearest back of machine, 10 Micron):
Aidco: 558493
Kidney Loop Filter (long red filter bowl, located nearest front of machine, 3 Micron):
Aidco: 558492
Return to Tank Filters (qty 2, on top of tank, silver housings, 10 Micron):

Aidco: 558495
Hydrostatic Charge, Hydrostatic Servo and Aux Pump Servo Filters (qty 3, blue, 3 Micron)
Aidco: 558150


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AIDCO DIV OF POWER TEST INC
THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF
POWER TEST INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT
ITEM NO. QTY. CUT LG. PART NO. DESCRIPTION
THE WRITTEN PERMISSION OF POWER TEST INC. IS PROHIBITED.
1 1 535424.12333334 PNET TD CONTROLLER BASE - 900 DAQ
2 1 63249.1 COMMANDER - PNET WS/LT/2.0 DESKTOP
3 1 23586.050 ETHERNET CABLE ASSEMBLY RJ45
4 4 H-0328 BTN HD SOC CAP SCR 3/8-16 X 1 1/2 S.S.
5 4 H-0265 HEX NUT 3/8-16 NYLOCK
6 4 H-040 FLAT WASHER 3/8
7 4 590618 PRESSURE TRANS 0-300 PSI 1/8NPTM 3pin
11 24 551648 HEX RED BUSH 1/4 X 1/8NPT STEEL
12 1 250 X-160 WIRE 22 AWG 2PR W/SHIELD PVC GRAY /FT
13 1 30 E-5105 THERMOCOUPLE WIRE TYPE"K"YLW/RED /FT
14 2 E-2814 COMP FTG 3/16T/C X 1/4NPTM
15 2 E-28 T/C TYPE K 3/16 X 6 LG
16 2 E-2841 PATCH CORD TYPE "K"
17 2 590622 PANEL JACK T/C TYPE K STANDARD RND HOLE
18 4 X-161 RD HD MACH SCR 4-40 X 3/8 SLT
19 4 X-1681 LOCK WASHER #4 INT TOOTH
20 4 X-178 HEX NUT #4-40 FIN MACH
21 1 X-2552 3 PIN BOX MOUNT
1
EST. WT. 135 LBS.

UNLESS OTHERWISE SPECIFIED
DIMENSIONS ARE IN INCHES
TOLERANCES ARE:
CAD GENERATED DRAWING,
DO NOT MANUALLY UPDATE POWER TEST INC.
DECIMALS: .XX ± .01 APPROVALS DATE
.XXX ± .005 DRAWN
JWP 10/03/08
FRACTIONS: ± 1/32 ± 1º CHECKED PNET TD CONTROLLER
MATERIAL
-- CHECKED ADD-ON 900K
FINISH
RESP ENG
-- SIZE REV.
535471.2
DWG. NO.
PROD MAN B 0
REV DATE ECN DO NOT SCALE DRAWING
SCALE: 1:6 CAD FILE: SHEET 1 OF 1
APPROVED 10/14/08
POWER TEST INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT ITEM NO. QTY. CUT LG. PART NO. DESCRIPTION
1 1 558517 PUMP 85gpm@30psi 3HP 230/460/3 (OIL)
2 1 P-254 PIPE NIPPLE 2 X CLOSE
3 1 P-715 PIPE ELBO 2 90°
4 1 P-905 PIPE COMBO NIPPLE 2NPTM X 2 H.B. PL
5 3 P-1158 HEX RED BUSH 2 X 1 1/2
6 9 P-904.5 PIPE COMBO NIPPLE 1 1/2NPT X 1 1/2H
7 8 H-049 HEX HD CAP SCR 3/8-16 X 1 1/2 GD5
8 16 H-029 LOCK WASHER 3/8 ZINC
9 8 H-026 HEX NUT 3/8-16 GD5 ZINC
10 2 505854 FILTER MOD-INLINE 3u 1 1/2NPTF w/ DRAIN
11 4 H-021 HEX HD CAP SCR 5/16-18 X 3/4 GD5
12 4 H-030 LOCK WASHER 5/16
13 4 551825 PIPE PLUG 1/8NPT SOC STL
14 4 P-775 PIPE STR ELBO 1 1/2 90°
15 4 558734 PIPE NIPPLE 1 1/2 X CLOSE(1 3/4) TBE BLK
16 1 P-712 PIPE ELBO 1 1/2NPT 45° BLACK
17 1 P-2423 PIPE NIPPLE 1 1/2 X 38 TBE
18 4 P-71 PIPE ELBO 1 1/2 90°
19 1 558737 CONDUIT CLAMP 1 1/2 IN ONE HOLE
20 1 H-03385 BTN HD SOC CAP SCR 1/4-20 X 3/8 S.S.
22 1 558477 PUMP 60gpm@65psi 7.5HP 230/460/3-(OIL)
23 1 558473 HEAT EXCHANGER 4-PASS
24 2 P-1165 HEX RED BUSH 3 X 1 1/2
27 1 558478 HEAT EXCHANGER 2-PASS
28 1 P-1156 HEX RED BUSH 2 X 1 1/4
29 2 P-4601 PIPE NIPPLE 1 1/4 X CLOSE
30 1 P-209 PIPE UNION 1 1/4in
31 1 13052 VALVE 1 1/4NPTF 2-WAY 0-10V ACTUATOR
32 1 P-1108 HEX RED BUSH 1 X 3/4
33 1 P-6402 PIPE NIPPLE 3/4 X 3 TBE
34 1 P-204 PIPE UNION 3/4in BLACK
35 1 P-6404 PIPE NIPPLE 3/4 X CLOSE TBE
36 1 12175 VALVE 3/4NPT 2-WAY W/ 0-10V ACTUATOR
37 1 558705 ADAPTER 1 1/2 X 1 1/2NPTM COPPER SWEAT
38 1 * 12 558709 COPPER TUBE 1 1/2 TYPE L /IN
39 1 558706 COPPER ELBO 1 1/2 SHORT COPPER SWEAT
40 1 *9 558709 COPPER TUBE 1 1/2 TYPE L /IN
41 1 558707 COPPER TEE 1 1/2 X 1 1/2 X 1 SWEAT
43 1 558708 ADAPTER 1 1/2 X 1 1/2NPT COPPER UNION
44 1 558712 ADAPTER 1 X 1NPTM COPPER SWEAT
45 1 * 17 558710 COPPER TUBE 1 TYPE L /IN
46 1 558714 COPPER ELBO 1 SWEAT
47 1 *2 558710 COPPER TUBE 1 TYPE L /IN
48 1 S60054 ADAPTER 1 1/4 MPT COPPER
49 1 558701 COPPER STR ELBO 1 1/4 SWEAT
51 1 558702 COPPER TEE 1 1/4 X 1 1/4 X 3/4 SWEAT
52 1 * 2 1/2 558703 COPPER TUBE 1 1/4 TYPE L /IN
53 1 558704 ADAPTER 1 1/4 X 1 1/4NPT COPPER UNION
54 1 558711 ADAPTER 3/4 X 3/4NPTM COPPER SWEAT
55 1 *6 558715 COPPER TUBE 3/4 TYPE L /IN
56 1 558713 COPPER ELBO 3/4 SWEAT
57 1 * 2 1/2 558715 COPPER TUBE 3/4 TYPE L /IN
58 1 * 3 1/2 23095.001 HOSE 1 1/2 ID - RADIATOR /FT
59 1 *5 23095.001 HOSE 1 1/2 ID - RADIATOR /FT
61 1 * 5 1/2 23095.001 HOSE 1 1/2 ID - RADIATOR /FT
63 1 *7 23095.005 HOSE 2 ID - RADIATOR /FT
64 12 23093.001 HOSE CLAMP-T-BOLT-1.88 - 1 1/2 HOSE
65 2 23093.004 HOSE CLAMP-T-BOLT-2.38 - 1 7/8 & 2 HOSE
NOTE:
1. " * " DENOTES ESTIMATED CUT LENGTH
ITEMS TO BE CUT TO LENGTH DURING ASSEMBLY
EST. WT. 555 LBS.

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 10/02/08
FRACTIONS: ± 1/32 ± 1º CHECKED HEAT EX- SUMP &
MATERIAL
-- CHECKED KIDNEY PUMP KIT 900K
FINISH
-- RESP ENG
SIZE REV.
535470.2
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
11 12
12 11 14 15 16
19 20 21
14
6 13
17 18
13
14
6
64
6 64
14
64
6
60
64
10
62
10 13
64
13
64
64 58 64
61
22 64
6
59
5 15
64 6
7 18
4 2 3 5 1
8 9 60 64 6
DETAIL: KIDNEY PUMP CIRCUIT
63 65
29 29 15 8
FROM SUMP
41 50 40 49 39 32 30 28 38 5 24 18 6 9
65
6 DETAIL: SUMP PUMP CIRCUIT
47 48 24 15 51
24 15
46
18
47 48 42
23
43 45
25 26 8
57 58 52
27
53
25 26 8
57 58
44
TOLERANCES ARE:
54 56 55 37 35 34 33 DECIMALS: .XX ± .01
.XXX ± .005
APPROVALS
DRAWN
DATE
JWP 10/02/08
FRACTIONS: ± 1/32 ± 1º CHECKED HEAT EX- SUMP &
36 MATERIAL
KIDNEY PUMP KIT 900K
-- CHECKED
FINISH
-- RESP ENG
DETAIL: HEAT EXCHANGER CIRCUIT SIZE REV.
535470.2
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
1 1 505785 MOTOR MOUNTING BRACKET-900/900C HYD LIFT
#7 ( .201) THRU FRAME ( 3/8")
C 2 1 556556 HYDRAULIC MOTOR CHAR-LYNN H 2.8CU IN
13 TAP 1/4-20 UNC THRU FRAME ( 3/8") 13
9" 4 PLACES 3 1 556566 WINCH- THERN MODEL 474 WORM GEAR
4 1 558588 JAW COUPLING TYPE C - SIZE 1 w/KEY
5 1 12471 JAW COUPLING TYPE C - SIZE 3/4 w/KEY
6 1 12478 HYTREL SPIDER INSERT L100
B A 7 6 H-008 HEX HD CAP SCR 3/8-16 X 3/4 GD5
9 8 H-009 HEX HD CAP SCR 3/8-16 X 1 GD5
1/2"
10 2 12270 FITTING -6 37° MALE X 1/2NPTM
14 15 11 16
11 1 505789 CABLE PULLEY MOUNT 900/900C -ABOVE WINCH
15 12 4 H-0007 SOC HD CAP SCR 1/4-20 X 1 1/2
16 12
13 4 421303 MACHINED BRACKET CABLE FINGER
14 14 4 505824 PULLEY MOD 2 1/2 O.D. X 1/2 - 900/900C
20 15 4 558371 SOC HD SHOULDER SCR 3/4 X 1(5/8-11 X7/8)
17
B 16 16 H-0428 FLAT WASHER 3/4 SAE HARD
22 17 1 505788 CABLE PULLEY MOUNT 900/900C -UPPER GIB
18 3 S50042 5/8-11 HEX JAM NUT
23 19 1 403377 CABLE PULLEY MOUNT-MOTOR 900/900C SAUER
20 2 H-03515 HEX HEAD C'SCR 1/2-13 X 3" LG.
21 1 H-03516 HEX HD CAP SCR 1/2-13 X 3 1/2
C
23 3 H-017 HEX NUT 1/2-13 GD5 ZINC
24 1 1/2 P-055 PIPE 1/2 SCH 40 BLK IRON /IN
25 1 556557 WIRE ROPE THIMBLE 1/4 DIA
26 1 H-041 1/2" FLAT WASHER
27 2 554025 1/4 CABLE CLAMP - IRON SADDLE
28 1 24 554026 WIRE ROPE 1/4 DIA 6x37 6040# BREAK /FT
29 29 1 505786 MOUNT PLATE-HYD MOTOR 900/900C - SAUER
30 1 558305 MOTOR HYDROSTATIC 51V - 250cc
46
31 1 590686 CONNECTOR 4PIN FOR 558305 & 558304
45 46 47
47 46 45 32 1 505764 SPEED SENSOR MOUNT - 900/900C
47
33 1 12902 ZERO-SPEED SENSOR w/ 20' CABLE
2 10 3 7 8 D 43 34 1 X-2635 CONN 3 SOCT
45 39 38
3 9/16" 35 1 X-264 CORD GRIP -4
49 48 30 31 50
REF. 36 1 X-2552 3 PIN BOX MOUNT
37 40
42 37 2 451495 MACHINED CLAMP GIB
41
1 38 2 H-035 HEX HD CAP SCR 1/2-13 X 2 GD5
47 46 44 39 2 H-0411 FLAT WASHER 1/2 SAE N SERIES ZINC
40 44 46 47
40 1 505790 MAIN DRIVE HUB 900/900C - SAUER SPLINED
43 8 7 41 1 505821 TACH GEAR - 4in BORE (900/900C SAUER)
43 1 558764 LOCKING ASM 50mm SHAFT 7005
.020 44 2 H-0062 SOC HD CAP SCR 3/4-10 X 3 1/2
32
.030 45 2 H-0061 SOC HD CAP SCR 3/4-10 X 3
A
BETWEEN SPEED SENSOR
AND TACH GEAR 36 35 34 33
47 4 H-023 HEX NUT 3/4-10 GD5 ZINC
48 2 558514 FLANGE KIT -20 C62
49 1 558615 FITTING -6 37° M X -6 STRT M
32
50 1 556482-1 FITTING -16 37° MALE X -16 STRT MALE
29 33 34 35 36 42 2 H-0379 1/4-28 X 5/16" LG. SOC SET SCREW
D
44 47 46
18 SECURE WITH LOCTITE RED (262)
15
SECTION A-A 19
SCALE 1 : 4
16
16
14
13
2 10 1 9 8 4 6 5 3 7 8 12 11 16 13 14 16 15
13
14
15
18
16
SECURE WITH
LOCTITE RED (262)
17
20
23
22
EST. WT. 440 LBS.
21 24 25 27 26 22 23
TOLERANCES ARE:
.XXX ± .005 DRAWN
FRACTIONS: ± 1/32 ± 1º CHECKED

JWP 9/25/08 HYDROSTATIC MOTOR &
SECTION D-D LIFT ASM 900K SAUER
SCALE 1 : 4 SECTION C-C SECTION B-B
MATERIAL
-- CHECKED
SCALE 1 : 4 SCALE 1 : 2 FINISH
-- RESP ENG
SIZE REV.
535469.2
DWG. NO.
PROD MAN D 0
APPROVED 10/21/08
POWER TEST INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT ITEM NO. QTY. PART NO. DESCRIPTION
1 1 505604 RESERVOIR WELDMENT-100GAL 450/900/900C
2 6 H-0495 HEX HD CAP SCR 3/8-16 X 3 GD5 Z
21 3 12 H-040 FLAT WASHER 3/8
4 6 H-0265 HEX NUT 3/8-16 NYLOCK
20 5 2 555633 RESERVOIR ACCESS COVER W/ SEAL
19 7 1 556171 GAUGE SIGHT LEVEL 10
22
4 7/16" A 27 8 1 553669 FILTER OIL FILTER CAP AND AIR FILTER UN
REF. 9 1 552036 PIPE PLUG 1 1/4NPTM SCO HD BI
17
18 19 26 10 2 P-6404 PIPE NIPPLE 3/4 X CLOSE BI TBE
15
11 1 P-741 PIPE ELBO 3/4 90 MAL
16 4 23 28
23 18 25 12 1 P-1261 BALL VALVE 3/4NPT BRASS
14 13 1 P-1227 PIPE PLUG 3/4, SOCKET, BRASS
3 24
17 14 1 E-2814 COMP FTG 3/16T/C X 1/4NPTM
15 1 E-28 T/C TYPE K 3/16 X 6 LG
A 3 16 1 555209 HEX RED BUSH 2 1/2 X 2NPTF BI
SECTION A-A
SCALE 1 : 4 17 2 P-1158 HEX RED BUSH 2 X 1 1/2
2 18 2 558734 PIPE NIPPLE 1 1/2 X CLOSE(1 3/4) TBE BLK
19 2 P-126 BALL VALVE 1 1/2 70-107-01
20 1 P-1153 HEX RED BUSH 1 1/2 X 1 1/4
21 1 558388 FITTING -20 37° MALE X 1 1/4NPTM
1 22 1 558621 FITTING -24 37° MALE X 1 1/2 NPTM
23 3 P-1225 PIPE PLUG 3/4NPT SQ HD
9 24 1 11406.04 HEX RED BUSH 1/2 X 1/4 BRASS
26 1 11626 BALL VALVE 1/4NPTF THREADED
27 1 551519 FITTING -6 37° MALE X 1/4NPT STRT
8
28 1 555240 FLOAT SWITCH-SIDE MOUNT 1NPTM (GEMS)
SCALE: 1:4
19 3/16" REF.
39" REF.
11 1/2" 15"
1" REF. 7/16" THRU ITEM 1
2 PLACES 8 9 2 3 3 4 29
2 3/4"
5
6
6 29
?
28
28
52 5/16"
REF.
23
2 3 4
23 7/16" THRU ( 1/4") ITEM 1

TAP 1/4-18 NPT
5
15 14
6
27
26
17 18 19 22 25 11 3/4"
24 4 7/16"
NOTE:
1. BREAK ALL EDGES EST. WT. 435 LBS.
TOLERANCES ARE:
DECIMALS: .XX ± .01
10 22 19 18 17 23 21 20 19 18 17 16 .XXX ± .005
APPROVALS
DRAWN
DATE
ALS 9/26/08
FRACTIONS: ± 1/32 ± 1º CHECKED HYDROSTATIC TANK
MATERIAL
-- CHECKED ASM 100GAL 900K
5 6 13 12 10 11 FINISH
-- RESP ENG
SIZE REV.
535468.2
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
1 1 505742 RESERVOIR WELDMENT-300GAL 900/900C
2 7 H-0212 HEX HEAD CAP SCR 5/16-18 X 1" LG.
5 2 558494 FILTER ASM-TANK TOP 10u -24 STRT 25psiBP
6 2 558687 TEE -24 37° M X -24 STRT M X -24 37° M
7 1 535449 HOSE ASM -24 37° F 90° X -24 37° F 90°
8 2 558496 FILTER INDICATOR SWITCH-20psi AC/DC
9 1 505780 TANK TOP COVER PLATE w/ (2) 1NPT PORTS
10 2 551590 PIPE PLUG 1NPTM SQ HD BI
13 5 P-254 PIPE NIPPLE 2 X CLOSE
14 3 P-715 PIPE ELBO 2 90°
15 1 P-25 PIPE NIPPLE 2 X 3 TBE
16 1 505770 RETURN MANIFOLD - 900/900C
17 3 552175 PIPE PLUG 3/8NPT SOC STEEL
18 6 12998 FITTING -6 37° MALE X 3/8NPTM
19 2 P-687 PIPE TEE 2NPT BLK IRON
20 3 P-1232 PIPE PLUG 2NPT SOC BI
21 2 P-452 HEX RED. BUSH 2 X 3/4
23 2 P-1261 BALL VALVE 3/4NPT BRASS
24 1 12918 FITTING -12 37º FLARE MALE X 3/4NPT MALE
25 4 558734 PIPE NIPPLE 1 1/2 X CLOSE(1 3/4) TBE BLK
26 4 P-71 PIPE ELBO 1 1/2 90°
27 1 P-2435 PIPE NIPPLE 1 1/2 X 4 TBE
28 3 P-904.5 PIPE COMBO NIPPLE 1 1/2NPT X 1 1/2H
29 1 555253 FILLER CAP ASSEMBLY SIDE MOUNTED INNER
30 1 556171 GAUGE SIGHT LEVEL 10
31 2 555240 FLOAT SWITCH-SIDE MOUNT 1NPTM (GEMS)
32 2 P-126 BALL VALVE 1 1/2 70-107-01
33 1 558767 PIPE PLUG 3NPTM SQ HD BI
34 1 P-222 PIPE CAP 1 1/2in
35 1 E-2814 COMP FTG 3/16T/C X 1/4NPTM
36 1 E-28 T/C TYPE K 3/16 X 6 LG
37 1 P-775 PIPE STR ELBO 1 1/2 90°
38 2 P-115 HEX RED BUSH 1 1/2 X 1
39 1 P-421S PIPE NIPPLE 1 X CLOSE TBE S.S.
40 1 558804 BODY - SUN INLINE 1NPTF
41 1 558801 CARTRIDGE CHECK VALVE SUN 65PSI
42 1 556254-1 FITTING -16 37° MALE X 1NPTM
43 1 505800 ADAPTER -48 CODE 61 X 3NPTM
44 2 558598 O-RING 2-237 (-48 CODE 61 FLANGE)
45 1 558558 BUTTERFLY VALVE 3 CODE 61
46 1 558765 FITTING -48 CODE 61 X 3 H.B. STRT
49 8 H-025 HEX NUT 5/8-11 GD5 ZINC
50 1 505801 ADAPTER -64 CODE 61 X 4NPTM
51 2 558599 O-RING 2-245 (-64 CODE 61 FLANGE)
52 1 558557 BUTTERFLY VALVE 4 CODE 61
53 1 505769 FLANGE SEAL PLATE -64 CODE 61 w/o O-RING
54 1 505827 ADAPTER -64 CODE 61 X 4 H.B. ELBO 90° LG
56 1 P-1166 HEX RED. BUSH 3 X 2
57 2 P-127 BALL VALVE 2 70-108-01
58 2 P-905 PIPE COMBO NIPPLE 2NPTM X 2 H.B. PL
59 1 P-1227 PIPE PLUG 3/4NPT SOC HD BRASS
60 4 P-42 PIPE NIPPLE 1 X CLOSE TBE
61 1 558636 FLOW DIFFUSER 1NPT 3.2 DIA X 5.4 LG
62 1 P-32 PIPE ELBO 1 90°
63 1 P-1262 BALL VALVE 1
EST. WT. 1115 LBS.

