AP Dynamometer Service Manual
Contents
1. i ITEM NO DESCRIPTION W TP N QTY 1 500 Ib AP Pressure Bar Assembly 30005 0010 1 l 1 000 Ib AP Pressure Bar Assembly 30005 0028 1 2 000 Ib AP Pressure Bar Assembly 30005 0036 1 4 000 Ib AP Pressure Bar Assembly 30005 0044 1 i 5 000 Ib AP Pressure Bar Assembly 30005 0051 1 1 6 000 Ib AP Pressure Bar Assembly 30005 0069 1 8 000 Ib AP Pressure Bar Assembly 30005 0077 1 10 000 Ib AP Pressure Bar Assembly 30005 0085 1 15 000 Ib AP Pressure Bar Assembly 30005 0093 1 maar 20 000 Ib AP Pressure Bar Assembly 30005 0101 1 ES 200 kg AP Pressure Bar Assembly 30005 0143 1 i i i PTIONAL OVERSIZE SHACKLE 500 kg AP Pressure Bar Assembly 30005 0135 1 N CUP TO 20 000 lb 1 000 kg AP Pressure Bar Assembly 30005 0150 1 2 000 kg AP Pressure Bar Assembly 30005 0127 1 a E De be Ec in 4 000 kg AP Pressure Bar Assembly 30005 0168 1 5 000 kg AP Pressure Bar Assembly 30005 0176 1 10 000 kg AP Pressure Bar Assembly 30005 0119 1 n PESE SHACKLE 2 Cap Screw Y x 1 L sst 26367 5639 2 i E 3 Pan HD Screw 6 32 x 4 L 26380 0021 3 1 4 Cap Screw Y x 3 4 L sst 26368 0068 4 5 Shackle Pin 30039 0010 2 6 Needle Bearings used with items 7 amp 10 only 30385 00104 4 7 Shackle standard size 30038 0011 2 8 Hex Nut 14507 0140 2 9 Cotter Pin 5 32 x 1 74 L 14448 0209 2 10 Over Size Shackle 15 000 Ib or less Optional 29286 00462 2 USE ITEMS 5 6 8 amp 9 11 Dillon Label 45150 0011 1 i eee 12 Cotter2. iiio e rrr deer ae ee ae 12 Defect Removal Allowances for Shackles and Shackle Pins oooooocccccccinnooccccccconanancnnccconnnan cnn nc cnnnan o e 12 Defect Removal Allowances for Pressure Bars sssssssssssse eene enne nenn 13 Proof LOAN MEE 13 Calibration Procedures cte REMEDIA a 14 Procedure for 20 000 Ib 10000 kg and Below ssseeeneennn mener nnns 14 Span adjustment procedure seed rt o sean Deae exe ee ee RERO eno ARR o ne x RENE idad 14 Procedure for 30 000 Ib 15000 kg and Higher ssssssssnnen nennen nennen 16 Span adjustment procedure secina a aE A a Ea aaa a EEA EE AEAEE 16 Pointer Part Numbers e c a 17 Standard 5 127 mm Dynamomeler miii ta ern 17 standard 10 254 mm Dynamomeler econ ein 17 Troubleshooting and Common Repairs sssssssssseeeee nennen nennen nennen enne 18 Calculating Tension ina Systelri it t A 18 5 Dial 500 20 000 Ib Cap Parts and Assembly ssssssssee eene nnne nnne nnns 19 10 Dial 500 20 000 Ib Cap Parts and Assembly aaa anna 20 10 Dial 30 000 50 000 Ib Cap Parts and Assembly aceite nennen 21 10 Dial 100 000 Ib Cap Parts and Assembly ssssssssse emm eem mmn nennen nennen 22 Shackle Pin Dimensional Outline Drawings oeresrsenronsennioniienii nennen nennen en enn nnne en nens 23 AP Dynamometer Service Manual 3 AP Dynamometer Service Manual AP Dynamometer
3. flat wash ers holding the gauge movement assembly Set aside the gauge movement assembly with the dial inlay and pointer attached Remove two 74 28 x socket head cap screws and two flat wash ers holding the zero adjust bracket Set aside the zero adjust bracket assembly The pressure bar has four needle bearings Remove the bearings with a mechanical press with the plunge ram within 72 degree of the bearing hole axis Under no circumstances should the bearings be removed by impact Take care that the plunger does not contact the sides of the bearing hole as you push out the bearing These steps cover reassembly of the 5 diameter units up to 20 000Ib 10000kg capacity See Table 2 for a list of proper torque for the screws 1 Reinsert the bearings with a mechanical press with the plunge ram within 72 degree of the bearing hole axis Insure that the bearing hole bearing outer surface and ram are all free of debris dirt or particles To facilitate bearing installation an anti seize compound such as Fel Pro C5 A may be used provided any excess lubricant is wiped off after bearing installation Carefully insert the bearings one at a time insuring that the bearing remains properly aligned to the bearing hole axis Reverse sides to install the second bearing Always assembly the bearing with the stamped end against the shoulder of the pressing tool Attach the zero adjust bracket assembly and the gauge movement assembly with the f
4. 5 000 kg AP Pressure Bar Assembly 30005 0176 1 10 000 kg AP Pressure Bar Assembly 30005 0119 1 2 Cap Screw Y4 x 1 L sst 26367 5639 2 3 Pan HD Screw 6 32 x Ya L 26380 0021 T 4 Cap Screw Y4 x 3 4 L sst 26368 0068 4 5 Shackle Pin 30039 0010 2 6 Needle Bearings used with items 7 amp 10 only 30385 00104 4 7 Shackle standard size 30038 0011 2 8 Hex Nut 14507 0140 2 8 Cotter Pin 5 32 x 1 4 L 14448 0209 2 10 Over Size Shackle 15 000 Ib or less Optional 29286 0046 2 11 Dillon Label 45150 0011 1 12 Cotter Pin 74 x 1 72 L 14448 0324 2 13 Flat Washer 33636 0029 4 14 Shackle Pin 30363 0024 2 15 Retaining Ring 15931 0028 2 16 Inner Race 26386 0025 4 17 Needle Bearing 26385 0166 4 18 Over Size Shackle 20 000 Ib Optional 29286 0020 2 19 Housing standard 30013 0010 1 20 Flat Washer 74 26431 0509 6 21 Max Hand Crystal Assy incl reset knob crystal max hand spring clip etc 30093 0013 1 22 Bezel 30099 0017 1 23 Spacer 30018 0015 1 24 Dial Case Assembly 30359 0012 1 25 Rubber Gasket 30012 0029 1 26 Gauge Movement Assy 30040 0017 1 27 Zero Adjust Bracket Assy w knob 30019 0014 1 28 Max Hand Assy w o crystal 30096 0010 1 10AP2 TOR VIEW MAX HAND NEEDLE RED ZERO FRONT VIEW SCREW LIVE READING NEEDLE BLAC
