Chassis Dynamometer SafetyChassis Dynamometer Safety

Cummins Southern Plains, Ltd.

Chassis Dynamometer SafetyChassis Dynamometer Safety

Setting Up the TruckSetting Up the TruckInspectionInspectionRunning the TruckRunning the TruckVentilation SystemVentilation SystemAdditional ConsiderationsAdditional Considerations

Setting up the TruckSetting up the Truck

Attach the rear safety chain.Attach the rear safety chain. The rear tie-down chain is the first The rear tie-down chain is the first

restraint to be installed, and the last to be restraint to be installed, and the last to be removed.removed.

Do not wrap the rear tie-down chain Do not wrap the rear tie-down chain around brake lines or other items that may around brake lines or other items that may be easily damaged.be easily damaged.

Setting up the TruckSetting up the Truck

Rear Safety ChainRear Safety Chain

A keeper to the “boomer” or load tensioner to keep handle from popping off.

Orange hook is a safety back up in case tensioner fails.

Setting up the truck (cont.)Setting up the truck (cont.) The front tie-down straps are the primary The front tie-down straps are the primary

restraints that provide safety in the event of a restraints that provide safety in the event of a problem.problem.

The rear chain prevents forward movements, but The rear chain prevents forward movements, but side-to-side movements may occur at the rear of side-to-side movements may occur at the rear of the vehicle.the vehicle.

Before beginning, know your dyno hood clearance Before beginning, know your dyno hood clearance distance and that a FE is in the area.distance and that a FE is in the area.

Setting up the TruckSetting up the Truck

Before placing vehicle Before placing vehicle on roller, make sure on roller, make sure air to the facility is air to the facility is turned on. If no air, turned on. If no air, truck will roll off roller truck will roll off roller and may hit wall. and may hit wall. Rollers have air Rollers have air applied brakes/spring applied brakes/spring released.released.

Picture shows a dent Picture shows a dent in the back wall from in the back wall from a unit that rolled off.a unit that rolled off.

InspectionInspection Always inspect the tie-down straps and Always inspect the tie-down straps and

ratchet mechanisms for wear. Do not use ratchet mechanisms for wear. Do not use excessively worn or damaged parts.excessively worn or damaged parts.

Tie down chains: inspect all bolts and keys.On tie down straps; inspect all strap material and bolts.

Running the TruckRunning the Truck Always remain in the drivers seat Always remain in the drivers seat

when conducting a test.when conducting a test. Never allow observers to be in Never allow observers to be in

the room when conducting a test.the room when conducting a test. Sensors may be connected to Sensors may be connected to

fluids under pressure, or may still fluids under pressure, or may still be hot after a cool-down period. be hot after a cool-down period. Use extreme caution when Use extreme caution when disconnecting sensors.disconnecting sensors.

Safety glasses and hearing Safety glasses and hearing protection must be worn during a protection must be worn during a test.test.

Running the TruckRunning the Truck Never apply the brakes or turn the steering wheel Never apply the brakes or turn the steering wheel

while a test is in progress.while a test is in progress. Always set the vehicle parking brakes and the Always set the vehicle parking brakes and the

dynamometer roll lock when not executing a test.dynamometer roll lock when not executing a test. Emergency stop button is located on the wall-Emergency stop button is located on the wall-

mounted interconnect box. In the event of an mounted interconnect box. In the event of an emergency, press the button.emergency, press the button.

Nobody else should be in area when in operation.Nobody else should be in area when in operation.

Hole in the rear wall from a rock dislodge from a tire during a test run.

Ventilation SystemVentilation System Engine exhaust fumes contain particulate matter, Engine exhaust fumes contain particulate matter,

Carbon Dioxide, and Carbon Monoxide..Carbon Dioxide, and Carbon Monoxide.. Never run the engine or conduct a test without Never run the engine or conduct a test without

the proper room ventilation and evacuation for the proper room ventilation and evacuation for exhaust fumes.exhaust fumes.

At least one door of the chassis dyno must be At least one door of the chassis dyno must be open during operation of the ventilation system.open during operation of the ventilation system.

Ventilation SystemVentilation System

These are different exhaust tubes designed for These are different exhaust tubes designed for different exhaust systems. The curved one in the different exhaust systems. The curved one in the right picture is for busses with exhaust out the right picture is for busses with exhaust out the top. Larger one in front for RVs. Be careful not to top. Larger one in front for RVs. Be careful not to place the tubes close to housing as it may bubble place the tubes close to housing as it may bubble the paint on an RV.the paint on an RV.

A variety of hose extensions should be available

Additional ConsiderationsAdditional Considerations

Minimum ladder needed to take opacity measurements on stacks is 8 ft.

Housekeeping with the hoses on the swing out rack should be maintained at all times.

Static ElectricityStatic Electricity

The rotation of rubber tires on steel rolls The rotation of rubber tires on steel rolls causes static electricity build-up.causes static electricity build-up.

If the rear tie-down chain is wrapped If the rear tie-down chain is wrapped directly around the rear axle or frame directly around the rear axle or frame cross member, no further grounding cross member, no further grounding should be necessary.should be necessary.

In all other cases it will be necessary to In all other cases it will be necessary to use a grounding clamp attached to the use a grounding clamp attached to the dyno frame or other suitable connection dyno frame or other suitable connection point to earth ground.point to earth ground.

Fuel SafetyFuel Safety Keep sparks and open flames away from fuel Keep sparks and open flames away from fuel

measurement system and the output of the vent measurement system and the output of the vent connection.connection.

Personal protective clothing should be worn to Personal protective clothing should be worn to prevent diesel fuel contact with the skin or eyes.prevent diesel fuel contact with the skin or eyes.

Only diesel fuel can be used with the SF-602 fuel Only diesel fuel can be used with the SF-602 fuel measurement system. Other fuels may produce measurement system. Other fuels may produce dangerous vapors. The system is NOT explosion dangerous vapors. The system is NOT explosion proof.proof.

The fuel can vent on the side of the cabinet must The fuel can vent on the side of the cabinet must be open to a safe place in the atmosphere.be open to a safe place in the atmosphere.

A blocked vent could cause the can to burst or A blocked vent could cause the can to burst or leak.leak.

CalibrationCalibration Calibration arm and Calibration arm and

weight (500 lbs.) for weight (500 lbs.) for calibrating the sensor on calibrating the sensor on the absorption unit. the absorption unit. Need two people for this Need two people for this lift and a cherry picker. lift and a cherry picker. Calibration takes place Calibration takes place once a year.once a year.

Need to open pit to Need to open pit to access the mounting access the mounting point for the torque arm point for the torque arm onto the absorption unit. onto the absorption unit. Uses cones and warning Uses cones and warning line around the pit to line around the pit to keep people out.keep people out.

Additional Safety NotesAdditional Safety Notes

Always remove all test lead and exhaust Always remove all test lead and exhaust management devices before removing management devices before removing straps and chains. This will save you from straps and chains. This will save you from driving off with expensive equipment.driving off with expensive equipment.

Trip hazards from the test equipment and Trip hazards from the test equipment and leads can be a problem in the dyno room. leads can be a problem in the dyno room. Keep main walkway clear as much as Keep main walkway clear as much as possible.possible.

Oil and coolant spills are common. Oil and coolant spills are common. Housekeeping is essential.Housekeeping is essential.