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/29/08
FRACTIONS: ± 1/32 ± 1º CHECKED HYDRAULIC TANK ASM
MATERIAL
-- CHECKED 300GAL 900K
FINISH
-- RESP ENG
SIZE REV.
535467.2
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
56 43
6 49
57 13 48 45
12
11 44
58 47
14
5 46
SECTION B-B 44
37 7
29
25 35 5
36 20
32 34
39 30 12
11 60
38
20 61
41 9
26
40 10
50
62
42 31
28
49 48 60
52 51 60 63 38 60
VIEW A-A 53 51
SCALE 1 : 4
47 54 55 SECTION C-C
15 14 13 31 6 8 5 7 5 8 6
2 25 26 27 26
3 14
4
28 16
29
29 17
31
30
30
18
A
19
25
1 20
C 26
21
25
20 B 22
32
23
A
28 24
13 33 34
20
19
21
B
22 23 59 13 57 58

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/29/08
FRACTIONS: ± 1/32 ± 1º CHECKED HYDRAULIC TANK ASM
MATERIAL
-- CHECKED 300GAL 900K
FINISH
-- RESP ENG
SIZE REV.
535467.2
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
POWER TEST INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT ITEM NO. QTY. CUT LG. PART NO. DESCRIPTION ITEM NO. QTY. CUT LG. PART NO. DESCRIPTION
40 1 558565 FITTING -4 ORFS F X -4 HOSE ELBO 90° 43 1 2 558813 FLANGE KIT -32 CODE 62
41 1 * 84in 558560 HOSE -4 5000PSI WP/IN 2 2 505837 FITTING -32 C62 X 1NPTF w/ O-RING GROOVE
42 1 558562 FITTING -4 ORFS F X -4 HOSE (43) 3 2 553532 PIPE PLUG 1NPT SOC STL
43 1 5M0016 METER DIGITAL VOLT 4 4 12079 O-RING 2-228
44 2 14106 IN-LINE PREAMPLIFIER (MAGNETIC PICKUP) 5 2 558727 TEE -24 C62 X -24 C62 X -32 C62
45 2 11894 FREQUENCY TO ANALOG CONVERTER 6 8 H-0065 SOC HD CAP SCR 3/4-10 X 6
46 2 590632 CONN 5 PIN CIRC 180°SCREW-LOC FLOW BLOCK 7 8 H-0165 LOCK WASHER 3/4 HIGH ALLOY SPLIT
47 1 20 X-160 WIRE 22 AWG 2PR W/SHIELD PVC GRAY /FT 8 2 558559 FITTING -4 ORFS M X 1/4 NPT M
48 1 3 X-142 WIRE 22 AWG BLACK STRAND /FT 9 4 552176 PIPE PLUG 1/4NPT SOC STL
49 1 3 14286.001 WIRE 16 AWG BLACK TFFN STRAND /FT 10 8 558515 FLANGE KIT -24 CODE 62
50 1 3 14286.003 WIRE 16 AWG WHITE TFFN STRAND /FT 11 2 505842 VALVE BODY MOUNTING BRACKET 900/900C
51 1 558541 RELIEF - SUN T-3A 12 8 H-009 HEX HD CAP SCR 3/8-16 X 1 GD5
52 1 558466 MANIFOLD - SUN T-3A 13 12 H-029 LOCK WASHER 3/8 ZINC
53 1 558615 FITTING -6 37° M X -6 STRT M 14 2 558472 LINE MOUNT BODY KC6/S SUN T-19A
54 2 558652 FITTING -6 37° F X -6 HOSE ELBO 90° (43) 15 2 558464 RELIEF VALVE-PILOT OPERATED SUN T-19A
55 1 * 30in 558650 HOSE 3/8 ID - MEDIUM PRESS /IN 16 2 558631 FITTING -6 ORFS M X -6 STRT
56 1 12998 FITTING -6 37° MALE X 3/8NPTM 17 2 505840 WELD FLANGE ASM -24 C61 X -24 C62 X 6LG
57 1 * 72in 558561 HOSE -6 5000PSI WP/IN 18 8 H-0221 SOC HD CAP SCR 5/8-11 X 3
19 8 H-0036 SOC HD CAP SCR 1/2-13 X 2 1/4
20 2 557803 SENSOR FLOW BLOCK 6-170 GPM -24 C61
EXISTING FRAME MEMBERS 21 2 558603.24 FLANGE SEAL PLATE -24 CODE 61 w/ O-RING
17 1/2" REF 22 2 505763 ADAPTER -24 CODE 61 X -24 CODE 62
7/16 THRU FRAME MEMBERS 23 8 H-00422 SOC HD CAP SCR 1/2-13 X 1 1/2
4 PLACES 4 3/8" REF 12 13 35 36 33
LOCATE AT ASSEMBLY 24 1 558577 TEE -6 ORFS X -6 ORFS X -6 STRT
25 6 558586 FITTING -24 C62 X -24 HOSE ELBO 90°
12
33 37 26 2 * 9in 558584 HOSE 1 1/2 ID - 5000PSI WP 782TC /IN
27 2 558585 FITTING -24 C62 X -24 HOSE (78)
35
32 13 37 28 2 * 12in 558584 HOSE 1 1/2 ID - 5000PSI WP 782TC /IN
29 3 558566 FITTING -6 ORFS F X -6 HOSE ELBO 90°
13 36
37 13 36 13 30 1 * 12in 558561 HOSE -6 5000PSI WP/IN
31 1 558563 FITTING -6 ORFS F X - 6 HOSE
36 34 36 32 2 16 M-973 UNISTRUT 1 5/8 SLOTTED 12GA GRN /IN
33 2 14003 UNISTRUT SPRING NUT 3/8-16
29 34 2 13 3/4 H-0445 THREADED ROD 3/8-16 /IN
34
35 35 8 H-040 FLAT WASHER 3/8
30
13 36 10 H-026 HEX NUT 3/8-16 GD5 ZINC
31 37 2 S50100 FLAT WASHER 3/8 FENDER ZINC
36 35 36 38 1 556250 GAUGE 4 DIA. 0-5000 PSI
11 24
39 1 558381 PIPE TEE 1/4NPTF STEEL
4 3 2 1 5 4 6 7 13 12 16 CONNECTS TO PANEL NOTE:
16 MOUNTED VALVE 1. " * " DENOTES ESTIMATED HOSE LENGTH
11 HOSES TO BE CUT TO LENGTH DURING ASSEMBLY
14
12
13
15
15
14
18
10 25 26 27 10 18
8
17
CONNECTS TO PANEL 17
MOUNTED GAUGE
19
19
20
20
23 9
21
4 3 2 1 5 4 6 7 10
21
22
22
23
10
9 10 25 28 25
SCALE: 1:10
EST. WT. 265 LBS.
TOLERANCES ARE:
.XXX ± .005
FRACTIONS: ± 1/32
DRAWN
± 1º CHECKED
JWP 10/08/08 FM4
MATERIAL 300GPM FLOW CIRCUIT
FINISH
-- CHECKED
ADD-ON 900K
DETAIL: FLOW OUT PANEL MOUNTED ITEMS -- RESP ENG
SIZE REV.
535466
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
SCALE: 1:8
38
43
38
51
9
52
39
42
A
41
CONNECTS TO -4 ORFS FITTING
40 ON FM4 300 GPM LOAD IN
43
56
54
55 CONNECTS TO
RETURN MANIFOLD
54
53
51 52
16
29
CONNECTS TO TEE ON
57 LINE MOUNT BODY
DETAIL: GAUGE PANEL MOUNTED ITEMS
29
SECTION A-A UNLESS OTHERWISE SPECIFIED
SCALE 1 : 2 DIMENSIONS ARE IN INCHES

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 10/08/08 FM4
FRACTIONS: ± 1/32
MATERIAL
± 1º CHECKED
300GPM FLOW CIRCUIT
-- CHECKED
ADD-ON 900K
FINISH
-- RESP ENG
SIZE REV.
535466
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
POWER TEST INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT ITEM NO. QTY. PART NO. DESCRIPTION
1 1 590467 MOTOR AC 300HP 3PH 460 VAC 1800RPM
2 2 505754 MOUNTING PLATE-ELE MOTOR 400HP 900/900C
5 4 558549 VIBRATION DAMPING MOUNT 1400LBS 40A DURO
6 24 H-0344 HEX HD CAP SCR 1/2-13 X 3/4 GD5 ZINC
8 2 350134 COUPLING HUB 2-3/8 B X 5/8 KEY BORE
9 1 2D0119 COUPLING INSERT MAGNALOY M670U URETHANE
10 1 350201 COUPLING HUB 600 14T 12/24P MAGNALOY
11 1 2D0035 COUPLING INSERT M670H HYTREL (350135)
12 1 350135 COUPLING HUB 600 13T 8/16P SPLINE
13 1 570141 MOUNT PUMP/MOTOR NEMA 447TSC X SAE C
16 1 570142 MOUNT PUMP/MOTOR NEMA 447TSC X SAE E
17 1 556541 PUMP VICKERS FIXED DISPLACEMENT VANE
97 1/2" REF. 19 1 558304 PUMP HYDROSTATIC 90 - 180cc ELEC DISP
20 1 590686 CONNECTOR 4PIN FOR 558305 & 558304
21 4 H-0507 3/4-10 X 1 3/4" HEX HD CAP SCR GRADE 8
22 4 H-048 FLAT WASHER 3/4 SAE ZINC
23 1 558303 PUMP DELIVER FIXED 24.2 GPM 10000 PSI
25 1 558754 BODY SUN T-19A FLANGE MT -20 STRT
26 1 558753 RELIEF VALVE T-19A 120GPM 50-1500PSI
27 1 558545 CHECK - FREE FLOW-SUN T-16A 80GPM 30psi
28 2 H-00374 SOC HD CAP SCR 1/2-13 X 4
29 2 H-0043 SOC HD CAP SCR 1/2-13 X 5
30 2 H-003782 SOC HD CAP SCR 1/2-13 X 8
31 4 557868-14 FITTING -16 37° MALE X -20 STRT STRT
32 1 558631 FITTING -6 ORFS M X -6 STRT
33 30 28 33 1 558661 TEE 1/4NPTM X -6 37° MALE X -6 37° MALE
43 43 7
34 1 558728 MANIFOLD SUN T-16A -24 C61 ALUM
57 53 35 1 505838 SHUTTLE VALVE MOUNT BRACKET 900 (SAUER)
36 1 H-097 HEX HD CAP SCR M8 X 1.25 X 20mm GD5
37 1 H-0401 FLAT WASHER 5/16
29 38 1 558635 LINE MOUNT BODY SUN T-11A -6 STRT
39 1 558634 SHUTTLE VALVE CARTRIDGE SUN T-11A
32
37 36 35 39 38 42 2 H-0402 FLAT WASHER 1/4
26 43 7 558777 FITTING -4 ORFS M X -6 STRT M
43
50 43 23 52 51 44 1 558664 TEE -4 ORFS M X -4 ORFS F X -4 ORFS M
24" 45 2 12087 FITTING -12 37° MALE X -12 STRT MALE
REF. 46 2 558514 FLANGE KIT -20 C62
49 48 45 44
47 1 558389 FITTING -20 37° MALE X -20 STRT MALE
48 1 558615 FITTING -6 37° M X -6 STRT M
49 1 558809 TEE -6 37° M X -6 37° M X -6 37° F
50 1 558771 FITTING -24 37° MALE X -20 STRT STRT
43
52 1 558559 FITTING -4 ORFS M X 1/4 NPT M
53 1 505855 ADAPTER -20 CODE 62 X -16 STRT F w1/4NPT
43 40 41 42 54 4 H-0035 SOC HD CAP SCR 1/2-13 X 2
55 1 558592 FITTING -48 CODE 61 X 3 H.B. ELBO 90°
DETAIL A
SCALE 1 : 4 56 1 558637 FITTING -40 CODE 61 X 2 H.B. ELBO 90°
57 4 558405 SOC HD CAP SCR 1/2-13 X 1 3/4
7
32
10 9 8 1 8 11 12 56 57 31 31 33
25 54 53 52 51
56 46
31
34
27
27 52
17
51
18
53
15
15 18 55
14 16 21 22 4 19 20 24 23 45 43 46 47
13 14 31
15 4
15 2
5 6 3 2 6 5 EST. WT. 2870 LBS.

5
7 4 7 UNLESS OTHERWISE SPECIFIED
TOLERANCES ARE:
.XXX ± .005
FRACTIONS: ± 1/32
DRAWN
± 1º CHECKED
JWP 12/05/08 MOTOR & PUMP ASM
MATERIAL 900K-300HP
FINISH
-- CHECKED
SAUER 180cc
-- RESP ENG
SIZE REV.
535465.1
DWG. NO.
PROD MAN D 0
1 1 505745 FRAME WELDMENT 900/900C
152" REF. 2 2 421667 PANEL LEFT SIDE - VERTICAL
18 3/4" 3 2 421668.01 PANEL RIGHT SIDE - VERTICAL
14 10 15 23 24 4 1 421668.02 PANEL RIGHT SIDE - LOWER
5 1 421668.03 PANEL LEFT SIDE - LOWER
1/8"
8 17 1 21 6 1 421671 PANEL FRONT-UPPER w/ NOTCH
TYP.
7 1 421669.01 PANEL TOP - RIGHT
25 8 2 421669.02 PANEL TOP - CENTER
9 2 421669.03 PANEL TOP - LEFT
21 10 1 421669.06 PANEL BACK - CENTER
23 3/4"
30 3/4" 35 11 1 421669.07 PANEL BACK - LEFT UPPER
34 3/4" 12 27
12 1 421669.08 PANEL BACK - LEFT LOWER
33 13 1 505804 PANEL FRONT - LOWER WITH HINGE
26 14 1 505805.1 PANEL BACK - FULL HEIGHT WITH LH HINGE
18 23 15 1 505805.2 PANEL BACK - FULL HEIGHT WITH RH HINGE
16 32 H-0339 FLAT HD SOC CAP SCR 1/4-20 X 1 S.S.
73 3/4" 73 3/4"
5/16 THRU EXISTING 24 17 50 H-00734 BTN HD CAP SCR 1/4-20 X 1 1/2 S.S.
TAPPED HOLE 18 1 H-00735 HEX HD CAP SCR 1/4-20 X 1 1/4 GD5
6 20 1 H-0263 1/4-20 NYLOCK HEX NUT
38 3/4" 11 21 16 H-007 HEX HD CAP SCR 1/4-20 X 1/2 GD5
22 1 32 558587 ACOUSTICAL INSULATION ADH BK 1x 54in /FT
34 3/4" 34 3/4" 23 2 505762 GIB RAIL SPACER - 900/900C
24 2 505761 GIB RAIL - 900/900C
36
25 13 H-0351 HEX HD CAP SCR 1/2-13 X 2 1/2 GD5 ZINC
SECTION A-A 26 16 H-028 LOCK WASHER 1/2 ZINC
SCALE 1 : 4 3 34 27 16 H-017 HEX NUT 1/2-13 GD5 ZINC
1/8" 28 2 H-03515 HEX HEAD C'SCR 1/2-13 X 3" LG.
TYP. 18 3/4" 4 19 20 29 1 H-03516 HEX HD CAP SCR 1/2-13 X 3 1/2
33
30 4 H-0328 BTN HD SOC CAP SCR 3/8-16 X 1 1/2 S.S.
21 32 4 H-0265 HEX NUT 3/8-16 NYLOCK
9 8 8 7
1 33 2 505828 GIB RAIL END COVER - BELLOWS MOUNT
34 2 505829 BELLOWS CLAMP - THREADED
35 2 505830 BELLOWS CLAMP - UNTHREADED
5 36 1 96 558590 WAY COVER BELLOWS 0.59in X 24in WIDE /IN
TRANSFER HOLE LOCATION

#7 ( .201) THRU FRAME ( 3/8") 1/4" NOTE:
TAP 1/4-20 UNC THRU FRAME ( 3/8") 1. PANEL DIMENSIONS GIVEN
2 PLACES REF.
FOR REFRENCE ONLY
53 3/4" TRANSFER HOLE LOCATION
SECTION C-C 5/16" THRU ( 1/4")
TYP.
21 SCALE 1 : 6
6 1/4"
28" 28" 21 1/4"
SECTION B-B TYP.
SCALE 1 : 4
9 1/8"
TYP.
55 3/4" TYP.
71 3/4"
1/8" 6 27 26 29
TYP. A
8 3/8" 28
A 26
73 3/4" 27
TYP. 3
1/8"
5 1/4" TYP. 36
B TYP.
C
B 86 5/8"
REF.
2 2
SCALE: 1:20
36
41 3/4" 5
27 34 3/4"
TYP. 4 7/8"
25 3/8" 26 TYP.
38 3/4" 71 3/4"
25
3
EST. WT. 3035 LBS.

TOLERANCES ARE:
C 4 7/8" DECIMALS: .XX ± .01 APPROVALS DATE
4 .XXX ± .005 DRAWN
30 31 32 1 13 TRANSFER MOUNTING HOLES AT ASSEMBLY FRACTIONS: ± 1/32 ± 1º CHECKED
JWP 9/24/08
FRAME & COVER PANEL
#7 ( .201) THRU FRAME ( 3/8") 46 5/8" MATERIAL
-- KIT - 900/900C
TAP 1/4-20 UNC THRU FRAME ( 3/8") CHECKED
32 PLACES 60 13/16" REF.