5. Crystal Assy incl reset knob crystal max hand spring clip etc 30093 0013 1 22 Bezel 30099 0017 1 23 Spacer 30018 0015 1 24 Cover Top amp Bottom 35030 0018 4 25 Cap Screw 4 x 1 AL 26367 5647 2 26 Dial Housing Assy 30368 0011 1 27 Gage Movement Mtg Bracket 30178 0011 1 28 Zero Adjust Mtg Bracket 30177 0012 1 29 Cap Screw Y x 72 L 26368 0043 4 30 30K Gauge Movement Assy 30184 0013 1 40K Gauge Movement Assy 30184 0021 1 50K Guage Movement Assy 30184 0039 1 31 Zero Adjust Bracket Assy w zero adjust screw 35026 0014 1 32 Max Hand Assy w o crystal 30096 0010 1 21 DILLON 10AP3 X 2 0 11 I TOP VIEW D o OF AP DYNAMOMETER W 10 DIAL 100 000 50 000 lb CAPACITY PARTS and ASSEMBLY 10AP3 MAX HAND NEEDLE RED ZERO SCREW LIVE READING NEEDLE BLACK CREF FIG 2 ON POINTER PART NUMBERS PAGE n s FRONT VIEW zer queue ZERO SCREW E CENE T is 10AP3 SI VIEW W SHACKLE LETTER DESIGNATION FOUND ON SURFACE OF BAR ASSEMBLY INDICATES CAPACIT
6. force com for more information This service manual contains information needed for maintenance of Dillon AP Dynamometers Included in this manual are the following instructions for disassembly and reassembly periodic inspection requirements and procedures instructions for calibration and zero adjustments technical illustrations Service details for the ProLift dynamometer can be found in the separate ProLift Dynamometer Service Manual AP Dynamometer Service Manual 5 Disassembly and Reassembly These steps cover disassembly of the 5 diameter units up to 20 000Ib 10000kg capacity to remove the pressure bar Separation of Pressure Bar and Gauge Movement on 5 Diameter Units up to 20 000 Ib 10000 kg Reassembly of Pressure Bar and Gauge Movement on 5 Diameter Units up to 20 000 Ib 10000 kg If you are installing a new pressure bar be sure the capacity marking on the new bar matches the marking on the old bar The capacity letter along with other numbers are located on the narrow side of the bar between the end of the radius and the end of the pressure bar See Table 1 fora list of letters and capacities 1 Remove the three 6 32 x Y4 pan head bezel screws holding the bezel to the housing Lift off the bezel crystal and max hand assembly Remove two 74 28 x socket head cap screws and two flat wash ers holding the housing to the pressure bar Remove two 74 28 x socket head cap screws and two
7. the other end AP Dynamometer Service Manual Periodic Maintenance Requirements Cleaning And Lubrication Inspection of the Pressure Bar Clean the bezel with a soft cloth dampened using ordinary glass cleaner You can remove the bezel retaining ring to clean the reverse side of the bezel Remove the ring by removing the Phillips screws that secure it to the housing The bezel edging material need not be removed for this cleaning Take care not to bend or damage the max pointer during cleaning Reas semble in reverse order from disassembly Shackle pin bearings should be cleaned if grease grime or dirt is apparent in the bearings With the shackles and pins removed apply a universal cleaning degreaser such as Blue Shower CRC Heavy Duty Degreaser Safety Kleen Solvent etc directly to the bearings Manually turn the bear ings and continue applying cleaner until traces of dirt disappears Sparingly apply a light lubricant such as Ace LPS2 Exxon Handy Oil 3 in 1 oil etc to coat all moving surfaces The gearing works or mechanical mechanisms within the dynamometer housing can be cleaned with a cleaning degreaser and then sparingly lubricated with a light lubricant The remainder of the dynamometer may be cleaned with a light duty general purpose cleaner In service the pressure bar should not be permitted to contact or otherwise sustain impression or impact loads Any pressure bar with cracks or sharp gashes shou
8. the screws 1 Reinsert the bearings with a mechanical press with the plunge ram within 72 degree of the bearing hole axis Insure that the bearing hole bearing outer surface and ram are all free of debris dirt or particles To facilitate bearing installation an anti seize compound such as Fel Pro C5 A may be used provided any excess lubricant is wiped off after bearing installation Carefully insert the bearings one at a time insuring that the bearing remains properly aligned to the bearing hole axis Reverse sides to install the second bearing Always assembly the bearing with the stamped end against the shoulder of the pressing tool 2 Attach the zero adjust bracket assembly and the gauge movement assembly with the four 74 28 x socket head cap screws and four Ya flat washers 3 Mount the dial pan over the pointer shaft and hold in place 4 Support the bearing at the end of the pointer shaft to prevent it from pushing out 5 Align the flats on the point to the shaft and install Still supporting the bearing tap lightly on the pointer button until the pointer is flush to the end of the shaft 6 Turnthis assembly onto the dial face you are still holding form step 3 7 Install the dynamometer housing to the pressure bar with the two 74 28 X 34 socket head cap screws and two flat washers 8 Install the dial pan with the three 6 32 x screw washer assemblies AP Dynamometer Service Manual 10 11 Separation
9. 46 0043 Front View Figure 1 5 dials There are four different main uN pointers for the AP Dynamometers n black To determine which pointer you need you must know where the zero is located on the dial See illustration below 9 12 00 PN 30079 0011 3 00 PN 30079 0029 BEE 6 00 PN 30079 0037 6 9 00 PN 30079 0045 Front View Figure 2 10 dials AP Dynamometer Service Manual 17 Troubleshooting and Common Repairs Common Probable Suggested Symptoms Causes Repair Nonlinear Bent bar Replace pressure bar Worn gauge movement Replace gauge movement Won t repeat Bad bar bearings worn rusty or dirty Replace bearings in pressure bar Worn gauge movement Replace gauge movement High on low end Bad pressure arm Replace gauge movement low on high end Max hand will not Spring too tight or Replace max hand assembly rotate smoothly rusty corroded Pointer jumps Bearings or pointer Clean bearings rubbing on dial face 1 drop LPS on bearing or replace gauge movement Calculating Tension in a System Truck Winch The setup shown above will give you an approximate tension reading This can vary from actual tension due to variables in equipment and environment 18 AP Dynamometer Service Manual AP DYNAMOMETER W 5 DIAL 500 20 000 Ib 200 10 000 kg CAPACITY PARTS and ASSEMBLY
10. DILLON AP Dynamometer Service Manual Table of Contents AP Dynamometer Introduction cece cence eter teenie eter canon cc nnnnn nan aiaeei eann EA EAA NAN EEEE REE iE 5 The Dillon Mechanical Dynamometer Family ssssesssenne enne enne nennen nen 5 About This Manual ss M 5 Disassembly and Reassembly 55 itte rr acre AAA e 6 Separation of Pressure Bar and Gauge Movement on 5 Diameter Units up to 20 000 Ib 10000 kg 6 Reassembly of Pressure Bar and Gauge Movement on 5 Diameter Units up to 20 000 Ib 10000 kg 6 Separation of Pressure Bar and Gauge Movement on 10 Diameter Units up to 20 000 Ib 10000 kg 8 Reassembly of Pressure Bar and Gauge Movement on 10 Diameter Units up to 20 000 Ib 10000 kg 8 Separation of Pressure Bar and Gauge Movement on 10 Diameter Units from 30 000 100 000 Ib 15000 50000 kg Capacities ssssssseeeeen 9 Reassembly of Pressure Bar and Gauge Movement on 10 Diameter Units from 30 000 100 000 Ib 15000 50000 kg Capacities sssssseemee n 9 Periodic Maintenance Requillermetnts ecce enn ee a ee E A 11 Cleaning And Lubrication ooooonccccnnnnocccccnonononncncnnnanon occ ncnnn nee nennen rr rn ran ennrenen sss nennen sen ASERNE 11 Inspection of the Press re Bar tto XR NER ais na ae aa A E anna Here aE 11 Inspection of the Shackles and Piris
11. IN 8 34 0 091 0 086 9 14995 15005 SHACKLE AND PIN 10 DIAL 30 000 50 000 lbs 5 000 20 000 kg HOOKol2 m 5 00 SHACKLE pe 998 997 h 3 00 3 40 Li E 0 10 4 PIN 0 091 0 086 Vx 1 50 10 62 f 1749 1748 AP DYNAMOMETER SHACKLE PIN DIMENSIONAL OUTLINE DRAWINGS UMBERS FOR SHAC LE PIN AND RELATED PAR S CAN BE PARTS AND ING EACH ELSEWHERE IN THIS FOUND ASSEMBLY MANUAL PAGES SIZE CAPACITY SHACKLE AND PIN 410 DIAL HOOKol2 F 8 25 Proa 22 50 3 50 Fe i 11 00 z p 5 50 dinis a N y 7 i 4 50 Jl er 1 6 84 SHACKLE 9 2 999 2 998 100 000 lbs 50 000 kg m 1745 1743 24
12. Introduction The Dillon Mechanical Dynamometer Family About This Manual The popular Dillon Model AP dynamometer is a rugged robust self con tained and portable tension measuring instrument Introduced in 1977 the Model AP is the most widely used dynamometer in the field today in count less different applications The Dillon ProLift mechanical dynamometer supplemented the Dillon Model AP dynamometer in 2001 Designed with the input of nuclear fuel handlers the ProLift satisfies all of the requirements for these ultra sensitive applica tions The ProLift offers the following enhancements over the Model AP 5 1 Ultimate safety factor in all capacities Exclusive material selection Rounded pressure bar ends Electroless nickel plating Non destructive examination of 100 of pressure bars in all capacities Non destructive examination of 100 of low capacity shackles and shackle pins Proof load tested to 15096 of capacity Anchor shackles in all capacities Dillon recommends that the ProLift should be the first choice when future periodic non destructive examination or proof loading is required These dynamometers are available in crane scale versions These employ hooks at the lower end the large 10 inch diameter dial and are shipped in plywood reinforced crates in all capacities In addition Dillon offers a popular electronic dynamometer family and other highly rated force measurement products See www dillon
13. K CREF FIG 2 ON POINTER PART NUMBERS PAGE S S ncm 10AP2 XXX XXXX X LETTER DESIGNATION FOUND ON SURFACE OF BAR ASSEMBLY INDICATES CAPACITY OF THAT BAR EXAMPLE 1 3 000 lb SI 10AP2 ZERO SCREW E VI EW lt W Lo e o9 SHACKLE gt AP DYNAMOMETER W 10 DIAL 30 000 50 000 Ib 15 000 20 000 kg CAPACITY PARTS and ASSEMBLY ITEM NO DESCRIPTION W T P N QTY 1 30 000 Ib AP Pressure Bar Assembly 30364 0015 1 40 000 Ib AP Pressure Bar Assembly 30364 0023 1 50 000 Ib AP Pressure Bar Assembly 30364 0031 1 15 000 kg AP Pressure Bar Assembly 30364 0049 1 20 000 kg AP Pressure Bar Assembly 30364 0056 1 2 Cap Screw Ya x 1 L 26367 5639 2 3 Pan HD Screw Washer Assy 6 32 x Ya L 26380 0021 8 4 Cap Screw 4 x 3 4 L 26368 0068 4 5 Shackle Assy w Bearings 30371 0016 2 6 Rubber Gasket 30012 0029 1 7 Shackle 30038 0011 2 8 Lock Washer 14474 0198 6 9 Cover Plate LH 30176 0013 1 10 Cap Screw 10 x 3 8 L 26367 5472 4 11 Lock Washer 10 14474 0057 4 12 Cotter Pin x 1 72 L 14448 0324 2 13 Flat Washer 30366 0013 4 14 Shackle Pin 30363 0016 2 15 Retaining Ring 15931 0028 2 16 Inner Race 26389 0105 4 17 Needle Bearing heavy duty 26388 0015 4 19 Cover Plate RH 30175 0014 1 20 Flat Washer 74 26431 0509 6 21 Max Hand