FINISH
-- RESP ENG
SIZE DWG. NO. REV.
(ALL HINGED COVERS) PROD MAN D 535463.1 0

APPROVED 10/13/08
75 1 558783 FITTING -12 ORFS F X -12 HOSE (79) 1 1 505823 FLOW-OUT PANEL WELDMENT - 900 CLASSIC
76 1 558807 FITTING -16 37° F X -12 HOSE (43) 2 12 H-00227 BTN HD SOC CAP SCR 1/2-13 X 1 S.S.
77 1 * 21in 558649 HOSE 3/4 ID - MEDIUM PRESS /IN 3 1 556561 SUBPLATE-HYD VALVE 1/4-4 WAY
78 1 558784 FITTING -12 ORFS F X -12 HOSE (43) 4 1 556560 HYD VALVE 1/4-4 WAY-LVR OPER SPRING CTR
79 2 558786 FITTING -12 ORFS F X -12 HOSE 45° (43) 5 4 H-03242 BTN HD SOC CAP SCR 10-32 X 1 S.S.
80 1 * 16in 558649 HOSE 3/4 ID - MEDIUM PRESS /IN 6 4 H-00113 SOC HD CAP SCR 10-24 X 1 1/4
EXISTING FRAME MEMBERS 81 2 16 M-973 UNISTRUT 1 5/8 SLOTTED 12GA GRN /IN 7 4 558643 FITTING -6 37° MALE X -8 STRT MALE
82 2 14003 UNISTRUT SPRING NUT 3/8-16 8 18 558533 QD 1/8 NIPPLE X -4 ORFS BULKHEAD STL(PD)
83 1 15 1/2 H-0445 THREADED ROD 3/8-16 /IN 9 3 558745 FITTING -4 ORFS CAP
84 1 X-389 1 CONDUIT/PIPE HANGER 10 1 505827 ADAPTER -64 CODE 61 X 4 H.B. ELBO 90° LG
85 6 H-009 HEX HD CAP SCR 3/8-16 X 1 GD5 11 1 557193 FITTING 1/4T X 1/8NPTM ELBOW PRESTOLOK
86 6 H-040 FLAT WASHER 3/8 12 2 505769 FLANGE SEAL PLATE -64 CODE 61 w/o O-RING
87 10 H-029 LOCK WASHER 3/8 ZINC 13 3 558599 O-RING 2-245 (-64 CODE 61 FLANGE)
88 10 H-026 HEX NUT 3/8-16 GD5 ZINC 14 1 558557 BUTTERFLY VALVE 4 CODE 61
89 2 S50100 FLAT WASHER 3/8 FENDER ZINC 15 1 505801 ADAPTER -64 CODE 61 X 4NPTM
90 1 505842 VALVE BODY MOUNTING BRACKET 900/900C 16 1 23310 QD 4 ADAPTER X 4NPTF WTR AL 40A
91 1 558472 LINE MOUNT BODY KC6/S SUN T-19A 17 1 558633 QD 4 COUPLER X DUST CAP WTR AL 40V
92 1 558464 RELIEF VALVE-PILOT OPERATED SUN T-19A 18 4 H-03669 HEX HD CAP SCR 5/8-11 X 5 1/2 GD5
93 2 558604.24 FLANGE SEAL PLATE -24 CODE 62 w/ O-RING 19 4 H-027 LOCK WASHER 5/8
94 2 505759 ADAPTER -24 CODE 62 X -16 CODE 62 20 4 H-025 HEX NUT 5/8-11 GD5 ZINC
95 8 H-022 SOC HD CAP SCR 5/8-11 X 2 GD8 21 1 558772 FITTING -32 CODE 61 X 2 H.B. STRT
96 1 552176 PIPE PLUG 1/4NPT SOC STL 22 2 12079 O-RING 2-228
97 1 558513 FLANGE KIT -16 CODE 62 23 2 558603.32 FLANGE SEAL PLATE -32 CODE 61 w/ O-RING
98 1 558554 ADAPTER -16 CODE 62 X -16 ORFS 24 1 505835 SPACER FLANGE -32 CODE 61
99 1 558510 TEE -16 ORFS M X -16 ORFS F X -16 ORFS M 25 1 558749 BUTTERFLY VALVE 2 CODE 61
100 1 558796 FITTING -24 STRT M X -16 STRT F 26 1 505799 ADAPTER -32 CODE 61 X 2NPTM
101 2 558795 ADAPTER -24 C61 X -24 STRT 27 1 558748 QD 2 ADAPTER X 2NPTF WTR AL 40A
102 1 557803 SENSOR FLOW BLOCK 6-170 GPM -24 C61 28 1 558766 QD 2 COUPLER X DUST CAP WTR AL 20V
103 1 558685 FITTING -16 37° MALE X -24 STRT M 29 4 H-0353 HEX HD CAP SCR 1/2-13 X 5
104 1 558580 FITTING -16 ORFS F X -16 HOSE (78) 30 4 H-028 LOCK WASHER 1/2 ZINC
105 1 * 24in 558579 HOSE 1 ID - 5000PSI WP 782TC /IN 31 4 H-017 HEX NUT 1/2-13 GD5 ZINC
106 1 558582 FITTING -16 C62 X -16 HOSE (78) 32 9 558747 FITTING -16 37° MALE X 1NPTM BULKHEAD
107 1 * 30in 558384 HOSE 1 ID HYDRAULIC TOUGH COVER /IN 33 5 553754 QD 1 COUPLER X 1NPTF (H) (V) VALVED
108 1 558802 FITTING -16 ORFS F X -16 HOSE (43) 34 5 558760 QD 1 COUPLER X 1NPTF (H) (V) UNVALVED
109 1 * 18in 558384 HOSE 1 ID HYDRAULIC TOUGH COVER /IN 35 3 558762 BULKHEAD -16 ORFS MALE X -16 ORFS MALE
110 1 558803 FITTING -16 ORFS F X -16 HOSE 45 (43) 36 3 558763 FITTING -16 ORFS F X 1NPTM
111 1 13 3/4 H-0445 THREADED ROD 3/8-16 /IN 37 2 558723 NEEDLE VALVE 1NPT 10000PSI@100° 90°BDY
112 1 558645 TEE -16 37° M X -16 37° F X -16 37° M 38 1 558724 NEEDLE VALVE 3/4NPT 10000PSI@100° 90°BDY
113 1 556482-1 FITTING -16 37° MALE X -16 STRT MALE 39 3 558725 PANEL MOUNT NUT (558723 & 558724)
114 1 * 36in 558384 HOSE 1 ID HYDRAULIC TOUGH COVER /IN 40 10 558761 QD 1 NIPPLE X 1NPTF (H) (V) UNVALVED
115 1 * 48in 558384 HOSE 1 ID HYDRAULIC TOUGH COVER /IN 41 10 553532 PIPE PLUG 1NPT SOC STL
116 4 590632 CONN 5 PIN CIRC 180°SCREW-LOC FLOW BLOCK 42 2 558757 QD 1 NIPPLE X 1NPTF HYD (WS)
43 2 558759 QD 1 DUST CAP - RIGID ALUM (WS)
NOTE: 44 2 558819 COVER PLATE -32 C62 (SHIPPING COVER)
1. " * " DENOTES ESTIMATED HOSE LENGTH
HOSES TO BE CUT TO LENGTH DURING ASSEMBLY 45 3 556254-1 FITTING -16 37° MALE X 1NPTM
46 1 521401 FITTING -16 37° MALE X 1NPTM w/ 1/8NPTF
47 1 11404.01 ADAPTER 1/4NPT FEMALE TO 1/8NPT MALE
49 6 558626 FITTING -16 37° F X -16 HOSE
50 1 * 32in 558384 HOSE 1 ID HYDRAULIC TOUGH COVER /IN
51 2 558627 FITTING -16 37° F X -16 HOSE ELBO 90°
52 2 558768 FITTING -16 37° FEMALE X 1NPTM
53 2 P-115 HEX RED BUSH 1 1/2 X 1
54 2 558800 HORIZONTAL SWING CHECK VALVE 1 1/2NPTF B
55 2 558621 FITTING -24 37° MALE X 1 1/2 NPTM
57 1 558792 FITTING -12 ORFS FEMALE X 3/4NPTM
58 2 558732 RELIEF VALVE PILOT OP 10000 50GPM
60 1 S60008 HEX HD PLUG -6 STRAGHT w/ O-RING STL
62 1 556482-7 FITTING -12 37° MALE X -10 STRT MALE
63 1 558797 FITTING -16 STRT M X -16 ORFS F
64 3 557796 SENSOR FLOW BLOCK 50GPM
65 1 558798 FITTING -12 ORFS M X -16 STRT M ELBO 90°
66 2 558799 FITTING -12 ORFS F X -12 HOSE 90° (79)
67 1 * 8in 558793 HOSE 3/4 ID - 6000PSI WP 791TC /IN
68 3 558770 FITTING -16 STRT M X -16 37° F
70 1 558778 FITTING -10 STRT HEX PLU
71 1 558781 TEE -12 ORFS M X -12 ORFS F X -12 ORFS M
72 1 558777 FITTING -4 ORFS M X -6 STRT M
73 1 558782 FITTING -16 ORFS F X -12 HOSE (79)
74 1 * 18in 558793 HOSE 3/4 ID - 6000PSI WP 791TC /IN
EST. WT. 520 LBS.

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/22/08
FRACTIONS: ± 1/32 ± 1º CHECKED FLOW-OUT PANEL ASM
MATERIAL
-- CHECKED 900K
FINISH
-- RESP ENG
SIZE REV.
535462
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
41 40 36 35 34 1 2
TO MOTOR RETURN TO TANK
6 5
4 3 7
3 4 5 6 SUPPLY FROM MAIN
FLOWOUT PUMP
44
35 36 42 43
TO MOTOR
33 32 40 41
37 39
37
41 40 32 33 48
46 47
SUPPLY FROM MAIN
37 39 47 46 FLOWOUT PUMP
34 32 40 41
48 TO PANEL MOUNTED
PRESSURE GAUGE 45
41 40 32 33 51
41 40 33 32 52 49
44
53
41 40 32 33 51
50
55
50
42 36 54
38 39
RETURN TO TANK
34 32 40 41 35
35 36 42 43
43
33 32 40 41
41 40 32 34 17 16 15 14 13 52 53 54 55
TO PANEL MOUNTED
PRESSURE GAUGES
TO PANEL MOUNTED
11 PRESSURE GAUGE 10
SUPPLY FROM TANK
10
13 12 18 19 20
12 13
21 22 SUPPLY FROM TANK
28 27 26 25 29 30 31
23 22
24
ALL ITEMS IN THIS
AREA ARE THE SAME 8 23 9

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/22/08
MATERIAL
-- CHECKED 900K
FINISH
-- RESP ENG
SIZE REV.
535462
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
56
66
67
66
58
61 62 58 61 57 38 39
61
62 RETURN TO TANK
SUPPLY FROM HIGH
PRESSURE PUMP
60
TO PANEL MOUNTED
59 CONTROL VALVE
64
65 64 56 63 35 36 42 43
66
67
66

TOLERANCES ARE:
DETAIL: DECIMALS: .XX ± .01 APPROVALS DATE
FM1 HIGH PRESSURE FLOWOUT .XXX ± .005 DRAWN
JWP 9/22/08
CIRCUIT FRACTIONS: ± 1/32 ± 1º CHECKED FLOW-OUT PANEL ASM
MATERIAL
-- CHECKED
900K
FINISH
-- RESP ENG
SIZE REV.
535462
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
EXISTING FRAME MEMBERS
7/16 THRU FRAME MEMBERS

2 PLACES 85
82 LOCATE AT ASSEMBLY
82
89 86 88 87 81
87 88
88
87
89
83
87
TO PANEL MOUNTED 58
CONTROL VALVE 59 58
88
35 36 42 43
TO PANEL MOUNTED 88 75 74 73
PRESSURE GAUGE 72 70
70
61 61 78 84 77 76
71
79
32 33 40 41
80
79
69 64 68 32 33 40 41
DETAIL:
FM2 50 GPM
CIRCUIT
TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/22/08
FRACTIONS: ± 1/32
MATERIAL
± 1º CHECKED FLOW-OUT PANEL ASM
-- CHECKED 900K
FINISH
-- RESP ENG
SIZE REV.
535462
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
EXISTING FRAME MEMBERS

82
82
7/16 THRU FRAME MEMBERS
85 2 PLACES
LOCATE AT ASSEMBLY
86
87
89
88 81 88
87 88
87
89 111
86
TO PANEL MOUNTED
48 PRESSURE GAUGE
TO PANEL MOUNTED 87 88
CONTROL VALVE 59
90
88 86 94 93 95 106 105 104
59 91
35 36 34 40 41
85
87 92
91 95
96
92 93
93
94 108 97 107 49 32 34 40 41
94
96
98
99
110
109
49
103 101 102 101 100 68 32 34 40 41
DETAIL:
FM5 150 GPM
CIRCUIT
TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/22/08
MATERIAL
-- CHECKED
900K
FINISH
-- RESP ENG
SIZE REV.
535462
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
115 49 45
49 32 33 40 41
37
SUPPLY FROM MAIN

45 FLOWOUT PUMP
IN 45 37 39
49
115
114
51
49
113 64 68 112 32 33 40 41
DETAIL:
FM5 / MAIN FLOWOUT
CIRCUIT

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/22/08
MATERIAL
-- CHECKED 900K
FINISH
-- RESP ENG
SIZE REV.
535462
DWG. NO.
PROD MAN D 0
APPROVED 10/13/08
75 2 11758 END BARRIER 1 1 505797 GAUGE PANEL w/ BEARING MOUNT-900 CLASSIC
76 7 11832 3 POS. TERM. BLOCK DIVIDER 2 1 561862 NAME TAG KIT - 900-300 (CLASSIC)
77 8 11829 JUMPER CLIP 3 1 505839 WORK SURFACE MAT - 900/900C GAUGE PANEL
78 5 11827 3 POS. TERM. BLOCK GND 4 1 505792 GAUGE PANEL LOWER HINGE BRACKET
79 1 11910 TRANSFORMER 4AMP 24V CENTER TAP 5 1 505793 GAUGE PANEL UPPER HINGE BRACKET
80 1 X-349 DRAWN 4 1/8X 2 1/8 HANDY BOX- 1 7/8 DP 6 8 H-04955 3/8-16 X 3 1/2" LG HHCS GR 5
81 1 X-350 DUPLEX RECEPTACLE 15A 120VAC WHT 7 8 H-040 FLAT WASHER 3/8
82 1 X-355 SINGLE DUPLEX WALLPLATE- STEEL 8 8 H-0265 HEX NUT 3/8-16 NYLOCK
83 4 S50058 BTN HD SOC CAP SCR 8-32 X 3/8 S.S. 9 4 S50048 3/8-16 ACORN NUT
84 4 X-1691 LOCK WASHER #8 EXT TOOTH 10 4 H-0345 1/2-13 X 1" LG. HHCS GR.5
85 4 X-177 8-32 HEX NUT 11 4 H-028 LOCK WASHER 1/2 ZINC
86 2 S50059 BTN HD SOC CAP SCR 10-32 X 3/8 S.S. 12 4 H-041 1/2" FLAT WASHER
87 2 X-1692 LOCK WASHER #10 EXT TOOTH 13 2 558370 FLANGED SLEEVE BEARING 3/4ID BRONZE
88 2 X-190 10-32 HEX NUT 14 2 505819 GAUGE PANEL HINGE PIN
89 4 14106 IN-LINE PREAMPLIFIER (MAGNETIC PICKUP) 15 2 H-0428 FLAT WASHER 3/4 SAE HARD
90 1 6 558587 ACOUSTICAL INSULATION ADH BK 1x 54in /FT 16 1 505794 GAUGE PANEL LATCH BRACKET
91 1 280174 WIRING SCHEMATIC-GAUGE PANEL 900 CLASSIC 17 1 505796 GAUGE PANEL LATCH NUT
20 1 H-0506 3/4-10 X 1 3/4" LG. HHCS GR5
24 1 558750 GAUGE 4 DIA 0-6000 PSI 1/4NPT BK MT
25 3 556247 GAUGE 4 DIA 0-10000 PSI
26 1 556249 GAUGE 4 DIA. 0-1000 PSI/KPA
27 1 556248 GAUGE 4 DIA 0-(-)30inHg/kPA
28 1 558751 GAUGE 4 DIA 0-1500 PSI 1/4NPT BK MT
29 9 558529 GAUGE 2 1/2 DIA 0-600 PSI 1/4NPT BK MT
30 3 558532 GAUGE 2 1/2 DIA 0-200 PSI 1/4NPT BK MT
31 2 556211 GAUGE 2-1/2 DIA. 0-100 PSI
32 2 556251 GAUGE 2-1/2 DIA 0-7500 PSI 1/4 NPT
33 2 558731 RELIEF VALVE DIRECT ACT 10000 5GPM
34 8 1/2 M-322 TUBE 3/8 OD X .049 WALL DOM SEAMLESS /IN
35 8 H-00734 BTN HD CAP SCR 1/4-20 X 1 1/2 S.S.
36 8 H-054 HEX NUT 1/4-20 GD5 ZINC
37 1 558471 PANEL MOUNT RIGHT ANGLE BODY SUN T-10A
38 1 558540 RELIEF VALVE-SUN T-10A w KNOB & PN MT
39 1 558755 RELIEF VALVE SUN T-10A 60ci 25-1500PSI
40 1 558756 BODY SUN T-10A -6 STRT PORTS
41 23 558381 PIPE TEE 1/4NPTF STEEL
44 1 14204 FITTING 1/4T X 1/4NPTM ELBO PRESTOLOK
46 4 558615 FITTING -6 37° M X -6 STRT M
47 9 556471-1 HOLE COVER - OIL-TIGHT 30mm (1 1/4)
48 2 556471-2 HOLE COVER- OIL-TIGHT 2 1/2 (CONDUIT 2)
49 1 556471-6 HOLE COVER- OIL-TIGHT 4 (CONDUIT 3 1/2)
50 4 556785 SWITCH SELECTOR 2 POS
51 2 590348 CONTACT BLOCK-2 NO. RATING-MA
52 9 590660 INDICATOR LIGHT- RED- PTT 120VAC 30mm
53 2 590661 INDICATOR LIGHT- GREEN- PTT 120VAC 30mm
54 1 590655 AMP METER 0-5 ACA 60Hz IRON VANE2 1/2in
55 1 590656 HOUR METER 6 DIGIT 90-240VAC 50/60Hz 2in
56 6 S50057 BTN SOC HD CAP SCR 4-40 X 3/8 S.S.
57 1 590511 KEY SWITCH 2 POS (M/M-LEFT KEY REM) 30mm
58 1 590662 PUSH BUTTON - BLACK - 30mm
59 1 4V0074 SWITCH POTENTIOMETER
60 1 13581 POTENTIOMETER 5K; 3-TURN
61 5 556540 TACH-GAGE RATE INDICATOR 6 DIGITS PAX
62 2 590659 PANEL METER-TEMP CONTROLLER
63 1 C-028 EMERGENCY STOP BUTTON
64 1 C-027 E-STOP OPERATOR
65 3 11137 CONTACT BLOCK (1-NO, 1-NC)
66 2 590675 COVER PANEL 1/16 DIN
67 4 590692 COVER PANEL 1/8 DIN BLACK 2 MOUNT HOLES
68 6 S50086 BTN SOC HD CAP SCR 4-40 X 1/2 S.S.
70 6 X-178 HEX NUT #4-40 FIN MACH
71 1 70 4W0042 WIRE WAY 3 X 2 GRAY SLOT /IN
72 1 70 4W0043 WIRE WAY GRAY SLOT COVER /IN
73 1 8 11912 DIN RAIL / IN.
74 17 11824 3 POS. TERM. BLOCK
EST. WT. 385 LBS.

TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/04/08 GAUGE PANEL ASM
FRACTIONS: ± 1/32 ± 1º CHECKED
MATERIAL
-- CHECKED
900 CLASSIC
FINISH
-- RESP ENG
SIZE DWG. NO. REV.
PROD MAN D 535461 0

APPROVED 09/15/08
43 41 42
46
46 46 33
6
SECTION B-B 35
SCALE 1 : 2 40 37 7
22 PLACES 34
38 G 71 72 85 84 83 82 81 80 17 18 19 20 21
39 8
36
79 83 84 85
44 41 42
19 9 SECTION A-A
45
45
45
DETAIL D DETAIL E
SCALE 1 : 2 DETAIL F 10
SCALE 1 : 2
SCALE 1 : 2
2 PLACES 88 87 86 75 74 78 75 11
12
15
14
SECTION C-C
SCALE 1 : 2 13
73 76 77 DETAIL G 12 11 10
SCALE 1 : 2
6 7 8
SECTION H-H
SCALE 1 : 2
5
54 55 56 27 61 25 61 25 61 24 67 68 69 70 49 28 61 2 1
H 10 11 12 13 14 15
ALL ITEMS IN THIS

56 H AREA ARE THE SAME
26 29
30
25 B B C C
31
47
32
50 34 35 36 19 47 40 39
30
70 69 68 66 48 D E F
ALL ITEMS IN THIS

62 AREA ARE THE SAME
33 38 37
65 57 52
47
3
53
A A
16
4
47 58 52 53 50 63 59 61 50 47 67 68 69 70 65 51 65
51 64 60 BACK VIEW
23 22 20 21 18 19 65 15 14 13 12 11 10 6 7 8 9
FRONT VIEW
TOLERANCES ARE:
.XXX ± .005 DRAWN
JWP 9/04/08
FRACTIONS: ± 1/32 ± 1º CHECKED GAUGE PANEL ASM
MATERIAL
-- CHECKED
900 CLASSIC
FINISH
-- RESP ENG
SIZE DWG. NO. REV.
PROD MAN D 535461 0

APPROVED 09/15/08
APPROVED 10/13/08
1 1 590657 ENCLOSURE 72 X 48 X 18 TWO DOOR
2 1 505820 SUB-PANEL MOD - 900/900C ELECTRICAL BOX
3 1 590651 POWER DISTRUBITION BLOCK 600V 600A 3POS
4 3 590653 COVER - POWER DISTRUBITION590651
48" REF.
1 2
34 1/4"
36 1/2"
45 1/4"
5 6 H-0335 BTN HD SOC CAP SCR 1/4-20 X 1/2
6 1 590697 DISTRIBUTION BLOCK 310A (1)6-350 (6)14-4
41"
47"
0"
1"
2"
4"
6"
7 1 S50038 PAN HD MACH SCR 10-32 X 1/2 PHILLIPS
8 13 X-1692 LOCK WASHER #10 EXT TOOTH
9 1 590654 TRANSFORMER-CURRENT DONUT 500A 100:5
0" 10 3 590680 CONTACTOR 300A .00HP@440V 120VAC COIL
1"
11 3 590681 TERMINAL COVER - GMC-300/GMC-400
12 16 H-0338 BTN HD SOC CAP SCR 1/4-20 X 3/8
13 1 590642 OVERLOAD RELAY FOR GMC 400 (260-400A)
5 4 3 8 7 6 14 1 590682 TERMINAL COVER - GTK-400
18 19 24 20 21 24 15 1 590643 MECHANICAL INTERLOCK FOR GMC 400 TO 400
16 1 505753 BRIDGE BAR-WYE DELTA CONTACTOR 900-400HP
17 1 4U0015 TRANSFORMER 1.5 KVA T1500
30 18 1 54 4W0042 WIRE WAY 3 X 2 GRAY SLOT /IN
8
24 23 22 29 20 4 16 4W0042 WIRE WAY 3 X 2 GRAY SLOT /IN
25
22 1 11 4W0042 WIRE WAY 3 X 2 GRAY SLOT /IN
9
24 15 X-1675 BTN HD SOC CAP SCR 8-32 X 1/4 S.S.
25 2 16 11912 DIN RAIL / IN.
11 10 12 11 10 15 11 10 16 20 21 24 26 1 9 11912 DIN RAIL / IN.
27 1 3 11912 DIN RAIL / IN.
5/8" THRU ( 1/4") 33 28 1 4 11912 DIN RAIL / IN.
31 32 31 34 35
4 PLACES 8 29 12 X-1643 BINDNG HD SCR 10-32 X 1/2 STL-NKL PLTD
39" 36 38 30 1 590684 BUSS BAR KLOCKNER MOELLER 12 POS
29
31 2 590650 CIRCUIT BREAKER / SWITCH 3 POLE 15A
25 32 1 590646 CIRCUIT BREAKER / SWITCH 3 POLE 10A
33 1 590610 CIRCUIT BREAKER / SWITCH 3 POLE 5A
34 1 590649 TRANSFORMER OUTPUT KLOCKNER MOELLER
35 1 590545 TIMING RELAY
36 1 590637 CONTACTOR 32A 20HP@440V 120VAC COIL
37 1 590638 OVERLOAD RELAY FOR GMC 32 TO 40
38 3 590635 CONTACTOR 18A 10HP@440V
37 39 39 1 590636 OVERLOAD REALY FOR GMC 9 TO 22
20 21 24
40 3 11420 IDEC RELAY SOCKET
41 3 12585 24VDC, 10A IDEC CUBE RELAY
13 14 42 1 535451.1 CIRCUIT BOARD ASM-PUMP CONTROLLER-SAUER
12 17
43 4 X-1629 PAN HD MACH SCR 6-32 X 1/4 PHILLIPS
8 44 4 X-2175 STANDOFF HEX SPACER M/F 6-32 X 1/2
67" 8 29 26 45 47 45 2 11832 3 POS. TERM. BLOCK DIVIDER
68" 29
72" REF. 27 47 2 11829 JUMPER CLIP
7/8" THRU ( 1/4") 48 2 11827 3 POS. TERM. BLOCK GND
3 9/16" THRU ( 1/4")
5 PLACES 49 1 590678 POWER SUPPLY 24VDC 10AMP DIN RAIL
BACK VIEW 1 3/8" THRU ( 1/4")
50 1 X-349 DRAWN 4 1/8X 2 1/8 HANDY BOX- 1 7/8 DP
SCALE: 1:8 40 51 2 H-007 HEX HD CAP SCR 1/4-20 X 1/2 GD5
41 52 1 X-350 DUPLEX RECEPTACLE 15A 120VAC WHT
53 1 X-355 SINGLE DUPLEX WALLPLATE- STEEL
44 43 42 60 41 40 46 48 49 54 2 11758 END BARRIER
50
55 2 590622 PANEL JACK T/C TYPE K STANDARD RND HOLE
51 20 21 24 56 1 X-2552 3 PIN BOX MOUNT
57 4 X-161 RD HD MACH SCR 4-40 X 3/8 SLT
52
53 59 4 X-178 HEX NUT #4-40 FIN MACH
60 1 X-026 CAP 220MF 35V EV220M35DE
7/8" THRU ( 1/4")
2 PLACES 61 1 280172 WIRING SCHEMATIC-POWER BOX 900 CLASSIC
55
1 1/2"
1/8" THRU ( 1/4")
4 PLACES 54 45 46 54
56
1 1/2" 28 29 8
.719
.360 A
3 1/8" 5/8" THRU ( 1/4")
57 58 59
55
3 7/8" NOTE: EST. WT. 570 LBS.