14. Pin 4 x 1 4 L 14448 0324 2 Eum eu aS m cem 13 Flat Washer 33636 0029 4 14 Shackle Pin 30363 0024 2 15 Retaining Ring 15931 0028 2 DIAL 16 Inner Race 26386 0025 4 CALL FOR PART ene 17 Needle Bearing 26385 0166 4 18 Over Size Shackle 20 000 Ib Optional 29286 0020 2 19 Housing plastic 46835 0012 1 20 Flat Washer 1 4 26431 0509 6 21 Max Hand Crystal Assy incl reset knob crystal max hand spring clip etc 30030 0027 Max Hand Assy w o crystal 30032 0017 22 Bezel plastic 30011 0020 23 Spacer top 30018 0015 24 Rubber Gasket 30012 0011 25 Gauge Movement Assy 30040 0025 26 Zero Adjust Bracket Assy w knob 30019 0014 27 Dial Pointer 5 30246 0043 LETTER DESIGNATION FOUND ON SURFACE 28 Spacer 0 0598 thk 30016 0017 N OF BAR ASSEMBLY INDICATES CAPACITY Spacer 0 006 thk 30014 0019 IF THAT BAR EXAMPLE A 500 lb Spacer 0 002 thk 30017 0016 DIAL INLAY i 7 CALL FOR PART 29 Instruction amp serial no Nameplate 30082 0016 30 Rivet 22382 0051 31 Dial Mounting Plate 47079 0015 32 Screw 6 x 31 L 26371 0238 33 Screw 6 x 19 L 15710 0215 DYNSAP 19 AP DYNAMOMETER W 10 DIAL 500 20 000 Ib 200 10 000 kg CAPACITY PARTS and ASSEMBLY PTIONAL DVERSIZ 15 000 lb OR LESS SHACKLE SE ITEMS 5 6 8 amp 9 BYNIOAP z O ATTACH THIS HOOK O PRESSURE BAR 4 c CENTER LABEL OVER HOLE AF
15. TER CALIBRATION DYNLOAP UP TO 20 000 lb PTIONAL OVERSIZE SHACKL 19 6 24 c TOP VIEW LIVE READING NEEDLE lt BLACK REF FIG 2 ON POINTER PART NO PAGE DYNIOAP ye I XXXXXX MAX HAND i LETTER DESIGNATIUN FDUND DN SURFACE NEEDLE CRED OF BAR ASSEMBLY INDICATES CAPACITY OF THAT BAR EXAMPLE A 500 Ik FRONT VIEW SIDE VIE genase ote aah ZERO KNOB 20 ITEM NO DESCRIPTION W T P N QTY 1 500 Ib AP Pressure Bar Assembly 30005 0010 1 1 000 Ib AP Pressure Bar Assembly 30005 0028 1 2 000 Ib AP Pressure Bar Assembly 30005 0036 1 4 000 Ib AP Pressure Bar Assembly 30005 0044 1 5 000 Ib AP Pressure Bar Assembly 30005 0051 1 6 000 Ib AP Pressure Bar Assembly 30005 0069 1 8 000 Ib AP Pressure Bar Assembly 30005 0077 1 10 000 Ib AP ressure Bar Assembly 30005 0085 1 15 000 Ib AP Pressure Bar Assembly 30005 0093 1 20 000 Ib AP Pressure Bar Assembly 30005 0101 1 200 kg AP Pressure Bar Assembly 30005 0143 1 500 kg AP ressure Bar Assembly 30005 0135 1 1 000 kg AP Pressure Bar Assembly 30005 0150 1 2 000 kg AP Pressure Bar Assembly 30005 0127 1 4 000 AP Pressure Bar kg Assembly 30005 0168 1
16. Y OF THAT BAR EXAMPLE 1 3 000 Ik 22 ITEM NO DESCRIPTION W T P N QTY 1 50 000 kg AP Pressure Bar Assembly 30330 0024 1 100 000 Ib AP Pressure Bar Assembly 30330 0016 1 2 Cap Screw x 1 L 26367 5639 4 3 Pan HD Screw Washer Assy 6 32 x 1 4 L 26380 0021 8 4 Cap Screw 74 x 3 4 L 26368 0068 4 5 Shackle Assy w Bearings 30326 0012 2 6 Rubber Gasket 30012 0029 1 T Shackle 30038 0011 2 8 Lock Washer 14474 0198 6 9 Cover Plate LH 30314 0016 1 10 Cap Screw 10 x 3 8 L 26367 5472 4 11 Lock Washer 10 14474 0057 4 12 Cotter Pin x 1 72 L 14448 0415 2 13 Flat Washer 30316 0014 4 14 Shackle Pin 30313 0017 2 15 Retaining Ring 15931 0069 2 16 Top label identifies pin that must remain TOP 33163 0012 1 17 Needle Bearing heavy duty 26388 0106 4 18 Inner Race for item 17 26389 0261 4 19 Cover Plate RH 30315 0015 1 20 Flat Washer 74 26431 0509 8 21 Max Hand Crystal Assy incl reset knob crystal max hand spring clip etc 30093 0013 1 22 Bezel 30099 0017 1 23 Spacer 30018 0015 1 24 Cover Top amp Bottom 35030 0026 4 25 Cap Screw 4 x 1 L 26367 5647 2 26 Dial Housing Assy 30108 0016 1 27 Gage Movement Mtg Bracket 30323 0015 1 28 Zero Adjust Mtg Bracket 30318 0012 1 29 Cap Screw x L 26368 0043 4 30 Gauge Movement Assy 30184 0047 1 31 Zero Adjust Bracket Assy w zero adjust screw 35026 0014 1 32 Max Hand Assy w o crystal 30096 0010 1 33 Wooden Storage Box for e
17. ach shackle not shown 30329 0019 2 34 Wooden Box for Dynamometer not shown 30328 0010 1 AP DYNAMOMETER SHACKLE PIN DIMENSIONAL OUTLINE DRAWINGS OVERSIZE SHACKLE AND PIN 5 amp 10 DIAL gt STANDARD SHACKLE AND PIN 5 amp 10 DIAL lt 500 lb THRU 15 000 llbs 200 kg THRU 5 000 kg CALL CAPACITIES THROUGH 20 000 lbs 10 000 kg j 4 50 gt 187 I 1 00 Le 1 62 0 75 Ld gt L 0 75 T r1 D 54 EN i75 ai mra 7 a n aes LC N J si 487 a 1 2 69 ijt PRESSURE BAR Lo ma d m 3 40 355 we 4 75 p WS MEE 340 355 Edu SHACKLE Mad BE o aa 9 0 762 PIN 015 9 46 E a y 175 834 PIN 051 0 94 j i 0 752 0 760 VERSIZE SHACKLE AND PIN 5 amp 10 DIAL 20 000 llos 10 000 kg ja 4 50 m 1 62 o c BE ee 0 75 275 F i 998 997 u a 112 NOTE 487 a RTAINING EACH SIZE CAPACITY ELSEWHERE IN IS MANUAL az di Es PART NUMBERS FOR SHACKLE PIN AND EE HEIR RELATED PARTS CAN BE FOUND N THE PARTS AND ASSEMBLY PAGES E L SHACKLE i 9 46 3 0 10 P
18. ach the dial pan with the four 10 32 X 3 8 socket head screws and flat washers into the two angle brackets holding on the dial pan cover plates Align the hole at the center of the dial face with the pointer shaft Snug up the screws but do not tighten yet Align the flats and attach the pointer onto the gauge movement shaft by hand Use a flat screwdriver end or similar device to reach into the housing to hold the lower shaft bearing from being driven out when setting the pointer to the shaft Tap the pointer hub to the shaft until firm while holding the bearing from coming out While holding the pan move the pointer clockwise at 90 degree increments to determine that it is centered to the pan and that the pan is uniform in height with the pointer Now tighten the four socket head screws that hold the pan to the mounting covers Recheck the pointer movement for interference and readjust if necessary Install the bezel to the pan with the four 6 32 X 74 pan head screws Calibrate per the procedures in the Calibration section of this manual Now install the remaining inch serial I D cover plate with two 74 28 X socket head screws flat and lock washers and torque Again this plate has 040 more clearance to the dial pan than the adjoining plate When reinstalling the shackles and or swivel hook install the snap ring end of the 1 diameter mounting pin toward the dial side of the pres sure bar Install the roll pin with more clearance on
19. air by welding is not authorized The Dillon Model AP mechanical dynamometer may be subjected to 150 proof loads of the rated capacity up to twice per year for inspection pur poses The applied loads must not exceed 155 of capacity of the instru ment The load may be held for any period desired provided the load does not cycle or vary The proof load must be conducted in a controlled area with appropriate safety mechanisms in place The dynamometer itself should not provide the load reference during the test Original shackle pins should not be proof loaded on the 15 000 Ib 20 000 Ib and 10000 kg Model AP dynamometers with the standard anchor shackle The bearings can apply impressions to the shackle pins that can negatively affect performance Substitute shackle pins should be used in proof loading to eliminate potential for distorting these pins Shackle pins that require testing should be proof loaded independently in a fixture with smooth contact surfaces The dynamometers will not experience mechanical damage under a 15096 proof load however the calibration and zero reference point may be altered Recalibration will restore the original performance AP Dynamometer Service Manual 13 Calibration Procedures Equipment required Procedure for 20 000 Ib 10000 kg and Below load frame dead weights or lever system applicable fixturing for applying load to the device torque wrench with 3 16 inch hex drive socket Typical re
20. amometer load 7c Tighten the two dial retaining screws and recheck the span adjustment of the unit Readjust the unit span and linearity as required AP Dynamometer Service Manual 10 Install the maximum pointer assembly bezel and housing on the dynamometer Check the maximum hand adjustment The maximum hand turned counter clockwise must not move the dynamometer pointer more than one division before the clutch mechanism slips Readjust the clutch mechanism as required Affix a calibration cover label seal over the zero adjusting bracket access hole as required Remove the dynamometer and any shackles from the calibration standard machine Verify the calibration entries satisfy the dynamometer accuracy specifi cation Enter the dynamometer serial number the verified accuracy tolerance percentage sign and date the certificate of calibration card AP Dynamometer Service Manual 15 Procedure for 30 000 Ib 15000 kg and Higher Typical recalibration interval is every 12 months although more frequent calibration is suggested for dynamometers in extreme service Only Dillon shackles and pins should be used with the dynamometer during calibra tion or use For best instrument performance use the shackles and pins during calibration that are used during routine use The shackle bearings included with the dynamometer must be used during calibration and operation These bearings are installed in the dynamometer and fac
21. bly The right plate holds the gauge movement bracket assembly Leave the thin cover plates attached to these two 77 thick plates Note that the pressure bar is located with the cutout away from the you and that the distance from the right end to the notch is 3 5 16 The distance from the left end to the notch is 3 9 16 This is important for correct assembly The shackles are each fitted with two needle bearings Remove the bearings with a mechanical press with the plunge ram within Y degree of the bearing hole axis Under no circumstances should the bearings be removed by impact Take care that the plunger does not contact the sides of the bearing hole as you push out the bearing Reinsert the bearings with a mechanical press with the plunge ram within 72 degree of the bearing hole axis Insure that the bearing hole bearing outer surface and ram are all free of debris dirt or particles To facilitate bearing installation an anti seize compound such as Fel Pro C5 A may be used provided any excess lubricant is wiped off after bearing installation Carefully insert the bearings one at a time insuring that the bearing remains properly aligned to the bearing hole axis Reverse sides to install the second bearing Always assembly the bearing with the stamped end against the shoulder of the pressing tool Again note that the pressure bar is located with the cutout away from the assembler and that the distance from the right end to the notch
22. calibration interval is every 12 months although The calibration technician must be qualified for and trained in the proce more frequent calibration is suggested for dynamometers in extreme service 14 dures for operating the calibration machine adjusting the calibration of the device and recording of the calibration data 1 Service the dynamometer Inspect the unit for damage and the Only Dillon shackles and pins condition of all load bearing surfaces Replace or repair parts and should be used with the assemblies as required Leave the crystal off the unit until the device dynamometer during calibra has been recalibrated after repair nel eus 2 Dynamometers received for recalibration and repair that are functional and pins during calibration that should have as found readings taken Install the dynamometer and are used during routine use shackles in the calibration machine The shackle bearings included 3 Check the maximum hand adjustment and record the number of A divisions to the nearest half division the maximum hand will move the with the dynamometer must be d uS ynamometer pointer in a counter clockwise direction used during calibration and operation These bearings are 4 Exercise the unit three times by applying 1 00 to 1 05 times rated installed in the dynamometer capacity load and then releasing the load completely Observe the and facilitate predictable and smoothness of pointer travel throughout the full