BACK OF ENCLOSURE 1. BREAK ALL EDGES
.360 56
.719
TOLERANCES ARE:
57 DECIMALS: .XX ± .01 APPROVALS DATE
.XXX ± .005 DRAWN
SECTION A-A ALS 9/06/08
SCALE 1 : 2 58 FRACTIONS: ± 1/32 ± 1º CHECKED ELECTRICAL BOX ASM
A MATERIAL
-- 900 300HP 460/60/3
CHECKED
59 SCALE: 1:16 FINISH

-- RESP ENG
SIZE REV.
535452.1
DWG. NO.
PROD MAN D 0
APPROVED 08/11/08
POWER TEST INC. ANY REPRODUCTION IN PART OR WHOLE WITHOUT ITEM NO. QTY. CUT LG. PART NO. DESCRIPTION ITEM NO. QTY. CUT LG. PART NO. DESCRIPTION ITEM NO. QTY. CUT LG. PART NO. DESCRIPTION
1 17 2 8 E-17 1/2" SEALTITE METAL CONDUIT /FT 1 9 2 P-73 PIPE COUPLING 1/2NPT 1 1 505748 WORK TABLE / SUMP WELDMENT 900/900C
1 18 2 12 14286.001 WIRE 16 AWG BLACK TFFN STRAND /FT 1 10 2 11142 1/2 SEALTITE CONN STRT 2 1 421457 SUMP EXTENSION 900/900C
1 19 2 12 14286.002 WIRE 16 AWG RED TFFN STRAND /FT 1 11 2 P-1231 PIPE PLUG 1NPT SQ HD 3 6 421447 BAR GRATING 11 1/2 X 24
1 20 2 12 14286.010 WIRE 16 AWG ORANGE TFFN STRAND /FT 1 12 2 P-254 PIPE NIPPLE 2 X CLOSE 4 2 421451 BAR GRATING 11 1/2 X 22 3/4
1 13 1 P-715 PIPE ELBO 2 90° 5 2 421453 BAR GRATING WITH MESH 66 X 24
1 14 1 13593 CHECK VALVE 2" NPT, BRASS - FOOD LINE SP 6 3 421454 BAR GRATING WITH MESH 34 X 24
1 15 1 P-905 PIPE COMBO NIPPLE 2NPTM X 2 H.B. PL 7 1 421455 BAR GRATING WITH MESH 34 X 22 3/4
1 16 2 11141 1/2 SEALTITE CONN ELBO 90 1 8 2 555240 FLOAT SWITCH-SIDE MOUNT 1NPTM (GEMS)
15 1/4" REF.
12 1/16" REF.
SCALE: 1:12
5 5 4 7 3 6 3 6 3 6 1 5
15
14
12
13
11
10
84 3/8"
REF. 58"
38 1/2" 9
REF.
REF.
8
66 7/8" 60"
REF. REF.
8 9
4 3 3 3 10
11 7/16" REF.
144 1/2" REF.
13
NOTE:
12 DETAIL A 1. BREAK ALL EDGES
SCALE 1 : 4 1
EST. WT. 1850 LBS.
A DIMENSIONS ARE IN INCHES
TOLERANCES ARE:
.XXX ± .005 DRAWN
3/4" REF. FRACTIONS: ± 1/32 ± 1º CHECKED
ALS 10/10/08 WORK TABLE
4 PLACES MATERIAL
--
SUMP ASM
117" REF. FINISH
CHECKED
900/900C
RESP ENG
120" REF. 12 1/4" REF. 1 10/10/08 4074 -- SIZE REV.
535444
DWG. NO.
PROD MAN D 1
APPROVED 10/13/08
1 1 12524 20 X 20 X 8 ENCLOSURE
2 1 505741 PNET TD SUB-PANEL MOD
3 1 14173 NATIONAL INST 8-SLOT BACKPLANE
4 1 14174 NATIONAL INST 12-BIT ANALOG IN/OUT MOD
5 7 14175 NATIONAL INST CONNECTOR BLOCK
6 5 14176 NATIONAL INST 8CH 16-BIT ANALOG INPUT
6 5 6 5 6 5 9 10
8 7 5 4 5 6 5 6 5 7 1 14177 NATIONAL INST DIGITAL IN/OUT MODULE
1
8 1 14178 NATIONAL INST ETHERNET NETWORK CONTROLLE
9 1 14217 NATIONAL INST 8CH INPUT MOD
10 1 14218 NATIONAL INST T/C CONNECTOR BLOCK
11 2 18 11912 DIN RAIL / IN.
12 4 X-1643 BINDNG HD SCR 10-32 X 1/2 STL-NKL PLTD
2 13 4 X-1692 LOCK WASHER #10 EXT TOOTH
14 4 11758 END BARRIER
16 8 11829 JUMPER CLIP
17 15 11827 3 POS. TERM. BLOCK GND
18 10 11832 3 POS. TERM. BLOCK DIVIDER
19 1 11830 4 POS. TERM. BLOCK DIVIDER
21 1 13947 POWER SUPPLY 24VDC 60W 85-264VAC INPUT
22 6 11894 FREQUENCY TO ANALOG CONVERTER
23 2 13907.1 SOLID STATE RELAY 5-48VDC
24 1 12892 NETWORK HUB 5 PORT
25 2 16 11869 WIREWAY 1 X 2 /IN
26 2 16 11803 WIREWAY COVER 1" /IN
27 1 12742 REGULATOR 12V
28 1 E-64 4-40 X 1/4" PAN HEAD
26
25 30 4 X-027 CAP 500MF 25V 477RAR025A
31 4 X-003 RESISTOR 1/4w 5% 1.0K OHM
32 5 X-020 RES RN55D 1.0K OHM
3 33 1 23586.004 ETHERNET CABLE ASSEMBLY RJ45
14 15 17 15 15 15 20 15 17 15 17 15 17 15 17 15 17 14
13
12
11
26
16 18 18 19 18 18 18 18 18
25
21 22 23 15 17 15 17
14
14 13
12
11
NOTE:
1. DRAWING NUMBER DESCRIPTION
0= UNPOPULATED
16 18 16 18 1= DIGITAL IN/OUT MOD
2= 12 BIT ANALOG IN/OUT MOD
3= 8CH 16 BIT ANALOG INPUT
4= T/C INPUT
5= 16 CH 16 BIT ANALOG INPUT
27 28 29 24

TOLERANCES ARE:
.XXX ± .005 DRAWN
ALS 8/29/08
FRACTIONS: ± 1/32 ± 1º CHECKED PNET TD
MATERIAL
-- CHECKED CONTROLLER 900/900C
FINISH
-- RESP ENG
SIZE REV.
PROD MAN D 535424.12333334 0

APPROVED 10/14/08
1 1 43678 GUARD HALF
2 1 43678 GUARD HALF
1 1/4" 24 1/2" 3 4 23475 GUARD INNER SUPPORT
7/8" 13/16" THRU 4 4 12589 HINGE 4" X 4" X 3/16" W/ Ø3/8" RMV. PIN
2 1/4" 5 2 23574 WELD HANDLE 1 X 6 - PTX GUARD
2 3/4"
5 1/8" 1 1/8" X 45° 6 2 2 3/4 M-533 BAR 1/2 X 2 3/4 HR /IN
REF. 5 1/8" .57 7 4 12790 BENT ARM PIN 3/8 OD X 4 1/2 w/ HOLE
REF. 0" 8 4 12790.1 HAIR PIN 11/16 DIA X 1 7/8-PTX GUARD
2 1/8"
0"
2 3/4"
.57
1 3/8"
26" REF.
1 1/4"
DETAIL: ITEM 2 DETAIL: ITEM 6
3 1/8"
8 4 7 5 7 4 8
4" A
3 1/8"
REF.
6
1" 1 1/2"
DETAIL: ITEM 1
TYP.
(HINGES MUST BE IN LINE) 3/16"
3" 4" 1/8" 2"-4"

8 4 7 5 7 4 8 TYP.
1/8" 2"-4"
TYP. 5 2 3 5
1/8" 5 8 1/2"
NO WELD TYP.
4
4
6
8
8
ITEM 6 TO ITEM 1 2"
1/4" TYP. 4 PLACES
1
1 1/4" TYP.
7 7
6
1 1/2" 1 1/2"
3 3 1/8"
SECTION A-A TYP. 1 6 3
10"
1/8"
17 1/2"
26 1/8" NOTE:
1.BREAK ALL EDGES
EST. WT. 58 LBS.
TOLERANCES ARE:
DRAWN
.XXX ± .005
JWP 6/12/08 DRIVE SHAFT GUARD
FRACTIONS: ± 1/32
MATERIAL
± 1º CHECKED
WELDMENT 900/900C
FINISH
-- CHECKED
SAUER
RESP ENG
-- SIZE DWG. NO. REV.
DATE
PROD MAN C 505787 0
REV ECN DO NOT SCALE DRAWING
APPROVED 10/13/08
APPROVED 09/02/08
APPROVED 09/02/08
APPROVED 09/02/08
APPROVED 09/02/08
APPROVED 09/02/08
APPROVED 08/25/08
APPROVED 08/25/08
78 32 558564 FITTING -4 ORFS F X -4 HOSE ELBO 45° 43 1 1 535463.1 FRAME & COVER PANEL KIT - 900/900C
79 4 *9 558560 HOSE -4 5000PSI WP/FT 2 1 535462 FLOW-OUT PANEL ASM - 900 CLASSIC
80 2 558662 FITTING -6 37° F X -4 HOSE ELBO 90° (43) 3 1 535461 GAUGE PANEL ASM - 900K
81 2 *7 558560 HOSE -4 5000PSI WP/FT 4 1 535444 WORK TABLE / SUMP ASM 900/900C
82 1 *9 E-40 TUBING 1/4 OD PLASTIC 150 PSI BLK /FT 5 1 535465.1 MOTOR & PUMP ASM-900K-300HP SAUER 180cc
83 7 558566 FITTING -6 ORFS F X -6 HOSE ELBO 90° 6 1 535467.2 HYDRAULIC TANK ASM 300GAL 900K
84 1 *8 558561 HOSE -6 5000PSI WP/FT 7 1 535468.2 HYDROSTATIC TANK ASM 100GAL 900K
85 2 *7 558561 HOSE -6 5000PSI WP/FT 8 1 535469.2 HYDROSTATIC MOTOR & LIFT ASM 900K SAUER
86 1 * 7 1/2 558561 HOSE -6 5000PSI WP/FT 9 1 535470.2 HEAT EX- SUMP & KIDNEY PUMP KIT 900K
87 1 558563 FITTING -6 ORFS F X - 6 HOSE 10 1 535445 ELECTRICAL BOX ASM - 900 300HP 460/60/3
88 1 *3 558650 HOSE 3/8 ID - MEDIUM PRESS /FT 11 4 H-0495 HEX HD CAP SCR 3/8-16 X 3 GD5 Z
89 1 *5 558650 HOSE 3/8 ID - MEDIUM PRESS /FT 12 8 H-040 FLAT WASHER 3/8
90 2 11141 1/2 SEALTITE CONN ELBO 90 13 4 H-0265 HEX NUT 3/8-16 NYLOCK
91 3 11142 1/2 SEALTITE CONN STRT 14 1 505841 FILTER MOUTING BRACKET (558149)
92 2 11140 CONDUIT CONNECTOR 45° 1/2" 15 1 558149 FILTER HEAD ASSEMBLY DONALDSON
93 1 1 1/2 E-17 1/2" SEALTITE METAL CONDUIT /FT 16 1 557218 FILTER MEDIA 7
94 1 6 E-17 1/2" SEALTITE METAL CONDUIT /FT 17 6 H-008 HEX HD CAP SCR 3/8-16 X 3/4 GD5
95 1 7 E-17 1/2" SEALTITE METAL CONDUIT /FT 18 6 H-029 LOCK WASHER 3/8 ZINC
96 1 10 12692 1 EMT CONDUIT /FT 19 2 558805 FITTING -12 37° MALE X -20 STRT MALE
97 1 3 12692 1 EMT CONDUIT /FT 20 1 590695 FILTER INDICATOR SWITCH AC/DC 3-WIRE
98 1 6 12692 1 EMT CONDUIT /FT 21 2 558626 FITTING -16 37° F X -16 HOSE
99 6 12693 1 EMT SET SCREW CONN STRAIGHT 22 1 *4 558623 HOSE 1 ID - MEDIUM PRESSURE /FT
100 2 590694 3 SEALTITE CONN STRT 23 6 558627 FITTING -16 37° F X -16 HOSE ELBO 90°
101 1 7 1/2 590693 3 SEALTITE METAL CORE CONDUIT /FT 24 4 558665 FITTING -12 37° F X -12 HOSE ELBO 90° 43
102 1 X-2552 3 PIN BOX MOUNT 25 2 *5 558649 HOSE 3/4 ID - MEDIUM PRESS /FT
103 1 250 X-160 WIRE 22 AWG 2PR W/SHIELD PVC GRAY /FT 26 4 558647 FITTING -6 37° F X -6 HOSE (43)
104 1 10 X-142 WIRE 22 AWG BLACK STRAND /FT 27 1 *9 558561 HOSE -6 5000PSI WP/FT
105 1 13 X-143 WIRE 22 AWG RED STRAND /FT 28 16 558652 FITTING -6 37° F X -6 HOSE ELBO 90° (43)
106 1 10 X-144 WIRE 22 AWG GREEN STRAND /FT 29 1 *9 558384 HOSE 1 ID HYDRAULIC TOUGH COVER /FT
107 1 10 14142.002 WIRE 18 AWG RED TXL STRANDED /FT 30 4 558788 FITTING -20 C62 X -20 HOSE ELBO 90° (79)
108 1 250 23091.007 WIRE 18 AWG, BROWN, INSULATED /FT 31 1 *7 558790 HOSE 1 1/4 ID - 6000PSI WP 791TC /FT
109 1 250 14194.001 WIRE 18 AWG BLUE TFFN STRANDED /FT 32 1 * 8 1/2 558790 HOSE 1 1/4 ID - 6000PSI WP 791TC /FT
110 1 180 13572.001 WIRE 12 AWG BLK THHN STRANDED /FT 33 3 558562 FITTING -4 ORFS F X -4 HOSE (43)
111 1 70 13572.002 WIRE 12 AWG WHT THHN STRANDED /FT 34 1 *1 558560 HOSE -4 5000PSI WP/FT
112 1 30 13572.003 WIRE 12 AWG GRN THHN STRANDED /FT 35 13 558565 FITTING -4 ORFS F X -4 HOSE ELBO 90° 43
113 1 30 13572.004 WIRE 12 AWG BRN THHN STRANDED /FT 36 1 * 1 1/2 558560 HOSE -4 5000PSI WP/FT
114 1 30 13572.005 WIRE 12 AWG BLU THHN STRANDED /FT 37 18 *5 558560 HOSE -4 5000PSI WP/FT
115 1 120 13573.001 WIRE 10 AWG BLACK THHN STRANDED /FT 38 1 558391 FITTING -20 37° FEMALE X 1 1/4 H.B. 90°
116 1 220 590611 WIRE 4/0 AWG THHN 600V STRANDED BLK /FT 39 1 *4 23095.0005 HOSE 1 1/4 ID - RADIATOR /FT
117 1 30 E-5105 THERMOCOUPLE WIRE TYPE"K"YLW/RED /FT 40 2 23093.0005 HOSE CLAMP 1.75" - 1-1/4" HOSE
118 1 400 14286.001 WIRE 16 AWG BLACK TFFN STRAND /FT 41 1 S60071 FITTING -20 37° FEMALE X 1 1/4 H.B. STRT
119 1 250 14286.002 WIRE 16 AWG RED TFFN STRAND /FT 42 5 558689 FITTING -24 37° F X -24 HOSE (43)
120 1 100 14286.003 WIRE 16 AWG WHITE TFFN STRAND /FT 43 2 *2 558690 HOSE 1 1/2 ID - MEDIUM PRESS /FT
121 1 50 14286.005 WIRE 16 AWG BLUE TFFN STRAND /FT 44 2 558639 FITTING -24 37° MALE X -24 STRT ELBO 90°
122 1 50 14286.006 WIRE 16 AWG PINK TFFN STRAND /FT 45 1 *5 23095.005 HOSE 2 ID - RADIATOR /FT
123 1 50 14286.007 WIRE 16 AWG YELLOW TFFN STRAND /FT 46 4 23093.004 HOSE CLAMP-T-BOLT-2.38 - 1 7/8 & 2 HOSE
124 1 100 14286.008 WIRE 16 AWG GRAY TFFN STRAND /FT 47 1 558738 SUBPLATE - VK DGMS-3-1E-10S
125 1 50 14286.009 WIRE 16 AWG TAN TFFN STRAND /FT 48 1 558739 DIRECTIONAL CONTROL VALVE 24VDC
126 1 250 14286.010 WIRE 16 AWG ORANGE TFFN STRAND /FT 49 2 558740 CARTRIDGE VALVE SUN T-162A 10GPM 30PSI
127 1 50 14286.011 WIRE 16 AWG BROWN TFFN STRAND /FT 50 1 558741 BODY-SUN T-162A
128 1 50 14286.012 WIRE 16 AWG PURPLE TFFN STRAND /FT 51 4 H-00112 SOC HD CAP SCR 10-24 X 3 1/2
52 4 558806 FITTING -8 STRT M X -6 STRT F
NOTE: 53 3 558777 FITTING -4 ORFS M X -6 STRT M
1. " * " DENOTES ESTIMATED HOSE LENGTH
HOSES TO BE CUT TO LENGTH DURING ASSEMBLY 54 1 558615 FITTING -6 37° M X -6 STRT M
55 3 H-0006 SOC HD CAP SCR 1/4-20 X 1 1/4 LG
57 2 590667 CONN DIN 43650 FORM A w/ 7.5 METER CABLE
58 2 *2 558650 HOSE 3/8 ID - MEDIUM PRESS /FT
59 3 558678 FITTING -24 37° F X -24 HOSE ELBO 90° 43
60 1 *8 558690 HOSE 1 1/2 ID - MEDIUM PRESS /FT
61 1 *9 558690 HOSE 1 1/2 ID - MEDIUM PRESS /FT
62 1 *8 558623 HOSE 1 ID - MEDIUM PRESSURE /FT
63 1 *7 558384 HOSE 1 ID HYDRAULIC TOUGH COVER /FT
64 2 558648 FITTING -12 37° F X -12 HOSE (43)
66 2 558799 FITTING -12 ORFS F X -12 HOSE 90° (79)
67 1 * 3 1/2 558793 HOSE 3/4 ID - 6000PSI WP 791TC /FT
68 2 *6 558561 HOSE -6 5000PSI WP/FT
69 2 558699 TWO-CHANNEL METAL STRAP 5/8 OD
71 1 * 12 558561 HOSE -6 5000PSI WP/FT
74 2 23093.011 HOSE CLAMP-T-BOLT-3.50 3 HOSE
76 2 23093.015 HOSE CLAMP-T-BOLT-4.50 - 4 HOSE
77 1 * 10 23095.005 HOSE 2 ID - RADIATOR /FT
EST. WT. 15000 LBS.

TOLERANCES ARE:
.XXX ± .005
FRACTIONS: ± 1/32
DRAWN
± 1º CHECKED
JWP 12/04/08 HYD TEST STAND
MATERIAL SYS 900K-300HP
FINISH
-- CHECKED
380/460/60
-- RESP ENG
SIZE REV.
JM0054
DWG. NO.
PROD MAN D 0
PowerNet TD
Data Acquisition and Control
Operator's and Administrator's Manual
© Copyright 2007, Power Test, Inc. PNTD071026

Contents
Contents
Table of Contents ........................................................................................................................... iii-iv
Chapter 1 - System Overview ........................................................................................................... 1

Data Acquisition and Control System Components ...................................................................................... 3
Software Overview ........................................................................................................................................ 4
The PowerNet File System .......................................................................................................................... 6
Chapter 2 - Basic Operation .............................................................................................................. 7

Starting the Commander Computer .............................................................................................................. 9
Connections .............................................................................................................................................. 10
Test Procedure .......................................................................................................................................... 12
Chapter 3 - Main Display .................................................................................................................. 13

The Main Display Window ......................................................................................................................... 15
Floating Pull-Down Menus ......................................................................................................................... 16
The File Menu ...................................................................................................................................... 16
The View Menu .................................................................................................................................... 18
Configuring Sensors ........................................................................................................................ 20
Alarms ............................................................................................................................................ 21
The Data Menu .................................................................................................................................... 23
The Window Menu ............................................................................................................................... 24
The Add-Ins Menu ................................................................................................................................ 25
The Help Menu ..................................................................................................................................... 25
Chapter 4 - TD Controller Interface ................................................................................................. 27

Controller Interface Window ....................................................................................................................... 29
Controlling the Dynamometer .................................................................................................................... 30
Throttle Control Modes ......................................................................................................................... 30
Dynamometer Control Modes ............................................................................................................... 30
Controller Interface Window Pull-Down Menus ........................................................................................... 31
The File Menu ...................................................................................................................................... 31
The Relays Menu ................................................................................................................................. 33
Chapter 5 - Pattern Runner .............................................................................................................. 35

Pattern Runner Pull-Down Menus .............................................................................................................. 37
The File Menu ...................................................................................................................................... 37
The Edit Menu ...................................................................................................................................... 38
Creating a New PowerNet Pattern ................................................................................................... 39
Saving a PowerNet Pattern ............................................................................................................. 39
Running a PowerNet Pattern ........................................................................................................... 39
Chapter 6 - Report Generator .......................................................................................................... 41

The Report Generator Program .................................................................................................................. 43
The Report Generator Window Pull-Down Menus ....................................................................................... 43
The File Menu ...................................................................................................................................... 43
iii
Contents
Chapter 6 - Report Generator(continued) ....................................................................................... 45
The Edit Menu ...................................................................................................................................... 44
Using the Edit Report Window .......................................................................................................... 45
Creating a New User Table ................................................................................................................ 46
Editing User Tables ........................................................................................................................... 47
Creating a New Data Table ................................................................................................................ 48
Reference Sensors .................................................................................................................... 48
Editing Data Tables ................................................................................................................... 49
Phases ...................................................................................................................................... 49
Function List ............................................................................................................................. 49
Creating a New Graph ....................................................................................................................... 50
Editing Graphs .................................................................................................................................. 51
Creating a New Spreadsheet ............................................................................................................. 52
Editing Spreadsheets ........................................................................................................................ 53
Creating a New Paragraph ................................................................................................................ 54
Editing Paragraphs ........................................................................................................................... 55
The View Menu .................................................................................................................................... 56
New Graph View ............................................................................................................................... 56
New Graph View Properties .............................................................................................................. 56
Creating a New Graph View .............................................................................................................. 57
Editing a New Graph View ................................................................................................................ 58
The Import Menu .................................................................................................................................. 58
The Export Menu .................................................................................................................................. 58
Ignore List ............................................................................................................................................ 58
Chapter 7 - Add-In Programs ........................................................................................................... 59

The Add-in Programs ................................................................................................................................. 61
Security Editor .......................................................................................................................................... 61
ECM Communicator .................................................................................................................................. 62
Gas Analyzer ............................................................................................................................................. 65
Calculated Sensors ................................................................................................................................... 65
Fuel Controller ........................................................................................................................................... 67
Correction Factors ..................................................................................................................................... 69
Reference Data Builder .............................................................................................................................. 71
Chapter 8 - Glossary ........................................................................................................................ 75
Copyright © 2007 by Power Test, Inc. All rights reserved. This manual may not be copied, photographed, reproduced, translated or
converted to any electronic media or machine-readable format in whole or in part without prior written approval of Power Test, Inc.
iv
System Overview
PowerNet TD
- CHAPTER 1 -
System Overview
1
System Overview
2
System Overview
Data Acquisition and Control System Components
The system is divided into three groups: the Commander Computer, the TD Controller Box and optional components.
Commander Computer
This terminal interfaces with the control box and the dynamometer and per-
forms all of the embedded control functions. It is also the location where new
tests and reports are generated, manipulated, stored, run, and printed.
TD Controller
The TD system controller box contains the system’s pressure and temperature
sensors. The sensors are housed in an industrial cabinet and supplied with quick
disconnect connections. Information is collected from the sensors and combined
with torque, speed and power measurements from the dynamometer and sent to the
Commander Computer.
Optional Components
Power Test offers a wide range of optional components and accessories for the PowerNet TD Data Acquisition and Software
System.
Our in-house manufacturing and electronics department guarantees that we will be able to provide a data acquisition and
control system for nearly any application. For more information, contact your Power Test representative, or visit us on the
web at www.pwrtst.com.
3
System Overview
Software Overview
The PowerNet TD Software Package is a complete data acquisition and control program for dynamometers and engines. TD
transforms a standard computer and specially designed electronic components into a highly efficient engine development and
qualification tool.
The software is comprised of several programs running at the same time, the Main Display, TD Controller Interface, Pattern
Runner and Report Generator. There may be other programs running minimized in the background (operational, but hidden)
according to what is listed under the add-ins menu of the Main Display.
Main Display TD Controller Interface
Pattern Runner Report Generator
4
System Overview
Main Display
The Main Display contains the readings for all of the available
visible sensors. All of the sensor parameters and configurations
can be modified from this window by right-clicking on the indi-
vidual sensor readings. Additionally, this window is used to open
and save PowerNet Templates and DataSpaces, as well as exit
the Commander program. The details of the functions and fea-
tures of the Main Display are discussed in Chapter 3.
TD Controller Interface
The TD Controller Interface provides essential control functions for the dynamometer. This
window identifies the dynamometer’s active load control mode and the current setpoint. It is
possible for a user at the Commander Computer to control the dynamometer and transmission
using the mode buttons and the input box directly from the TD Controller Interface. The details
of the functions and features of the Controller Interface are discussed in Chapter 4.
The Pattern Runner Interface Window

The Pattern Runner program allows the user to create, load, save and execute
PowerNet Patterns. PowerNet Patterns are pre-configured tests that are de-
signed to run in a specific order. The details of the functions and features of the
Pattern Runner are discussed in Chapter 5.
The Report Generator Interface Window

The PowerNet Report Generator allows the operator to arrange the data into a
meaningful visual format. The data can be arranged as spreadsheets and/or
graphs, while any customer and vehicle information can be put into paragraphs
and/or tables. The details of the functions and features of the Report Generator
are discussed in Chapter 6.
5
System Overview
The PowerNet File System
The PowerNet File System consists of the following components: PowerNet Templates, PowerNet DataSpaces, and Pow-
erNet Patterns. It is important to understand the function of each of these file types.
PowerNet Template (.tds)

A Template is a file containing pre-configured, basic test information. All Templates can be customized with information
applicable to the kind of test you wish to perform. This may include sensor configurations and report formats and patterns.
Templates are created by the administrator. Templates do not contain any data. Once a test is performed, data can then be
collected and saved in the form of a DataSpace.
PowerNet DataSpace (.pds)

After a Template has been used to acquire data, it is then saved as a DataSpace. A DataSpace contains the same information
as the Template with the addition of specific test data. A DataSpace is utilized whenever an operator wishes to save new test
data, or recall data from a previously saved test and is the area where live data is stored.
PowerNet Pattern (.pcp)

Patterns are pre-configured tests that are designed to run in a specific order. Patterns are created by the administrator and
they can be saved within a Template or as individual files to be loaded into existing Templates.
PowerNet Tuning Files (.pct)

Tuning Files are individual files storing dynamometer tuning parameters. The tuning parameters should not be modified unless
otherwise instructed to do so by Power Test.
PowerNet ECM Information (.pei)

Specific vehicle ECM Communication configurations can be saved and loaded as individual files.
NOTE: All file types should be stored in the C:\Program Files\PowerNet\Commander 2.0 directory.
6
PowerNet TD
- CHAPTER 2 -
Basic Operation
Basic Operation
8
Basic Operation
Starting the Commander Computer
Once the Commander Computer and all related components have been
installed and set up by your PTI representative, you are ready to turn on
the Commander Computer. At this time, make sure the monitor and
printer are also on.
Note: Each program on the computer utilizes a system of command

choices, called Menus. If you click on a Menu, and it drops down with
multiple choices for you, it is called a pull-down menu. To make the
computer follow instructions, simply point the mouse and click on the
menu selections you wish to have performed.
Sample PowerNet Splash Screen
The computer should automatically execute the PowerNet TD program, and the splash screen will become visible during the
time the program is loading. Once closed, the program may be restarted by clicking on the “P” icon on your screen. Double
click that icon to launch the software. For administrative functions, a log-in name and password are required.
Note: If the program does not automatically start, or the icon

does not appear, contact your Power Test representative.
Once you have powered up (for operators) or logged-in (as an

administrator), the default PowerNet Template should be loaded
and visible (right).
The program will automatically open the “default” template upon

start-up. Typically, the operator will open one of several tem-
plates created by the administrator and select a template based
on the type of engine or test being performed.
Note: Depending on the operating system used, the software may have a slightly different appearance than the examples in this
manual. This does not affect the performance of the program in any manner.
9
Basic Operation
Connections
Note: Before performing a test, the following connections may need to be made.
Pressure Connections
To connect to a pressure port, simply route the hose to the pressure source and connect accordingly.
Pressure Connection at Pressure Connection

the Panel at Transmission
ECM Connection (Optional)

To connect to the transmission’s ECM, plug the ECM cable (provided by Power Test) into the Commander Comuter on one end,
and to the appropriate diagnostic adapter (available separately from Power Test) on the other end.
Other Connections Please refer to a specific component’s installation manual for other connections.
10
Basic Operation
Test Procedure
Once the transmission has been prepared for testing, including mounting the transmission to the test stand and installation of
any necessary components (drive shafts, etc.), the next step of the process is to perform the actual test. Once the safety and
integrity of all of the systems, connections, supplies and the transmission are verified, you are ready to begin. The following
information outlines a typical test sequence.
Prepare for Testing

Connect Throttle Cable to Engine
If a throttle actuator is used, set the throttle actuator to the “low idle” position (slack removed from cable).
Turn on the Transmission Test Stand

To turn on the Test Stand, press the green button on the front panel.
Turn on the Commander Computer

Turn on the computer, monitor and printer. The PowerNet TD Data Acquisition and Control Software will load automatically.
Enter in Your User Password

Login to the systems from the Main Display menu. Enter your assigned user name and password.
Load a PowerNet Template

Load an appropriate template by selecting File > Open > Template from the Main Display. This Template is normally identified
by engine model. If an appropriate Template does not exist, one must be created by the System Administrator.
Begin Testing
If a closed loop test is being run, click the Play button in the Pattern Runner program. If the appropriate Pattern is not visible,
select a Pattern from the file or consult the administrator. If a manual test is being run, test the engine as specified by your
supervisor.
After Testing is Completed

Edit Data
Enter any test specific data using the Report Generator program. Use the Print Preview function to view the edited report.
Save Test Data

From the Main Display, click File > Save As > Data Space. Assign a file name, typically determined by work order #, etc. If
desired, print a hard copy of the report by selecting File > Print from the Report Generator program.
Shut down the Commander Computer

Shut down the computer by clicking File > Shut Down System in the Main Display window.
Turn off the Transmission Test Stand

To turn off the Transmission Test Stand, press the red button on the outside of the box.
11
Basic Operation
12
Main Display
PowerNet TD
- CHAPTER 3 -
Main Display
13
Main Display
14
Main Display
The Main Display Window
The Main Display Window contains all of the sensors that are connected to the system. The Sensors can be displayed in two
formats. The Single Main Form format displays all of the individual gauges in fixed format. The Floating Form format
allows the user to customize the size and location of the individual gauges on the screen. Each of these sensors can be
displayed in one of four available gauge types as explained on page 20, Sensor Properties.
Example of the Single Main Form Format
Example of the Floating Form Format
NOTE: The illustrations throughout the rest of this manual will display sensors in the floating form format. This may or may
not represent how your system is configured.
15
Main Display
Main Display Window - Pull-down Menus
The pull-down menus are located in the header of the Main Display when the Single Main Form format is applied, or in a
floating window if the Floating Forms format is applied (as illustrated throughout this manual). If the floating window is
selected, the full pull-down menus will appear by putting your cursor on the "P" icon. The pull down menus consist of: File,
View, Data, Window, Add-Ins and Help.
Single Main Form Pull Down Menu Floating Form Pull Down Menu and Icon
The File Menu
File Menu: From the File Menu, many of the file management tools needed to operate Commander can be accessed. The
File Menu consists of Log in, New, Open Template, Open DataSpace, Save, Save As Template, Save As DataSpace,
Revert to Saved, Shut Down System and Exit.
File > Login: Opens the Login screen so an administra-

tor can login to perform administrative functions.
* Note: Without logging in, many menu items will be

grayed out and the corresponding administrative func-
tions can not be performed. All functions requiring login
will be noted with an * throughout the rest of this chap-
ter.
File > New: Creates a new blank Template.
* File > Open > Template: Loads an existing Template

from which to use for running a pre-configured test. If
not logged in, the user will only have the option of open-
ing a Template within the program directory. If logged
in, the user will have the ability to search the Commander
Computer and all removable drives for a Template.
File > Open > DataSpace: Loads an existing DataSpace

that contains previously saved test data.
Open Template Screen Open Template Screen (logged in) Open DataSpace Screen
16
Main Display
The File Menu - (continued)
* File > Save: Saves the current active DataSpace or
Template, overwriting the current file.
Note: Use caution when using the Save function. Once

changes have been saved and the original file has been
overwritten, the original file can not be retrieved.
File > Save As >Template or DataSpace: Saves the

active Template or DataSpace as a new Template or
DataSpace. The user will be prompted to name the new
file before saving. In addition to the new file being saved
to the system, the original file will still exist.
File > Revert to Saved: Ignores recent changes in the

active Template or DataSpace and reverts back to the
previously saved version.
File > Shut Down System: Closes the software pro-

gram and powers down the Commander Computer.
File > Exit: Closes the program and returns the user to
the Windows Desktop. If changes have been made to
the current open DataSpace, the user will be given the
option of saving the changes before closing the program.
17
Main Display
The View Menu
View Menu: From the View Menu, hidden sensors can be made visible and the sensor layout can be changed. The View
Menu consists of More Sensors, Display Layout, Chart, Find Overlapped Sensor(s) and Lock Sensors Positions.
View > More Sensors: Produces a pop-up window

(shown below) that allows the user to make hidden sen-
sors visible. Check the boxes of the sensors you wish to
show and click OK.
Note: A sensor does not

have to be visible for its
data to be shown in the
Report.
View > Display Layout: Clicking Display Layout will

automatically open the Sensor Order window (shown
below). There are two options in the Sensor Order win-
dow, Sensor Order and Sensor Configuration.
The Single Main Form

There are two formats to display the sensors: Single
Main Form and Floating Forms. In the Single Main
Form format, all of the available sensors are grouped
together in the Main Display window. To display all sen-
sors in a Single Main Form, click on the Sensor Con-
figuration tab and click on the All Sensors check box.
To change the order in which sensors appear in a Main Form, click on the Sensor Order tab. To change the order, highlight
a sensor by clicking on it, then use the navigational buttons at the right of the window. Click OK when finished to save the
new sensor order, or click cancel to disregard changes.
Note: The Sensor Order function will not work if all sensors are displayed in a Floating Form format.
Sensor List
Move Sensor Position Up
Move Sensor Position Down
18
Main Display
The Single Main Form (continued)
From the Sensor Configuration tab, the user can select how many sensors appear in each row of the Single Main Form in
the Main Display.
If the 3 on top row (stationary) 5 on remaining rows option is selected,

a Single Main Form will display three sensors in the top row, and five
sensors in each row thereafter until all sensors are displayed. ex. If
there are 13 sensors in the Main Form, three sensors will be displayed in
the first row, five sensors will be displayed in the second row, and five
sensors will be displayed in the third row. If selected, the sensors in the
first row will all be square in size.

a Single Main Form will display four sensors in the top row, and five sen-
sors in each row thereafter until all sensors are displayed. ex. If there
are 13 sensors in the Main Form, four sensors will be displayed in the
first row, five sensors will be displayed in the second row, and four sen-
sors will be displayed in the third row. If selected, the sensors in the first
row will all be square in size.

a Single Main Form will display five sensors in the top row, and five sen-
sors in each row thereafter until all sensors are displayed. ex. If there
are 13 sensors in the Main Form, five sensors will be displayed in the first
row, five sensors will be displayed in the second row, and three sensors
will be displayed in the third row. If selected, the sensors in the first row
will all be square in size.
If the 5 on all rows (non-stationary) option is selected, a Single Main Form will display five sensors in each row . ex. If
there are 13 sensors in the Main Form, five sensors will be displayed in the first row, five sensors will be displayed in the
second row, and three sensors will be displayed in the third row. If selected, each sensor will be equal in size, regardless of
number selected.
Floating Forms
Floating Forms can exist anywhere on screen and can be sized individually. The use of the Floating Form format allows a
highly customizable appearance to the Main Display. A Single Main Form display and Floating Forms display can exist
together.
The Sensor Display frame of the Sensor Configuration tab is used to determine how many sensors will be displayed on
the Single Main Form display and how many Floating Forms exist. If the All Sensors check box is selected, all sensors
will be displayed in a Single Main Form mode. To display sensors in both a Single Main Form and Floating Forms format,
enter the number of sensors that should remain in the Single Main Form in the Number of Sensors on Main Form text box.
ex. If there are 13 sensors available, and a number of six is entered into the Number of Sensors on Main Form text box,
then six sensors will be displayed in the Single Main Form, and the remaining seven sensors will exist as Floating Forms.
To change which sensors appear in the Single Main Form, click on the Sensor Order tab and rearrange the sensors.
To have all sensors display as Floating Forms, un check the All Sensors check box and enter the number zero (0) into the
Number of Sensors on Main Form text box.
To move a sensor's position in the Floating Form format, confirm that the Lock Sensor Positions option in the View Menu
is unchecked. Clicking on Lock Sensor Positions will check or un check that option. If it is not unchecked, click on Lock
Sensor Positions to unlock the sensors. This will allow the sensors to be placed anywhere on the screen. Next, click on the
sensor and drag it to its new location. To change the size of a sensor, click on an edge or corner of the sensor window, and
drag it to the desired size. Once all sensors have been placed, click on Lock Sensors Positions from the View Menu. This
will lock the sensors in their current position, and help to avoid the possibility of accidentally moving, re-sizing, or hiding a
sensor.
19
Main Display
Sensor Properties
Right-clicking on any of the sensors allows the user to modify the sensor’s properties. Right-clicking brings up the option box
shown below right.
Properties: Selecting Properties will open the Sensor Properties window.
Hide: Selecting Hide will remove that sensor from the Main Display window and return it to the list of sensors under More
Sensors on the Main Display window’s View Menu. Select View > More Sensors to undo the hide sensor command.
Sensors displaying readings with an Optimal (an administrator defined "normal") range will display in GREY. Sensors in a
Low alarm range will display BLUE. Sensors in a High alarm range will display RED.
Sensor Properties Window: The Sensor Properties window contains five tabs that allow the user to customize the
sensor. The tabs are Gauge, Display, Units, Low Alarm and High Alarm. In addition, the name of the sensor can be
changed by entering the new name into the Sensor Name input box.
Display: This is where the operator can select which type of gauge should be displayed for a
sensor. The operator can select from a Digital, Sweep Dial, Round Dial or Bar gauge.
Note: Bar gauges are only available as Floating Forms.
Digital Sweep Dial Round Dial Bar
Gauge: This tab provides the operator options to define the displayed range and multiplier for
the gauge. Maximum Reading: Establishes the top, or highest number displayed in a dial or
bar gauge. Minimum Reading: Establishes the bottom, or lowest number displayed in a dial
or bar gauge. Display Multiplier: The number by which the numbers in a display are divided
by, ex. A multiplier of ten will display 1000 RPM as 100 RPM. This will also change the display
unit to RPM x 10 (or whichever multiplier is chosen). Decimal Places without Display Multi-
plier: The number of decimal places to which is displayed as determined by the number en-
tered in the input box. ex. If a value of three (3) is entered in the input box, data will be
displayed to .000, or thousandths.
Units: This is where the user defines the units displayed for the gauge display. Common stan-
dard units can be chosen by selecting Use List and picking from the menu. To define a custom
unit, select Custom and enter a unit name, description and display symbol. Enter the values
that the sensor’s standard unit must be multiplied by and/or added to achieve the custom unit.
Once all information is entered, the custom unit can be added to the list of standard units. To
find the base unit, select units from the Use List until you find one with adder of zero and a
multiplier of one (usually, the first listing).
20
Main Display
Sensor Properties (continued)
Low Alarm/High Alarm: These tabs are where the user defines what
actions (explained below) will be taken during a Low Alarm/High
Alarm state.
When finished, select OK to keep changes or Cancel to disregard