23. ed the above stated percentages should be removed from service Repair by means of welding is prohibited You may remove small defects from Dillon shackle assembles by grinding but care must be taken to keep the removal of material to a minimum This section gives you guidelines on this procedure You may grind the following Dillon shackle assemblies P N 30010 0013 Anchor shackle P N 33202 0015 up to 15 000 Ib oversize P N 33202 0023 20 000 Ib 5 1 oversized P N 30371 0016 30 000 Ib through 50 000 Ib standard P N 30332 0014 100 000 Ib Discontinuities that run parallel to the contour of the shackle or pin are usually not serious and do not need removal Discontinuities that are trans verse to the contour of the shackle or pin are more serious and may reduce longevity of the shackle or pin Items with apparent cracks in any direction should be removed from service immediately Discontinuities may be removed by grinding longitudinally following the contour of the shackle or pin producing a smooth undulating surface The ground area must have a smooth blended transition with adjacent surfaces and a minimum taper of 3 1 No more than 0 06 inches 1 5mm of material should be removed in depth and should not reduce any nominal dimension of the shackle by five percent 596 or pin by more than 2 5 percent 2 5 Grinding in the roller bearing contact area of the shackle pin is not authorized as a smooth and round surface is r
24. equired for proper dynamometer performance Re inspection is required after grinding to determine if the original discontinuities were relevant Shackles showing a wear reduction due to use that reduces any nominal dimension by more than 5 or the pin by more than 2 5 shall be perma nently removed from service AP Dynamometer Service Manual Defect Removal Allowances for Pressure Bars After grinding apply suitable corrosion protection to the pressure bars Proof Loading Minor scratches and dents may be removed from AP Dynamometer pres sure bars using the following criteria and guidelines 1 This type of action may not take place in any one location more than once during the life of the unit Use a Dremmel type drum flexible disk or buffer attachments to remove scratches and dents No more than 005 inch may be removed from the surface of the pressure bar 2 The grit of the tool must be fine enough that the result is no worse than a 63 microinch surface finish 3 On square corners material may be removed to a depth of 1 16 inch as measured from the corner due to these areas being at very low stress levels during use Blunt dents less than 1 16 inch deep from the corner do nat require removal for safe operation 4 The serial number and traceability information is stamped near one of these low stress corners Do not use a material removal tool in the area of these stamped numbers in order to maintain traceability Rep
25. ilitate predictable and repeatable rotational movement of the pressure arm under load We do not recommend that the instruments be calibrated or have any type of performance reviewed with the bearings removed Span adjustment procedure 16 Equipment required load frame dead weights or lever system applicable fixturing for applying load to the device torque wrench with 3 16 inch hex drive socket The calibration technician must be qualified for and trained in the proce dures for operating the calibration machine adjusting the calibration of the device and recording of the calibration data You should have assistance from the department or other areas in manipu lating large heavy dynamometer assemblies into and out of the calibration machine 1 Service the dynamometer Inspect the unit for damage and the condition of all load bearing surfaces Replace or repair parts and assemblies as required Leave the crystal off the unit until the device has been recalibrated after repair Leave the serial plate cover off the unit 2 Dynamometers received for recalibration and repair that are functional should have as found readings taken Install the dynamometer and shackles in the calibration machine 3 Check the maximum hand adjustment and record the number of divisions to the nearest half division the maximum hand will move the dynamometer pointer in a counter clockwise direction 4 Exercise the unit three times b
26. is 3 5 16 The distance from the left end to the notch is 3 9 16 Install the left plate with the zero bracket to the pressure bar with the two 74 28 X Y socket head screws no washers Align this plate parallel to the pressure bar and torque AP Dynamometer Service Manual 9 If you are installing a new pressure bar be sure the capacity marking on the new bar matches the marking on the old bar The capacity letter along with other numbers are located on the end of the bar with the 3 9 16 wide end It is on the outside corner which is on the same side as the center cutout The identifier is the far most right number in the string of numbers See Table 1 for a list of letters and capacities 10 10 11 12 13 Install the right plate with the gauge movement bracket assembly Tip the plate downwards to engage the pressure arm into the zero adjust bracket Do not force Attach with the two 74 28 X Y socket head screws no washers Align this plate parallel to the pressure bar and torque Note that the left plate is narrower than the right plate by 040 to clear the dial pan and eliminate interference during loading Install the right side inch thick cover plate with the spacer and attach with two 74 28 X socket head screws flat and lock washers and torque The end of the spacer must be flush with the end of the plate Leave the remaining left inch thick cover plate and spacer until calibration is completed Att