any changes.
Alarms
As soon as the sensor travels out of its operational range, it will change color. Blue indicates it has fallen below its opera-
tional range (Low Alarm) while red indicates it has exceeded its operational range (High Alarm). There will be two options
available to the operator, Hold (suspend) or Reset the alarm. If the Hold button is clicked during alarm state, the software
will suspend the alarm Action for the period of time indicated in the “Suspend Time”. Reset clears the alarm condition.
Shown below are examples of alarm conditions and the resulting alarm buttons that may be displayed on screen. To remove
the condition, simply click on one of the function buttons, either Hold or Reset.
The user has the option of setting a high and low alarm to activate during an engine test. As previously discussed, they are
located by right clicking on a sensor in the Main Display Window. The user may then choose from the following options:
Trigger Point, Wait Secs Before Action, Suspend Time, a variety of Actions to perform, Grab Data Point if Triggered,
and Auto Reset. In both the Low Alarm and High Alarm state, the administrator has the following options available.
Trigger Point: The value at which the software will indicate that the sensor is out of the operational range. The units of the
value entered are selected from the Units tab. For example, if the sensor is configured in RPM, then the value entered will
reflect RPM.
Wait Secs Before Action: Indicates how many seconds the software should wait before performing the alarm Action.
Suspend Time: Indicates how long the alarm action will be delayed if the Hold button is clicked.
Action: The Action state of the alarm allows the administrator to set the following actions to be performed by the software
after the number of “Wait Secs Before Action” has completed.
None: Indicates no action is to be performed and only a color change is indicated on the screen.
Soft Stop: When the alarm is triggered, the software will first apply the "Wait Secs Before Action" value, then perform a soft
stop. Both the speed control and the dyno control return to zero and the Stop relays fire automatically. These actions stop
the engine as if it were shut down normally, as no load is applied during a soft stop. If selected, an alarm will sound.
E Stop: The throttle returns to zero and the valve is fully opened, applying a preset load to the engine, the stop relays are
fired, and the engine is brought to an abrupt stop. If selected, an alarm will sound.
Warning Only: In this condition, only an alarm warning is displayed on screen, no actions are performed.
Grab Data Point if Triggered: If checked, the software will immediately grab data if the Trigger Point is reached. Grabbing
data once a trigger point has been reached will help in identifying the problem area, and cause of the alarm. If Grab Data
Point if Triggered is not checked, the data will be gathered normally.
Auto Reset: If checked, the software will automatically reset the alarm after the sensor limit has returned to normal.
21
Main Display
The View Menu (continued)
View > Chart:
By selecting Chart under the View Menu, the Real-Time
Chart (shown below) will be displayed. This chart dis-
plays the real-time data change. Additionally, Reference
Data Can be viewed on the Real Time Chart.
To customize the Real-Time Chart, right click the chart and

choose Properties. The user has the option to choose what
information will appear on the X (horizontal) axis and Y (ver-
tical) axis of the Chart.
From the Points frame, the user is able to select how many Points appear in the
Real Time Chart. The number of Points (30, 60 or 90) will determine the actual
width of the Chart. From the Speed frame, the user can select the speed (Me-
dium or Fast) at which the system updates and displays data. The actual ranges
of the Chart are determined by the minimum and maximum values of the sensor
as established in the Sensor Properties Window.
To display the information from the Current Active Data Space as it is being re-
corded, select Rolling Time Chart from the X Axis list. If Rolling Time Chart is
selected, the chart will scroll to the left as data selected as the Y Axis is being
displayed.
Note: Real-Time graphing consumes a greater amount of processor speed as the number of sensors and the update rate
are increased.
Selecting Chart Reference Data will display Reference Data on the chart in addition to Data from the Current Active Data
Space. More information on Reference Data can be found on page 24 and in Chapter 7, Add-In Programs
To hide the real-time chart, right click the chart and choose Hide.
View > Find Overlapped Sensor(s): This menu item

will be active only if there are some sensors displayed
as Floating Forms. In this case, some visible sensors
may be overlapped by other sensors. This selection will
point out the positions of overlapped sensors. As shown
in the figure far right, the positions of the overlapped
sensors are marked by the Overlap symbol. Clicking
the Overlap symbol will cause the overlapped sensor
to appear.
View > Lock Sensors Positions: This menu item will

be active only if there are some sensors displayed as
Floating Forms. Normally, the positions of sensors shown
as Floating Forms can be any size or anywhere on the
screen. Checking this menu item will disable the ability
to size or move floating sensors.
22
Main Display
The Data Menu
Data Menu: Test data from the sensors can be cleared and recorded from the Data Menu . The Data Menu consists of
Clear Data, Grab Data , AutoGrab, Delete Data Point(s), Load Reference Data and Assign Sensors to Reference Data.
This data is later used in reports and graphs.
Data > Clear Data: Erases any stored data in the cur-
rent open DataSpace. This change will not be saved
until the current DataSpace is saved.
WARNING: Once data has been erased, it can not be

recovered.
Data > Grab Data: Instantly records the current data

readings. The Grab Data function can be performed by
clicking on this menu item or by using the Windows key-
board shortcut keys Ctrl + G.
Data > AutoGrab: Allows you to turn AutoGrab off

or select an interval in which data will be recorded.
The user is able to choose one of several preset
intervals or custom configure time intervals.
AutoGrab only records data when the engine is run-
ning.
Note: The data you grab is saved into the current

active DataSpace and can be printed using the Re-
port Generator program, as described in Chapter 6.
Data > Delete Data Points: Deletes data points or data

phases. If this function is selected, a pop-up window
(shown below) will appear. The user can choose to de-
lete individual data points or delete entire phases.
Note: Phases are only available with the Advanced Pat-

tern Runner.
To delete Data Points, enter the Data Point number and

click the Delete button. A confirmation window will ap-
pear. If the information in the window is correct, click
OK. The selected point will be deleted. Data Points are
numbered consecutively.
To delete a Data Phase, select the Delete Phase op-

tion. A window (shown right) will list the available phases
to delete. Highlight the phase to delete and click the
Delete button. Confirm the selection by clicking “OK” in
the confirmation window. .
23
Main Display
The Data Menu (continued)
* Data > Load Reference Data: This menu item allows
the user to load Reference Data into the report from an
external data source.
Reference Data is data that is typically used for com-

paring results of a test to accepted standards when view-
ing a graph. This data can be imported from a
DataSpace, a text file created in Excel, or created by
the administrator using the Reference Data Builder fea-
ture found in the Add Ins Menu. Further details can be
found in Chapter 7, The Add Ins Menu.
Once reference data has been loaded to the DataSpace, the Assign Sensors to Reference Data window will automatically
open. The user is given the choice of available sensors to assign reference data to.
* Data > Assign Sensors to Reference Data: To

change sensors assigned to the reference data after it
has been loaded, select Assign Sensors to Reference
Data... from the Data menu. After the reference data is
loaded, this menu item will become active. It is used to
associate the reference data to existing sensors.
Note: Once Reference Data has been assigned to a specific sensor, it will appear in any Graph in which that sensor is
assigned if the Use Reference Data check box is checked in the Graph Properties window found in the Report Generator.
The Window Menu

Window Menu: From the Window Menu, the arrangement of the Main Display Window can be modified. The Window
Menu consists of Default Positions and Show Main Form (which toggles to Hide Main Form) and AutoHide.
Window > Default Positions: If the active windows have

been modified or moved by the user, selecting the De-
fault Positions will return them to their default display
positions.
24
Main Display
The Window Menu (continued)
Window > Show Main Form: If the sensors are only
displayed in a Floating Form format, the Main Form will
remain empty. To display the Main Form, select the
Show Main Form option. To hide the Main Form, se-
lect the Hide Main Form function.
After the main form appears, the Show Main Form menu
item will change to Hide Main Form. By selecting Hide
Main Form, the Main Form will be hidden again.
Window > Auto Hide: Checking Auto Hide will reduce

the floating menu to an icon (shown below) after a short
period of time. To reactivate it, simply place your cursor
over the icon.
The Add-Ins Menu

Add-Ins Menu: The selections in the Add-Ins menu
may vary with different embedded programs. Any op-
tional component programs that do not come standard
will be listed under the Add-Ins Menu. Programs found
in the Add-Ins Menu are explained in Chapter 7, Add-
In Programs.
Note: For instructions and specifications for specific

hardware included with your system, please consult
the information provided with the equipment.
The Help Menu

Help: The Help menu of the Main User Interface Window consists of Show Versions, Release Notes, Show Manual, and
Go To Program Directory.
Help > Show Versions: Displays the

current version specifications of the software
(shown below).
25
Main Display
The Help Menu - (continued)
Help > Release Notes: Opens a .txt file
that contains the historical changes to the
software program. This is used as a refer-
ence file by PTI employees.
Help > Show Manual: Opens a .pdf file

of the software manual supplied with your
equipment. Adobe Acrbat Reader was in-
stalled with the system software.
Help > Go To Program Directory: Opens

the program directory (shown below), or the
file on the Commander Computer where all
of the files pertaining to the PowerNet soft-
ware are located. This provides a quick link
to this file in order to locate a specific file
type or make changes.
26
Controller Interface
PowerNet TD
- CHAPTER 4 -
27
28
Controller Interface Window
The Controller Interface window provides essential control functions for the dynamometer. This window identifies the
dynamometer’s active load control mode and the current setpoint.
It is possible for a user at the Commander computer to control the dynamometer using the mode buttons and the input box
directly from the Controller Interface window. Additionally, the dynamometer tuning parameters, torque and pressure calibra-
tions, and the relays for ancillary components can all be accessed from this window.
29
Controlling the Dynamometer
There are two methods for manually controlling the dynamometer and/or engine directly from the Controller Interface. The first
method is by entering a number in the Setpoint Entry Box directly above the relay buttons. Entering a value in this window and
pressing enter on the keyboard will move the yellow Slide Bar to the desired set point. Additionally, a blue bar will display the
progress of the change being made. The second method for controlling the dynamometer and/or engine is by clicking on the
Side Bar and dragging it to the desired set point. As the Slide Bar is moved, its position will be displayed in the Setpoint Entry
Box. A blue bar will display the progress of the change being made. Additionally, clicking on the arrows at the top and bottom
of the Slide will move the Slide Bar 5% for each click.
Note: The system can only be controlled using the Slide Bar in the Throttle Position and Load Position modes as described
below.
Throttle Control Modes

There are seven standard methods by which the transmission operating speed may be controlled during testing. They can be
selected by clicking the Input or Output buttons above the slider bars.
1) Throttle Percentage (%): A method of controlling the transmission in which the throttle is set at a percentage of the pre-
calibrated throttle range and is maintained at this position during testing. Speed adjustment may be made by using the Slide
Bar or entering the percentage value.
2) TorqueIn and TotalTorqueOut: A method of controlling the transmission in which an actual torue value is entered and the
system will move the throttle in an effort to maintain the entered value during testing (may overload transmission if set point is
too large).
3) PowerIn and TotalPowerOut: A method of controlling the transmission in which a horsepower set point is entered and the
throttle tries to maintain that amount of load, regardless of the engine’s speed or its ability to achieve that load.
4) SpeedIn and AveSpeedOut: A method of controlling the transmission in which a speed set point is entered and the throttle
tries to maintain that amount of load, regardless of the dynamometer’s speed or the engines ability to achieve that load.
Load Control Modes

Whether performing automated or manual setpoint operation, the dynamometer will ultimately be controlled by one of the
following four modes:
1) Load Percentage (%): A method of controlling the transmission in which the load is set at a percentage of the pre-calibrated
load range and is maintained at this position during testing. Speed adjustment may be made by using the Slide Bar or entering
the percentage value.
2) TorqueIn and TotalTorqueOut: A method of controlling the transmission in which an actual torue value is entered and the
system will move the throttle in an effort to maintain the entered value during testing (may overload transmission if set point is
too large).
3) PowerIn and TotalPowerOut: A method of controlling the transmission in which a horsepower set point is entered and the
dynamometer tries to maintain that amount of load, regardless of the engine’s speed or its ability to achieve that load.
4) SpeedIn and AveSpeedOut: A method of controlling the transmission in which a speed set point is entered and the throttle
tries to maintain that amount of load, regardless of the dynamometer’s speed or the engines ability to achieve that load.
30
Controller Interface Window Pull-Down Menus
The TD Controller Interface Window consists of the View and Relays menus.
The View Menu

View Menu: From the View menu, the user can modify the Tuning Parameters, adjust the Settings, and view the Statistics of
the Controller Interface. The View menu consists of Tuning, Ramping, Calibrations, and Settings.
View > Tuning: Displays the dynamometer tuning parameters. The

PowerNet Data Acquisition and Control software utilizes a Propor-
tional Integral Derivative controller. The PID controller compares a
measured value from a process with a reference setpoint value. The
difference or “error” signal is then used to calculate a new value for the
throttle or valve. The PID loop occurs many times/second.
The Proportional, or gain, positions

the throttle or valve at a percentage
proportional to the error.
The Integral is the rate at which the

dynamometer will reach that
setpoint.
Derivative controls the rate of

change, and is seldom used.
Determining the appropriate settings for P and I can be a difficult task. A simple method for tuning is to first set the I and D
values to zero. Increase the P until the system begins to oscillate, and then divide by 2. Then increase I until oscillation starts,
and divide by 2. A fast PID loop tuning usually overshoots slightly to reach the setpoint more quickly; however, some systems
cannot accept overshoot. If this is the case, the tuning will need to be slower.
View > Ramping: Clicking on Ramping displays the Ramping (shown at right), or
percentage of change per second, of the value being changed. When selected, ramping is
displayed directly below the setpoint boxes.
ex. Entering a throttle value of 50 in the Setpoint Entry Box and a value of 10 in the %/sec
Entry Box will increase the throttle percentage by 10 percent every second or five seconds.
31
The View Menu - (continued)
View > Calibrate: This selection will show a pop-up window allow-
ing the administrator to calibrate attached sensors (shown below).
Torque: To calibrate the torque:
1. Make sure there is no torque being applied to dyno.

2. Attach the calibration arm to the torque arm of the dyno.
3. Zero the torque by clicking on the Zero Offset Button
4. Stack a known amount of weight on the calibration arm (200 Lbs is recommended). The calibration torque is the weight
multiplied by the calibration arm length, as measured from the pivot point of the absorber.
5. If the calibration is correct, no change is needed. Proceed with other calibration procedures. If the displayed torque is not
correct, repeat steps 1-4.
6. Enter the calibration torque value and click on the Adjust Gainbutton.
NOTE: The Adjust Gain function will only become active when a number is entered in the box, and torque is applied to the
dyno.
7. Remove weights and calibration arm.
8. Zero the torque again
Pressures: To calibrate pressures:

WARNING: An abrupt change in pressure may result in damage to the sensor being calibrated. Make certain that the
regulated air supply is set to zero before introducing pressure at a slow pace. When finished calibrating, slowly bleed
off the air supply before removing from the sensor being tested.
1. Make sure there is no pressure source connected to the sensor.

2. Connect a regulated air supply set to 0 psi.
3. Zero the pressure by clicking on the Zero Offset button.
4. Slowly adjust the pressure regulator to a known pressure range near the
sensors rating.
5. Enter the known pressure value into the text box for the corresponding
sensor and click on the Adjust Gain button.
6. Slowly bleed off the air supply.
7. Disconnect the pressure source.
Regulator Assembly
for Calibrating Pressures
32
The View Menu - (continued)
View > Settings: Displays the currently active Interface settings
(shown below). The throttle adjustment is made from this location.
The Relays Menu

Relays Menu: From the Relays menu, the user can manually turn
on/off any relays connected to the system. By default, the first three
relays connected to the system display as buttons at the bottom of
the Controller Interface window (shown below). Clicking on any of
these buttons turn the relays on/off.
33
34
Pattern Runner
PowerNet TD
- CHAPTER 5 -
Pattern Runner
35
Pattern Runner
36
Pattern Runner
The Pattern Runner Interface Window
The Pattern Runner program allows the user to create, load, save and execute PowerNet Patterns. Patterns are pre-
configured load and speed set-points that are designed to automatically run in order. Each of these set-points is represents an
action executed by the Controller Interface. Once a Pattern has been created, that Pattern is used to run individual commands
of the Controller Interface.
NOTE: A thorough understanding of the dynamometer load and throttle controls, modes of operation, and effects on the engine
are required before creating new Patterns. When creating new Patterns, it is recommended to insert many small steps between
changes in RPM and load. It is also recommended that the time interval (Point Duration) is set long is set long enough to allow
for each step to stabilize before advancing to the next.
Example of a PowerNet LT Test Pattern
Each row represents one point in the Pattern. Each row is divided into as many as five columns.
The first column represents the Point, or step of the pattern. ex. 1), 3), etc....
The second column, Th:, represents the Throttle position during the test. The throttle value can be set by either the percentage
of the throttle that is desired (%), or by a set speed (RPM).
The third column, V:, represents position of the load control valve. There are four settings for determining the valve position:
Valve position, Torque, Power, and Speed.
Note: The units for each of these settings are selected from the Sensor properties menu of the Main Display. To access a
Sensor’s properties, right click on the sensor and select the appropriate unit from the Units tab.
The fourth column, Wait, represents the Duration, or the elapsed time during each step of the pattern.
Column five indicates whether or not data will be recorded, including activation of the AutoGrab feature.
Pattern Runner Window Pull-Down Menus

The Pattern Runner Window consists of two pull down menus, the File menu and the Edit menu.
The File Menu

File Menu: There are four options within the File Menu, New, Open, Save, and
Save As.
File > New: Clears the current Pattern to allow the user to create a new Pattern,
as explained on page 43.
37
Pattern Runner
The File Menu (continued)
File > Open: Allows the operator to open an existing PowerNet Pattern.
File > Save: Overwrites the active PowerNet Pattern with a file having the same
name.
Note: Use caution when using the Save function. Once changes have been saved
and the original file has been overwritten, the original file can not be retrieved.
File > Save As: Saves a copy of the current PowerNet Pattern as a new Pattern.
The user will be prompted to name the new file before saving.
The Edit Menu

Edit Menu: There is one option available for the Edit menu, Edit Full Pattern.
Edit > Edit Full Pattern: This allows the operator to edit the active Pattern.
Selecting Edit > Edit Full Pattern brings up the Edit Pattern Window as
shown right.
38
Pattern Runner
Creating a New Pattern
A new PowerNet Pattern can either be created from new or by modifying an existing Pattern and saving it as a new file name. To
create a new Pattern from the beginning, click on New under the Pattern Runner’s File pull-down menu. To modify an existing
Pattern, select open from the file pull-down menu and open the Pattern to be modified. In either case, the Pattern must be
edited. (See Edit > Edit Full Pattern on page 42).
There are two options for controlling the engine operating speed: Throttle (%), and Speed (RPM). By using different variations
of load control methods (Valve (%), Torque (ft-lbs), Power (Hp), or Speed (RPM)) in combination with these settings, the
operator can run a variety of tests. For more information about control modes, see Chapter 4, The Controller Interface.
Displays the current point of

the pattern
Indicates the Throttle mode Displays the throttle set

during the selected point point
Indicates the Valve mode

Displays the Valve set point
during the selected point
Indicates the duration (in

seconds) of the selected Displays the selections of
point the AutoGrab feature and
Grabs data at the end of the indicates the frequency
selected point if checked rate at which data is
grabbed.
Selects the previous point in Confirms selections and

the pattern for editing saves point(s) to the cur-
Selects the next point in the Adds another point to the Deletes the current point rent pattern
pattern for editing pattern after the current point
The example at right uses the throttle Speed Mode for

points 1-11 and point 15, and the throttle Percentage Mode
for points 12-14. In addition, the dyno Valve Percentage
Mode is used for points 1-3 and 14-15, the Valve Torque
mode is used for points 4-11, and the dyno speed mode
is used for points 12-13.
The data entered for Current Point 5, as shown above, is

displayed as step five in the pattern runner example at
right.
Saving a PowerNet Pattern

When finished editing the Pattern, it will be saved with the active DataSpace or Template. The Pattern can also be saved as its
own file by selecting Save As from Pattern Runner’s File pull-down menu.
Running a PowerNet Pattern

When all of the Pattern Points have been edited and saved, the Pattern is now ready to run. To run a Pattern, click on the Play
tab. This will display the time remaining for the current Pattern Point. Clicking the Pause tab pauses the current Pattern and
changes the function of the Play tab to Stop. To resume the Pattern, click the Pause tab again. To stop the Pattern, click on
the Stop tab. The <<Previous and Next>> tabs are used to navigate to different points in the Pattern.
39
Pattern Runner
40
Report Generator
PowerNet TD
- CHAPTER 6 -
Report Generator
41
Report Generator
42
Report Generator
The Report Generator Program
A copy of the data recorded during a dynamometer test should be saved following each test session. The Report Generator
allows the operator to arrange the data into a meaningful visual format. Customer, engine, and set up information can be put into
User Tables and Paragraphs. The information gathered during a test can then be arranged in a Data Table, Spreadsheet,
and/or Graph. Report formats can be created and edited before or after a DataSpace has been created.
Report Generator Window
There are two types of information tables, a User Table and a Data Table. A User Table provides blanks for the operator to
enter specific information about the test being performed. This can include, but is not limited to: Customer Information, Engine
Information, Test Specific Information, etc. A Data Table contains information gathered from the attached sensors during a
test, and displays only that information that is specified for that particular Data Table, such as maximum and minimum values.
The data gathered during a test can also be arranged in a Spreadsheet and/or Graph. A Spreadsheet is a computer
generated arrangement of the test data into rows and columns. A Graph is a drawing representing the relationship between two
sets of data. One set, such as gathered information, is represented on a vertical scale or axis, the other, such as time or other
data, is represented on a horizontal scale or axis.
In addition to tables, graphs, and spreadsheets, information can also be entered into a Paragraph. A Paragraph is typically
used to enter notes, disclaimers, descriptions, etc. relating to a specific test or stage of testing.
Report Generator Window Pull-Down Menus

The Report Generator Window consists of the File, Edit, View, Import, Export, and Ignore List menus.
The File Menu

File Menu: The File Menu allows the user to access the Reporter print
features. The menu consists of Print Preview, Print, and Print Screen.
File > Print Preview: This selection allows the user to view the printed
report on screen. Once selected, a report preview appears (below right).
From the preview, the user can print a hard copy of the report by clicking
on Print in the upper left-hand corner.
The operator may print out reports that can be configured to display your
company’s logo and contact information. Contact your Power Test repre-
sentative for assistance in creating a custom header.
43
Report Generator
File > Print: Displays a preview of the report and opens up the print
properties screen.
File > Print Screen: Sends a snapshot of the entire Commander screen
to the printer. It makes no difference which interface windows are open,
some may be minimized. It simply takes a screen capture of whatever is
on the screen at the time.
The Edit Menu

Edit Menu: The Edit Menu consists of one selection, Edit Report.
*Edit > Edit Report: This function allows the administrator to modify the
active data report.
* Note: Without logging in, many menu items will be grayed out and the
corresponding administrative functions can not be performed. All func-
tions requiring login will be noted with an * throughout the rest of this
chapter.
Click on Edit Report and a new window will appear. The Edit Report
window (shown right) allows the user to configure the printed reports and
the entry fields of User Tables, Data Tables, Graphs, Spreadsheets and
Paragraphs.
44
Report Generator
Using the Edit Report Window
From the Edit Report Window, the user can move, add, delete, copy and edit sections. The information displayed on the
report will display as it appears in the list. Clicking on a section highlights that section, and enables the function buttons on the
left side of the window.
Report Sections
Move Section Up
Move Section Down
Delete Section
Add Section
Copy Section
Edit Section
Edit Report Window

Edit Report Function Buttons
Move Section Up: Clicking this button will move the highlighted section up, changing the order in which information appears on
the final report.
Move Section Down: Clicking this button will move the highlighted section down, changing the order in which information
appears on the final report.
Delete Section: Clicking this button will delete the highlighted section.
Add Section: Clicking this button will bring up the Add Section window (above left), allowing the user the option of adding one
of five section types: User Table, Data Table, Graph/Spreadsheet, Paragraph, and Page Break, all of which are explained
throughout this chapter.
Copy Section: Clicking this button makes a copy of the highlighted section and all of its properties. This is useful for creating
a similar section without having to create it from new.
Edit Section: Clicking this button allows the user to edit the particular section of the report that is highlighted. Additionally, the
edit report window can also be accessed by double clicking on any highlighted section.
Creating and Editing Report Section Types

Details for creating and editing User Tables, Data Tables, Graphs, Spreadsheets and Paragraphs are explained in detail on
the following pages.
45
Report Generator
Creating a New User Table
To create a new User Table, select User Table from the list of section types under the Add Section (+) function of the main
Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new User Table
to edit the new User Table.
Table Name
Field Name
Number of Columns Assigned to the Table
Report Fields
Navigational Buttons
Begin by assigning a name to the new User Table by entering a name in the Table Name text box. This will name the new
User Table. To change the name of a Report Field, click on the field name in the Report Field box. Entering a name in the
Field Name text box will change the name of the Report Field.
To add a Report Field, click on the Add Section (+) button. Report Fields can be also be moved up/down and deleted from the
User Table using the navigational buttons. The navigational buttons perform the same function as previously described in
Using The Edit Report Window section, found on page 49.
The user also has the option to choose how many columns are assigned to the table.
Note: It is recommended to keep the number of columns in a User Table a multiple of the number of fields. i.e. 3 fields - 1 or
3 columns; 4 fields - 1,2 or 4 columns. This will help to ensure that the data is presented in an organized manner.
46
Report Generator
Editing User Tables
To edit a User Table, highlight the desired table, and either click on the Edit Section button, or double click on the highlighted
selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the same function as
previously described in Using The Edit Report Window section, found on page 49.
To change the name of the User Table, highlight

the current name in the Table Name text box and
either press the delete key, or overwrite the cur-
rent name with the new name.
To change the name of a Report Field, click on

the field name in the Report Field box. Next,
either press the delete key, or overwrite the cur-
rent name with the new name.
To add a new Report Field to the User Table, click

on the Add Section (+) button. Report Fields can
be also be moved up/down and deleted from the
User Table using the navigational buttons.
Note: A User Table is limited to 12 Report Fields.
The user also has the option to choose how many

columns are assigned to the table.
Note: It is recommended to keep the number of

columns in a User Table a multiple of the number
of fields. i.e. 3 fields - 1 or 3 columns; 4 fields -
1,2 or 4 columns. This will help to ensure that the
data is presented in an organized manner.
Sample User Table
Examples of User Tables - As Printed (left) and On Screen (right)
47
Report Generator
Creating a New Data Table
To create a new Data Table, select Data Table from the list of section types under the Add Section (+) function of the main
Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Data Table
to edit the table.
Table Name
Number of Columns Assigned to Table
Function
Available Sensors
Reference Sensor
Add Sensors to the Data Table Sensors List
Available Phases
Data Table Sensors
Navigational Buttons
Remove Sensors from the list of Sensors
*Plot Individual Phases
*Requires Advanced Pattern Runner
Assign a name to the new Data Table by entering a name in the Table Name text box. This will name the new Data Table.
Report data is gathered from the sensors displayed in the Available Sensors list. This list displays all of the sensors
connected to the system at the time of the report’s creation (available sensors may vary depending on version of software). The
Data Table Sensors list displays all of the sensors whose data will be displayed on the final report. To add a sensor to the Data
Table Sensors list, first click on a sensor from the Available Sensors list. The Available Sensors list displays all of the
sensors currently connected to the system. Next, select a function to be performed on the sensor from the Function list
(explained on the following page). Then click the Add button to add the selected sensor and function to be performed to the list
of Data Table Sensors. To change the order in which the Data Table Sensor information appears on the printed report,
highlight a sensor in the list, and click on the Navigational Buttons to the left of the Data Table Sensors list.
The user also has the option to choose how many columns are assigned to the table.
Note: It is recommended to keep the number of columns in a User Table a multiple of the number of fields. i.e. 3 fields - 1 or
3 columns; 4 fields - 1,2 or 4 columns. This will help to ensure that the data is presented in an organized manner.
Reference Sensors
Selecting the Reference Sensor function will display a particular sensor values and it’s correlation to another sensor’s greater
or lower value. i.e. Speed at Peak Torque.
To display Reference Sensor data in the final report, choose a Reference Sensor from the drop-down menu. The list of sensors
available as Reference Sensors is the same as the list of sensors available in the Available Sensors list. When the desired
reference sensor has been selected, click on Hi Ref to display the peak value, or Lo Ref to display the low value.
48
Report Generator
Editing Data Tables
To edit a Data Table, highlight the desired table, and either click on the Edit Highlighted Section button, or double click on the
highlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the same
function as previously described in Using The Edit Report Window section, found on page 49.
To add a sensor to the Data Table Sensors list,

first click on a sensor from the Available Sen-
sors list. Next, select a function to be performed
on the sensor from the Function list (explained
below). Then click the Add button to add the
selected sensor and function to be performed to
the list of Data Table Sensors. To change the
order in which the Data Table Sensor informa-
tion appears on the printed report, highlight a sen-
sor in the list, and click on the Navigational But-
tons to the left of the Data Table Sensors list.
Phases (Optional)
A Phase represents a segment of the data gath-
ered during a test. The Phases section displays
the list of stored phases from the current
DataSpace. Selecting a phase will include it in
the generated report. If the Individual Phases
box is left unchecked, all function values for the
included Data Table Sensors will be calculated
by grouping data from the selected phases. If the
Individual Phases box is checked, the function
values will be calculated on a per phase basis.
i.e. If there were six phases selected, and three
sensors in the Data Table Sensors list, the report
would yield a total of 18 values. Sample Data Table
The Function List

The Function List defines which data points will be displayed in the Data Table.
First: This will display the first value of the sensor selected. If “Individual Phases” is also selected, it will display the first
value of the sensor selected for each selected phase.
Last: This will display the last value of the sensor selected. If “Individual Phases” is also selected, it will display the last
value of the sensor selected for each selected phase.
Delta: This will display the difference between the first and last value of the sensor selected. If “Individual Phases” is
also selected, it will display the difference between the first and last value of the sensor selected for each selected
phase.
Average: This will display the average value of the sensor selected. If “Individual Phases” is also selected, it will
display the average value of the sensor selected for each selected phase.
Peak: This will display the largest value of the sensor selected. If “Individual Phases” is also selected, it will display the
largest value of the sensor selected for each selected phase.
Low: This will display the lowest value of the sensor selected. If “Individual Phases” is also selected, it will display the
lowest value of the sensor selected for each selected phase.
49
Report Generator
Creating a New Graph
To create a new Graph, select Graph/Spreadsheet from the list of section types under the Add Section (+) function of the
main Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Graph
to edit the graph.
Graph Name
Section Type (Graph/Spreadsheet)
X-Axis
Available Sensors
Use Reference Data
Hide Symbols
Plot Individual Phases
Available Phases
Y2
Included Sensors
Size (Height/Width)
Copy to Graph View
Begin by selecting Graph under Section Type. Next, create a name for the new Graph by entering a name in the Heading
text box.
Choose which sensors to display on the X Axis and Y Axis of the Graph. The X Axis menu contains the sensors available for
display on the X (horizontal) axis of the Graph. The graph can only display 1 (one) sensor on the X axis per graph. Select a
sensor from the X Axis pull-down menu. Clicking on the Hide Symbols box will create lines on the graph without showing a
symbol at the individual points. If the Plot Individual Phases box is left unchecked, the graph will show each Included
Sensor as a continuous line throughout all of the phases selected. If the Plot Individual Phases box is checked, each
Included Sensor will be graphed with multiple lines corresponding to each phase selected.
A Phase represents a segment of the data gathered during a test. The Phases section displays the list of stored phases
from the current DataSpace. Selecting a phase will include the selected phase in the generated report.
Note: Phases are only available with the Advanced Pattern Runner software.
The Available Sensors list displays the sensors available for display on the Y (vertical) Axis. The sensor displayed on the Y
Axis is displayed on the left side of the graph. To add a sensor to the Included Sensors list, click on a sensor from the
Available Sensors list, then click on the Add button. To remove a sensor from the Included Sensors list, click on the sensor
to be removed, and click the Remove button.
Clicking the Use Reference Data check box will plot Reference Data on the Graph in addition to the data being recorded
during the test. Reference Data is data that is typically used for monitoring and comparing the results of the test. Instructions
for creating and loading Reference Data can be found in Chapter 3, Main Display and is further discussed in Chapter 7, Add-
In Programs.
The Y2 feature allows the user to display a second sensor’s data on the Y2 (vertical, right) axis of the Graph. To assign a sensor
to the Y2 Axis, click on that sensor in the Included Sensors box, then check the Y2 box.
The user has the option of setting the Height and Width of the Graph, determining the size of the Graph on the generated report.
50
Report Generator
Editing Graphs
To edit a Graph, highlight the desired graph, and either click on the Edit Highlighted Section button, or double click on the
highlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons perform the same
function as previously described in Using The Edit Report Window section, found on page 49.
If a Graph is selected the user has the ability to

decide which sensors they wish to display on the
X Axis and Y Axis of the Graph. The X Axis
menu contains the sensors available for display
on the X (horizontal) axis of the Graph. The graph
can only display 1 (one) sensor on the X axis per
graph. Clicking on the Hide Symbols box will
create lines on the graph without showing a sym-
bol at the individual points. If the Plot Individual
Phases box is left unchecked, the graph will show
each Included Sensor as a continuous line
throughout all of the phases selected. If the Plot
Individual Phases box is checked, each In-
cluded Sensor will be graphed with multiple lines
corresponding to each phase selected.
The Available Sensors list displays the sensors

available for display on the Y (vertical) Axis. To
add a sensor to the Included Sensors list, click
on a sensor from the Available Sensors list, then
click on the Add button. To remove a sensor from
the Included Sensors list, click on the sensor to
be removed, and click the Remove button.
Sample Graph
Clicking on the Copy To Graph View tab takes the data created from the report and displays it in a new window. The New
Graph View will have all of the same properties of the graph it was created from. A Graph View displays recorded data from a
test and is refreshed every time a data point is recorded. This is different from the real-time chart, which displays data
regardless if data points are recorded or not.
Note: Clicking Copy To Graph View opens a Graph in a new window. Any changes made to the New Graph View will not be
saved as part of the report. Consequently, any changes made to the Graph from the Edit Graph window will not appear on the
New Graph View unless the Copy To Graph View tab is clicked again, opening a New Graph View in a new window.
All functions and properties of the graph created by clicking the Copy To Graph View button are the same as those for a New
Graph View, as described on page 60.
51
Report Generator
Creating a New Spreadsheet
To create a new Spreadsheet, select Graph/Spreadsheet from the list of section types under the Add Section (+) function
of the main Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new
Spreadsheet to edit the spreadsheet.
Spreadsheet Name
Section Type (Graph/Spreadsheet)

Enable Grouping
Available Sensors
Key Sensor
Group By Sensor
*Group By Phase
*Available Phases
Included Sensors
Remove from the List of Sensors
Begin by selecting Spreadsheet under Section Type. Next, create a name for the new Spreadsheet by entering a name in
the Heading text box.
The Available Sensors list displays the sensors available for display on the Spreadsheet. To add a sensor to the Included
Sensors list, click on a sensor from the Available Sensors list, then click on the Add button. To remove a sensor from the
Included Sensors list, click on the sensor to be removed, and click the Remove button.
If a Spreadsheet is selected from the Section Type, the user has the option of clicking on the Enable Grouping check box. If
the Enable Grouping check box is not selected, the Included Sensors will display as a continuous column throughout the
whole Spreadsheet. If the Enable Grouping check box is selected, the user will have option to the select a Key Sensor (the
sensor that data is matched to, typically speed), and whether the data will be grouped by Sensor or Phase in the final report.
By selecting Sensor, the data is paired by sensors and displayed under each phase. By selecting Phase, the data is grouped
by phase under each sensor.
52
Report Generator
Editing Spreadsheets
To edit a Spreadsheet, highlight the desired spreadsheet, and either click on the Edit Highlighted Section button, or double
click on the highlighted selection itself. The Edit Report window (shown below) will appear. The navigational buttons
perform the same function as previously described in Using The Edit Report Window section, found on page 49.
The Available Sensors list displays the sensors

available for display on the Spreadsheet. To add
a sensor to the Included Sensors list, click on a
sensor from the Available Sensors list, then click
on the Add button. To remove a sensor from the
Included Sensors list, click on the sensor to be
removed, and click the Remove button.
If a Spreadsheet is selected from the Section

Type, the user has the option of clicking on the
Enable Grouping check box. If the Enable Group-
ing check box is not selected, the Included Sen-
sors will display as a continuous column through-
out the whole Spreadsheet. If the Enable Group-
ing check box is selected, the user will have op-
tion to the select a Key Sensor (the sensor that
data is matched to, typically speed), and whether
the data will be grouped by Sensor or Phase in
the final report. By selecting Sensor, the data is
paired by sensors and displayed under each
phase. By selecting Phase, the data is grouped
by phase under each sensor.
Example of a Spreadsheet (Grouped by Sensor)
Example of a Spreadsheet (Grouped by Phase)
53
Report Generator
Creating a New Paragraph
To create a new Paragraph, select Paragraph from the list of section types under the Add Section (+) function of the main
Edit Report Window. Click on the Edit Section button on the main Edit Report Window or double click on the new Paragraph
to edit the Paragraph.
Paragraph Name
Text Input Box
Browse for Text File
Make Paragraph Importable
Assign a name to the new Paragraph by entering the name in the first box. This will name the new Paragraph. To create a
new Paragraph, click anywhere in the Text Input Box and enter the information you wish to appear on the report.
Clicking the Browse for text file opens a window (shown below) which displays available text files. Opening the .txt file will
import the text into the box.
Selecting the Importable option displays the paragraph input box on the main form of the Report Generator, as explained on
page 58. From this window, the user can import text without having to go into the edit feature.
54
Report Generator
Editing Paragraphs
To edit a Paragraph, highlight the desired table, and either click on the Edit Highlighted Section button, or double click on
the highlighted selection itself. The following Edit Report window (shown below) will appear.
The name of the paragraph can be changed by

entering a new name into the Paragraph Name
test box. The paragraph text can be entered into
the Text Input Box.
Clicking the Browse for text file opens a win-

dow which displays available text files. Opening
the .txt file will import the text into the box.
Selecting the Importable option displays the

paragraph input box on the main form of the Re-
port Generator, as explained on page 62. From
this window, the user can import text without hav-
ing to go into the edit feature.
55
Report Generator
The View Menu
The View Menu: The View menu item lists only one option - New Graph View.
View > New Graph View: Automatically creates a new Live Graph and
opens the Properties window of that graph (described below). In addition,
right-clicking the New Graph View will display the Options window.
New Graph View

New Graph View displays recorded data from a test and is refreshed every time a data point is recorded. This is different from
the real-time chart, which displays data regardless if data points are recorded or not.
Example of a New Graph View New Graph View Options
New Graph View Properties

The Properties window opens automatically when a new graph is created. In addition, right-clicking the New Graph View will
display the Properties window. The users has the following options for modifying the New Graph View.
Print: Prints the current New Graph View

Symbols: Displays the symbols indicating each point where data has been recorded.
Legend & Title: Displays the Legend (displayed at the bottom of the graph) and the Title (displayed at the top) of the graph.
Grid Lines: Displays the grid lines of the New Graph View.
Undo All Changes: Resets any changes made using the Zoom, Move and Scale functions.
Zoom: Allows the user to zoom-in on a specific point on the graph while retaining the X axis and Y axis.
Move: Allows the New Graph View to be repositioned within the window.
Scale: Allows the New Graph View to be re-sized, enlarging and reducing the actual size of the graph.
Properties: Opens the Properties window.
56
Report Generator
Creating a New Graph View
To create a New Graph View, select New Graph View from the View Menu in the Report Generator. This will automatically
open the Properties window for the New Graph. Begin by creating a name for the New Graph View by entering a name in the
Graph Name text box.
Graph Name
X-Axis
Use Reference Data
Plot Individual Phases
Available Sensors
Add Sensor to the List of Included Sensors
Y2
Included Sensors
*Phases
Remove Sensors from the List of Included Sensors
Choose which sensors to display on the X Axis and Y Axis of the New Graph. The X Axis menu contains the sensors
available for display on the X (horizontal) axis of the New Graph. The graph can only display 1 (one) sensor on the X axis per
graph. The Available Sensors list displays the sensors available for display on the Y (vertical) axis. The sensor displayed on
the Y Axis is displayed on the left side of the graph. To add an additional sensor to the list of Included Sensors, click on a sensor
from the Available Sensors list, then click on the Add button. The Y2 feature allows the user to display a sensor’s data on the
Y2 (vertical, right) axis of the New Graph. To assign a sensor to the Y2 Axis, click on that sensor in the Included Sensors box,
then check the Y2 box.
Below the X Axis pull down menu are two options: Use Reference Data and Plot Individual Phases. Clicking the Use
Reference Data check box will plot Reference Data on the Graph in addition to the data being recorded during the test.
Reference Data is data that is typically used for monitoring and comparing the results of the test. Instructions for creating and
loading Reference Data can be found in Chapter 3, Main Display and further discussed in Chapter 7, Add-In Programs. If the
Plot Individual Phases box is left unchecked, the graph will show each Included Sensor as a continuous line throughout all
of the phases selected. If the Plot Individual Phases box is checked, each Included Sensor will be graphed with multiple
lines corresponding to each phase selected.
Editing a New Graph View

To change the name of the New Graph, enter the new name in the Graph Name text box. Choose which sensors to display on
the X Axis and Y Axis of the New Graph. To add an additional sensor to the list of Included Sensors, click on a sensor from
the Available Sensors list, then click on the Add button. The Y2 feature allows the user to display a sensor’s data on the Y2
(vertical, right) axis of the New Graph. To assign a sensor to the Y2 Axis, click on that sensor in the Included Sensors box,
then check the Y2 box.
Clicking the Use Reference Data check box will plot Reference Data on the Graph in addition to the data being recorded
during the test. If the Plot Individual Phases box is left unchecked, the graph will show each Included Sensor as a
continuous line throughout all of the phases selected. If the Plot Individual Phases box is checked, each Included Sensor
will be graphed with multiple lines corresponding to each phase selected.
57
Report Generator
The Import Menu
Import Menu: The Import Menu contains one option, Text File.
Import > Text File: If a Paragraph has been made importable (as
introduced on page 59), this menu item will become active and the
name of the paragraph will be listed in this menu. If there is text within
the saved paragraph, a check mark will appear next to its name. If no
importable paragraphs are available, the tab will display the text “No
Importable Paragraphs”.
The Export Menu

Export Menu: There are three options available for the Export Menu: As .chm file, Excel and Text File. By selecting those
options, the user can export the report to the desired file type.
Export > As .chm file: This menu item gives the user the option to export
a report as a .chm file. A .chm file is a compressed html page. This type
of file normally used by Microsoft to create help files is perfect for creating
small files easily e-mailed. By compressing the html page, not only is the
file size made significantly smaller, it also includes all of the support files.
To create a .chm file simply click on the menu item and choose a file name.
The Reporter program will then recreate the html page, compress it and
save it to the location specified. A .chm file may be requested by your
Power Test representative when providing technical assistance.
Export > Excel: This allows the user to

export data directly into Microsoft Ex-
cel. The administrator must choose
which Excel template will be available
to the operator to export the data into.
All available Excel templates (.xlt files)
will be listed under the arrow of the “Se-
lect Template” menu.
Note: All available templates must have
a sheet labeled “Data”.
Export > Text File: This allows the operator to export all the data from a
DataSpace to a tab delimited text file (.txt). By exporting data to this type
of file, the data may be imported into virtually any spreadsheet program.
Simply click on the “Text File...” menu item, select a file name and click
on “Save”. The default path is C:\Program\PowerNet\Commander 2.0.
The Ignore List