27. ld be immedi ately removed from service Any pits impressions or other surface inconsistencies larger than 0 031 1 32 inch are cause for replace ment Smooth or rounded imper fections with depths less than 0 062 1 16 inch are permissible on the corners indicated in the illustration at right Scratches across the bearing hole greater than 0 005 inch in depth are cause for replacement Machining marks running the circumference of the bearing hole are not cause for rejection Under no circumstances should any surface of the pressure bar be sub jected to grinding The pressure bar cannot be repaired by welding For organizations that perform periodic nondestructive testing of the pres sure bar relevancy checks may be performed using a Dremmel type tool and fine grit drum flexible disc or buffer type attachments such that the resulting finish is no worse than 63 micro inches and the depth is not greater than 0 005 inches Any one location may only be relevancy checked once during the lifetime of the pressure bar Relevancy checks may not be performed in the area of the stamped traceability numbers AP Dynamometer Service Manual 11 Inspection of the Shackles and Pins The shackles and pins that are supplied with the AP dyna mometer are produced to tight tolerances to mate with the AP components in order to main tain the accuracy specifications of the instrument Substitution elimination or improper re placement of the
28. of Pressure Bar and Gauge Movement on 10 Diameter Units from 30 000 100 000 Ib Zz 15000 50000 kg Capacities 5 It is helpful to be consistent in the location of the pressure bar In the directions at right the dial pan is face up with the plate containing the serial number to the left and facing you AG Reassembly of Pressure Bar and Gauge Movement on 10 Diameter Units from 30 000 100 000 Ib 15000 50000 kg Capacities Install the bezel assembly to the housing with the four 6 32 x Y pan head bezel screws Reinstall shackles and or hook assemblies Calibrate per procedures in the Calibration section of this manual Remove the four 6 32 x Y pan head bezel screws holding the bezel to the pan Lift off the bezel crystal and max hand assembly Remove the pointer from the gauge movement shaft with a pointer puller P N 29945 0023 Remove the four 10 32 x 3 8 socket head cap screws and flat washers from the two angle brackets holding on the dial pan cover plates Remove two 28 x socket head screws flat and lock washers from each of the 74 thick side plates The left plate contains the serial number and zero adjustment access hole Leave the thin cover plates attached to these two plates Note that the end of the two spacer plates are flush to the end of the 74 thick plates Remove two 74 28 x socket head screws no washers from the Y thick side plates The left plate holds the zero adjust assem
29. our 74 28 x socket head cap screws and four Ya flat washers Install the dynamometer housing to the pressure bar with the two 74 28 x socket head cap screws and two flat washers Install the bezel assembly to the housing with the three 6 32 x Y pan head bezel screws Reinstall shackles and or hook assemblies Calibrate per procedures in the Calibration section of this manual AP Dynamometer Service Manual Table 1 Pressure Bar Capacity Identification Capacity Capacity Length of Bar Letter Number Range 20 000 LB 30 000 LB 40 000 LB 50 000 LB 100 000 LB 500 LB A 1 000 LB B 2 000LB C Helpful Unit Conversions 4 000 LB D 1 lb 0 4536 kg 5 000 LB E 1 kg 2 205 Ib 6 000 LB F 8 000 LB G 1 in 2 540 cm 10 000 LB H 1 cm 0 3937 in 15 000 LB 1 2 3 1 200 KG 500 KG 1000 KG 2000 KG 4000 KG 5000 KG 10000 KG 15000 KG 20000 KG 50000 KG NORODOVZEC Table 2 Recommended Torque Specifications Torque 6 32 UNC 10 12 in Ib 10 32 UNF 70 in Ib 74 28 UNF 144 in Ib 596 AP Dynamometer Service Manual 7 Separation of Pressure Bar and Gauge Movement on 10 Diameter Units up to 20 000 Ib 10000 kg Reassembly of Pressure Bar and Gauge Movement on 10 Diameter Units up to 20 000 Ib 10000 kg If you are installing a new pressure bar be sure the capacity marking on the new bar matches the marking on the old bar The capacity letter along with other numbers are located on the narr