*Ignore List: The Ignore List lists all of the phases in the DataSpace. If
a phase is added to the Ignore List, the data from that particular phase
will not be displayed in the entire report. To eliminate (but not delete) any
particular phase from the entire report, simply check the phase name
under this menu item.
*Requires Advanced Pattern Runner software.
58
Add-in Programs
PowerNet TD
- CHAPTER 7 -
Add-in Programs
59
Add-in Programs
60
Add-in Programs
The Add-In Programs
In this chapter, some add-in programs will be introduced. For some systems, Security Editor and ECM Communicator are
standard components. All other add-in programs are optional, such as the Smoke Check Transfer program, Fuel Controller
and Gas Analyzer. All existing add-in programs are listed in the Add-Ins menu in the Main Display Window.
NOTE: The following are some examples of add-in options available for Power Test data acquisition systems. For instructions
and specifications for specified equipment, please consult the information provided with the option.
Security Editor
Security Editor: The Security Editor is an administrative tool used to assign rights to operators.
To access the Security Editor program, the user must have full administra-
tive rights. The administrator has to log in, even if they have logged in to the
program.
Edit Users: The administrator can add, delete, or edit user

names, passwords, and security levels. To add a new user,
click Add, and a New User will be added to the list of current
users. To delete a user, highlight the user name and click
Delete.
NOTE: If there is only one user with full administrative rights in

the list, the program will not allow you to delete their security
level. If an attempt is made to do so, the following warning will
appear (shown below).
To edit a user’s security levels, highlight the user whose levels you want to edit and click Proper-
ties. The Edit Security Levels window (shown right) will appear, in which the user’s name, pass-
word and security can be assigned. Edit the user name and password and check the appropriate
boxes to grant those individual security rights to the user. When finished editing, click OK to keep
the changes or Cancel to ignore them
NOTE: If there is only one user with full administrative rights in the list, the program will not allow
you to edit their security level. If an attempt is made to do so, the following warning will appear
(shown below).
61
Add-in Programs
ECM Communicator (if included)
ECM Communicator: This program is designed to communicate with the engine’s ECM system using the SAE 1708 or SAE
1939 protocol. The program has four pull-down menus: File, Edit, View and Protocol.
The File Menu

File Menu: The File Menu allows the user to open or save an ECM communication file. The menu consists of Open, Save
and Save As.
File > Open: opens a previously saved ECM communication sensor list
file
File > Save: Overwrites the current ECM communication sensor list as a
file having the same name.
File > Save As: Saves a copy of the current ECM communication sensor
list as a new file. The user will be prompted to name the new file before
saving.
62
Add-in Programs
ECM Communicator (continued)
The Edit Menu
Edit Menu: The Edit Menu consists of the following options : Add Sensors, ECM Connections, and Local MID.
Edit > Add Sensors: Adds sensors from the ECM to the data acquisition
system. To add a sensor to the system, click the Add Sensors menu
item. The Add Sensor window will appear. The left drop-down box con-
tains the possible modules connecting to the communication bus to the
system. If you are connecting to the engine module, choose “128: Engine
#1”. The right drop-down box contains a list of parameters or sensors.
Choose the sensor you wish to monitor through the data acquisition sys-
tem and click the Apply button. Continue this process to add all desired
sensors, and click OK to make the additions permanent.
Edit > ECM Connections: When the ECM Connection is selected, the
Connections window will appear. If the ECM Communicator is connected
through an ethernet connection, use 123.123.123.129:10004 as the ECM
Address. If connected to a serial port, enter the serial port number. If an
ECM communicator is not connected, click on the Reset Connection
button to disconnect and reconnect to the ECM. Status lines below the
ECM Address input box will indicate the current state of the ECM Con-
nection.
Edit > Local MID: In order for the ECM Communicator to enter into the
ECM communication bus, the Local MID must be 180.
63
Add-in Programs
ECM Communicator (continued)
The View Menu
View Menu: There are three options under the View menu. The menu consists of the Summary, All Info, and Show
Reserved PID Fault Codes menus.
View > Summary: If Summary is selected, only the sensors added to

the system will be displayed in the communicator.
View > All Info: If All Info is selected, all sensors (or parameters) being
read by the ECM will be displayed.
View > Show Reserved PID Fault Codes: Fault codes can also be
displayed if Show Reserved PID Fault Codes is checked. (PID 194
under MID 128 must be added to display fault codes.
The Protocol Menu

Protocol: Allows the operator to choose the proper communication proto-
col for the system. Available protocols are: 1708, 1708 Intelligent and
1939. When communicating in SAE 1708 protocol, either 1708 or 1708
Intelligent will work. 1708 intelligent uses additional hardware to speed up
and simplify communication between the ECM and computer. If the con-
nection is lost while changing from one protocol to another, it maybe nec-
essary to cycle the power on Controller Box.
64
Add-in Programs
Gas Analyzer (if included):
This program is designed to communicate with the Gas Analyzer.
Once this program is started, the system will begin to communicate
with the Gas Analyzer and show the real time gas analysis result
(shown right).
65
Add-in Programs
Calculated Sensors
Calculated Sensors: This program has the ability to take two sensors or typed values and add, subtract, multiply, divide or
power the two values. The user must choose a sensor type, determining what type of units to use on the new calculated sensor.
When a Calculated Sensor is created, it is permanently added to the list of available sensors.
A user must be logged in to access the Calculated Sensors program. To begin calculating sensors, click View > Edit.
Clicking the Add Sensor button will allow the user to configure the sensors. By selecting the Sensor Input or Typed Input,
either a sensor value or a literal value can be used in the calculation. Select the calculation function by clicking on the various
option buttons in the Operator section. Clicking the Add Sensor button saves the new Calculated Sensor.
To add additional sensors, click on the Add Sensor button. The name of the new sensor is assigned ex. CALC0, CALC1, etc.
The name of the sensor, as well as its variables and calculations used to determine the value of the calculated sensor can be
edited from the Sensor Properties function in the Main Display. Additionally, a custom unit can be assigned to a Calculated
Sensor from the Sensor Properties function in the Main Display. Any custom unit can be assigned by choosing the Custom
option button on the Units tab. If the Sensor name has been changed, it will not be renamed until the DataSpace has been
reopened.
If more than one sensor is added, the Previous and Next buttons allow navigation from one Calculated Sensor to the next.
If two like sensors are selected and either add or subtract is selected as an operator, all calculations are performed on the base
unit. ex. if two volume flow sensors are added or subtracted, the units selected for each individual sensor would have no effect
on the outcome of the calculated sensor. If the two like sensors are divided, a ratio will be assigned.
Example: 20 degrees C = 68 degrees F

Subtracting two sensors with a value of 20 degrees C would be 68 - 68 = 0 0 Degrees F = -18 Degrees C
If the program has determined that it will use a generic sensor type, all operations are performed based on the displayed value.
For instance, if 10 is added to a temperature sensor with units of degrees F displaying 68 degrees, the calculated sensor would
read 78. Changing the temperature sensors units to degrees C would change the value of the display to 20. The added 10 would
still have the same effect, causing the calculated sensor to read 30.
Note: There is no way to remove a sensor. Sensors can only be added. If a calculated sensor is no longer needed, a new
template must be created from an existing template not containing the calculated sensor.
66
Add-in Programs
Fuel Controller (if included)
Fuel Controller: This program is designed to communicate with PTI fuel system. When the fuel system is operating, the
following data can be measured and shown in the Main Display as sensors:
Volume Burn Rate Volume Burn Rate is defined as the total volume of fuel being burned by the engine during testing.
The default unit is measured in gallons/hour.
Mass Burn Rate Mass Burn Rate is defined as the total weight of fuel being burned by the engine during testing.
The default unit is measured in pounds/hour.
Fuel Density Fuel Density is defined as the total density of fuel being used by the engine during the test.
The default unit is measured in pounds/gallon.
Total Volume Total Volume is defined as the total volume of fuel being used by the engine during the entire test run.
The default unit is measured in cubic gallons.
Fuel API Fuel API is a standard method established by the American Petroleum Institute to measure fuel
quality.
The default unit is a standard number measured in API degrees.
BSFC BSFC is defined as Brake Specific Fuel Consumption. This number represents the overall efficiency of
the engine at the time of the test. The unit is measured in Pounds/Horsepower Hour.
DPV Distance Per Volume is the distance that the vehicle travels on the chassis dynamometer “virtual
road” and is measured in miles/gallon. (Chassis dynos only)
Fuel Controller Interface Buttons

There are three buttons located on the Fuel Controller Interface window. They are as follows: Empty Fuel System - purges the
fuel in the system. Fill Fuel System -readies the system to run. Shut Down System - empties the fuel system, then shuts
down the power to the fuel system only.
The Setup Menu

Setup: The Fuel Controller program only has a Setup menu. The Setup Menu contains the following options: Power Sensor,
Speed Sensor, Average Rates, and Calibration Density.
Power Sensor: This allows the operator to select the source of

power for the fuel controller. If there is only one source of power,
there will be only one calculating BSFC selection in the menu.
67
Add-in Programs
Fuel Controller (continued)
The Setup Menu (continued)
Speed Sensor: This selection allows the operator to set the source
of the speed sensor. For use in calculating DPV.
Average Rates: This menu selection allows the operator to choose

the average time period that the sensors sample the readings for
mass and volume burn rate. The time periods are either none, 5, 10
or 30 seconds, and there is a custom option to allow the operator to
enter a custom time period.
Calibration Density: The calibrate density choice initiates the pro-

cedure for calibrating fuel density. The measurement is manually
entered. The operator indicates the temperature in degrees Fahren-
heit and the fuel specific gravity from a sample of the fuel to be used
in the testing.
68
Add-in Programs
Correction Factors (If included)
The Correction Factors option allows the user to ap-
ply SAE or custom corrections to torque and horse-
power readings, and creates a five new sensors: Cor-
rected Gross Torque, Corrected Gross Horse-
power, Corrected Net Torque, Corrected Net Horse-
power and the Correction Factor itself.
Note: Corrected Net Torque and Corrected Net Horse-

power are only used in some custom corrections, and
are normally not available.
The Configuration Menu: The Configuration

Menu contains the following options: SAE, Custom
Correction, Search for Custom Correction and
Rebuild All.
Configuration > SAE: Allows the user to select correction formulas as specified in SAE documents J607 and J1995/J1394.
SAE J607 is intended for spark ignition engines only. SAE J1995/J1394 allows for both spark and compression ignition
systems.
To apply the correction factor settings to a particular engine type, select the appropriate options from the sub-menus as
illustrated below.
Configuration > Custom Correction: Allows the user to select a Cor-

rection file containing a custom formula for determining Corrected Power
and Corrected Torque. These files can been created by your Power Test
representative to your administrator’s specifications.
69
Add-in Programs
Correction Factors (continued)
Configuration > Search for Custom Correction: Searches all remov-
able drives for any Custom Correction files.
Configuration > Rebuild All: Refreshes the sensor names in the Sen-
sor Input drop down lists.
NOTE: If changes are made in the Main Display to sensors names that
correspond to those listed in the Sensor Input drop down boxes, the user
must click on the Rebuild All menu item to reflect the changes made.
Correction Factor Inputs

After applying all necessary SAE correction settings, all Correction Factor formula inputs will be listed on the main form of the
Correction Factors program. The first button, Sensor Input, allows the user to select a sensor to obtain information needed for
the correction formula. The second button, Typed Input, allows the user to enter a fixed value and the unit of measurement
applied to the correction formula.
Sensor Input
Typed Input
NOTE: A simple method for configuring Correction Factors is to select J1995/J1394 - Spark Ignition, regardless of ignition type
(illustrated below). This configuration allows for atmospheric correction only, yet is an effective method of establishing correc-
tions for atmospheric corrections only.
70
Add-in Programs
Reference Data Builder
Reference Data is data that is typically used
for comparing the results of a test.
The Reference Data Builder creates a file

containing reference data that can be dis-
played in Charts, Report Graphs, and Graph
Views. Reference Data can be obtained from
an existing DataSpace, a tab delimited file
created in a spreadsheet program such as
Microsoft Excel, or manually entered by the
user.
The File Menu

The File Menu contains the following options: New, Open, Save, Save As, Import From DataSpace, Import Tab Delimited
File and Exit.
File > New: Clears the current Reference Data file to allow the user to create a
new Reference Data file.
File > Open: Prompts the user to open an existing Reference Data file.
File > Save: Overwrites the current Reference Data file as a file having the same
name.
71
Add-in Programs
Reference Data Builder (continued)
File > Save As: Saves a copy of the current Reference Data file as a new file. The
user will be prompted to name the new file before saving.
File > Import from DataSpace: This menu item allows the user to import Refer-
ence Data into the report from an existing DataSpace by opening the Choose
Traces and Phases window, as described on page 62.
File > Import Tab Delimited File: This menu item allows the user to import
Reference Data into the report from a program such as Excel.
File > Exit: Provides the user with the option to save their data (shown below),
and closes the Reference Data Builder program.
72
Add-in Programs
Reference Data Builder (continued)
Importing Reference Data from a DataSpace
To import data from an existing DataSpace,
click on File > Import from DataSpace. The
Choose Traces and Phases window (shown
right) will appear.
Select the Sensors and Phases to be included

in the Reference Data File. Assign a preface
to the sensor name ex. Ref. in the Trace Pref-
ace input box. When finished, click OK.
Traces
A Trace is a line on a graph representing a specific sensor’s values.
To add a trace to a Reference Data File, click on the Add Trace
button. This will open the Add Trace window (shown right). From the
Add Trace window, the user will be able to assign a name to the new
Trace, and select the Sensor type.
To edit an existing trace, highlight the Trace and click the Edit Trace
button. This will open the Edit Trace window (shown right). From the
Edit Trace window, the user can edit the Trace Name and Sensor
Type of the selected Trace.
To delete a Trace, highlight the Trace and click the Delete Trace
button.
Individual Data Points can be edited by manu-

ally entering values directly into the text box.
To add Data Points, the user can click on the
Insert Data Point at End button.
Clicking on the numeral to the left of the Data

Point will highlight that particular line and
change the button to Insert Data Point Be-
fore Selection.
NOTE: To load Reference Data into a DataSpace or Template, refer to the Data Menu section of Chapter Three, The Main
Display.
73
Add-in Programs
74
Glossary
PowerNet TD
- CHAPTER 8 -
Glossary of Terms
75
Glossary
Glossary of Terms
Absorber: The device that actually absorbs the power from the engine. Converts mechanical horsepower to thermal horse-
power.
Administrator: The person(s) in charge of creating and editing the PowerNet Data Templates. This person(s) has the highest
level of security access to the Commander Computer and may or may not be the person that is actually performing the tests
(operator).
API: See Fuel API.
BSCF (Brake Specific Fuel Consumption): Rate of fuel flow per measured horsepower.
Commander Computer: The desktop computer that is the “brains” behind the dynamometer. It establishes connections
between the chassis dynamometer controller, the vehicle’s ECM, and the optional fuel measurement system.
Controller Interface: See PowerNet Controller Interface
DataSpace: See PowerNet DataSpace
Data Template: See PowerNet Data Template.
ECM Communicator: See PowerNet ECM Communicator
Engine Speed Mode: A method of controlling the dynamometer in which either the operator or an automated PowerNet Pattern
enters an engine speed value (usually in RPM) and the dynamometer loads the engine to that value and maintains it. This mode
is generally used for maximum horsepower pulls. Can only be used when the dynamometer is reading engine speed (either
through the ECM or external speed pickup).
Fuel Cabinet: Optional equipment that provides gravimetric fuel measurement data. Allows measurement of burn rate, BSFC,
Fuel Quality, etc.
Home: A command button on the user interface window that when pressed, returns the control mode to valve position and
enters a zero as the setpoint.
Horsepower Mode: A method of controlling the dynamometer in which a horsepower set point is entered and the dynamom-
eter tries to maintain that amount of load, regardless of the engine’s speed or its ability to achieve that load. This is typically
used for endurance testing or warm up and may overload the engine if the set point is too large.
LT Controller or Control Box: Receives and processes signals between the Commander computer and the dynamometer.
Operator: The person(s) that execute the tests and automated patterns as created by the Administrator. Will be responsible
for securing the test engines, loading a PowerNet DataSpace, and executing the PowerNet Patterns. Will generally have a
lower level of security access to the Commander Computer.
Pattern: See PowerNet Pattern
Power Mode: A method of controlling the dynamometer in which either the operator or an automated PowerNet Pattern enters
a power value (usually in horsepower) and the dynamometer loads the engine to that value and maintains it.
PowerNet Controller Interface: One of the five primary windows on the Commander main screen. The Controller Interface
provides most of the control functions for the dynamometer. From this window, the dynamometer control mode can be changed
and viewed and set points can be entered and viewed. This window also provides access to the tuning parameters, some
calibrations, and allows the user to activate and deactivate the dynamometer.
PowerNet DataSpace: Once a Template contains data, it is referred to and saved as a DataSpace.
PowerNet ECM Communicator: One of the five main windows on the Commander main screen (although usually minimized).
ECM Communicator establishes a connection to the vehicle’s ECM to allow for bringing in ECM data. From the ECM Communicaot
window, detailed information about the connection can be viewed.
76
Glossary
PowerNet Pattern: The automated “road” that the vehicle will drive during a test. The pattern is a sequential program of set
points that the vehicle will be put through. The pattern is created using PowerNet Pattern Runner by the dynamometer system
Administrator.
PowerNet Pattern Runner: One of the five primary windows on the Commander main screen. Pattern Runner allows the user
to load, create, edit, save and execute PowerNet Patterns.
PowerNet Report Format: How the data will be displayed in hard copy format.
PowerNet Report Generator: One of the (5) primary windows on the Commander Main Screen. The Report Generator allows
the user to enter work order data and configure the appearance and content of the printed report.
PowerNet Template: Basically a blank test. When a dyno test is performed, it is done so using one of several Templates.
Report: See PowerNet Report Format.
Report Generator: See PowerNet Report Generator
Set Point: User defined data that determines from at which point data is collected or retrieved. Could be dependent on
speed, etc.
Soft Stop: When activated sends the dynamometer water valve to zero, gradually unloading the dynamometer. Soft Stop does
not stop the engine , it only effectively unloads the dynamometer.
Stator: The stationary part of a dynamometer within which the rotor turns.
Template: See PowerNet Template
Torque: A measurement of twisting force.
Tractive Force: A measure of the horizontal pull force exerted by the vehicle; also referred to as draw bar pull.
Torque Mode: A method of controlling the dynamometer in which either the operator or an automated PowerNet Pattern enters a
tractive force value (usually in pounds) and the dynamometer loads the engine to that value and maintains it.
Tuning: A set of parameters that can be modified the adjust the speed and stability of the dynamometer’s load control circuit.
Valve Mode: A method of controlling the dynamometer in which either the operator or an automated PowerNet Pattern enters
a valve position (usually as % of valve open) and the dynamometer maintains that valve position.
77
Glossary
78

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AIDCO 900 Series

Transmission and Hydraulic

Publication Number: 080801

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

 ervices performed beyond preventive maintenance by personnel other

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

JM0054 HYD TEST STAND SYS 900K-300HP 480/60

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

Indicates an imminent hazard, which, if not properly addressed and

Indicates precautions relating to operation or usage of the machine or highlights

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

3.1 Ordering Parts

3.2 Service Calls

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

4.1 Oil and Filters

Changing the Oil

Main Reservoir Kidney Loop Filter

Main Reservoir Sump Filter

Main Reservoir Return to Tank Filters

Hydrostatic Reservoir Filters

4.2 Electric Motors

4.3 Heat Exchangers

Closed Water Cooling System

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

5.2 Primary Hydraulic Systems and Their Functions

Max Speed 3,400 RPM 3,400 RPM

Max Torque Speed Range 0-1,260 RPM 0-1,750 RPM

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

Flowmeter Yes Yes

Flow 0-30 GPM (114 L/min) 0-30 GPM (114 L/min)

Flow 0-22 GPM (83 L/min) 0-22 GPM (83 L/min)

Pressure 0-7,200 psi (496 bar) 0-7,200 psi (496 bar)

Pressure 0-6,500 psi (448 bar) 0-6,500 psi (448 bar)

Load Valve Yes Yes

Flowmeter 0-150 GPM (568 L/min) 0-150 GPM (568 L/min)

Pressure 0-6,000 psi (413 bar) 0-6,000 psi (413 bar)

Load Valve Yes Yes

Gauge 6,000 psi 6,000 psi

Flowmeter 0-300 GPM (1136 L/min) 0-300 GPM (1136 L/min)

Pressure 0-5,000 psi (345 bar) 0-5,000 psi (345 bar)

Load Valve Yes Yes

Flowmeter 0-60 GPM (227 L/min) 0-60 GPM (227 L/min)

Can not be used Can not be used

simultaneously with Main simultaneously with Main

Flow Out Flow Out

Flowmeter 0.5-5.0 GPM 0.5-5.0 GPM

Flowmeter 0.2-2.0 GPM 0.2-2.0 GPM

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

6.2 Unwrapping the Unit

Work Support Sump

6.3 Sump Pump, Water and Electrical Connections

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

7.1 Reservoirs and Fluids

7.2 Initial System Check

1. The CONTROL POWER key switch is off.

7.3 Start-Up and Check

1. main flowout to fm3 150gpm load in.

Main Motor Start Interlocks

N60 W22700 Silver Spring Drive Ι Sussex, WI 53089

High-Pressure System Checks

ervices performed beyond preventive maintenance by personnel other

Indicates an imminent hazard, which, if not properly addressed and

Indicates precautions relating to operation or usage of the machine or highlights

he Sump Pump is limited to a maximum 85 GPM. Care should be taken not to