30. ow side of the bar between the end of the radius and the end of the pressure bar See Table 1 fora list of letters and capacities These steps cover disassembly of the 10 diameter units up to 20 000Ib 10000kg capacity to remove the pressure bar 1 Remove the four 6 32 x 74 pan head bezel screws holding the bezel to the housing 2 Lift off the bezel crystal and max hand assembly 3 Remove the pointer from the gauge movement shaft with a pointer puller P N 29945 0023 4 Remove the three 6 32 x 1 4 dial pan screw washer assemblies 5 Remove two 74 28 x socket head cap screws and two flat wash ers holding the housing to the pressure bar 6 Remove two 74 28 x socket head cap screws and two 74 flat wash ers holding the gauge movement assembly Set aside the gauge movement assembly with the dial inlay and pointer attached 7 Remove two 74 28 x socket head cap screws and two flat wash ers holding the zero adjust bracket Set aside the zero adjust bracket assembly 8 The pressure bar has four needle bearings Remove the bearings with a mechanical press with the plunge ram within Y degree of the bearing hole axis Under no circumstances should the bearings be removed by impact Take care that the plunger does not contact the sides of the bearing hole as you push out the bearing These steps cover reassembly of the 10 diameter units up to 20 000Ib 10000kg capacity See Table 2 for a list of proper torque for
31. range Zero the pointer repeatable rotational movement and calibration transfer standard indicator of the pressure arm under load ee We do not recommend that the 5 Apply four to five point calibration with the pointer and division mark instruments be calibrated or aligned at each reading as found have any type of performance reviewed with the bearings removed Span adjustment procedure 6a Apply the rated capacity load with the unit pointer and division mark aligned Move the zero adjusting bracket towards the center of the unit if the load shown on the calibration machine indicator is greater than the rated dynamometer load Move the bracket away from the center of the unit if the load shown on the calibration machine indicator is less than the rated dynamometer load Repeat this procedure until the unit is properly spanned 6b Tighten the zero adjustment bracket cap screws to 144 8 inch pounds torque Ta Linearity adjustment procedure Slight adjustments can be made to the midrange readings of the dynamometer 7b Loosen the two dial retaining screws Load the dynamometer until the pointer and the one half of rated capacity division mark are aligned Shift the bottom of the dial to the right if the load shown on the calibra tion machine indicator is greater than the half scale dynamometer load Shift the bottom of the dial to the left if the load shown on the calibra tion machine indicator is less than the half scale dyn
32. se compo nents can result in substandard performance and possible safety issues Defect Removal Allowances for Shackles and Shackle Pins After grinding apply suitable corrosion protection to the shackles The maximum cross sectional area reductions for the shack les and shackle pins are 10 and 5 respectively The nominal dimension removal allowances noted above will insure that the cross sectional areas remain within permis sible range 12 Wear of shackles Shackles showing a wear reduction due to use that reduces any nominal dimension of the shackle by five percent 5 or pin by more than 2 5 percent 2 5 shall be permanently removed from service For units up to 20 000 lbs shackle pins found to have needle bearing impression marks not greater than 0 004 inch deep are acceptable provided the dynamometer calibrates satisfactorily If the impression marks are greater than 0 004 inch deep the pin shall be permanently removed from service Deformation of shackles Shackles that are determined to have been deformed aside from local distortion at contact sites shall be permanently removed from service Any visually apparent bending or twisting out of the natural plane of the shackle or any distortion of nominal shackle profile beyond the localized wear found at the shackle loading point is cause for permanent removal from service Any shackles or pins that have a combination of wear and ground out areas that exce
33. t of the unit Apply five point calibration with the pointer and division mark aligned at each reading Readjust the unit span and linearity as required AP Dynamometer Service Manual 9 Install the maximum pointer assembly bezel and serial plate cover on the dynamometer Check the maximum hand adjustment The maxi mum hand turned counter clockwise must not move the dynamometer pointer more than one division before the clutch mechanism slips Readjust the clutch mechanism as required 10 Apply five point calibration with the pointer and division mark aligned at each reading 11 Remove the dynamometer and shackles from the calibration standard machine 12 Verify the calibration data satisfy the dynamometer accuracy specifica tion Enter the dynamometer serial number the verified accuracy tolerance percentage sign and date the certificate of calibration card Pointer Part Numbers Standard 5 127 mm Dynamometer All capacities through 20 000 Ib 10000 kg amp 100K newtons Standard 10 254 mm Dynamometer All capacities through 20 000 lb 10000 kg 8 100K newtons 30 000 through 100 000 Ib use PN 30079 0029 There are four different main pointers for the AP Dynamometers black To determine which pointer you need you must know where the zero is located on the dial See illustration below 12 12 00 PN 30246 0019 ee a i 3 00 PN 30246 0027 3 9 6 00 PN 30246 0035 G J 9 00 PN 302
34. y applying 1 00 to 1 05 times rated capacity load and then releasing the load completely Observe the smoothness of pointer travel throughout the full range Zero the pointer and calibration transfer standard indicator 5 Apply four to five point calibration with the pointer and division mark aligned at each reading 6a Apply the rated capacity load with the unit pointer and division mark aligned Move the zero adjusting bracket towards the center of the unit if the load shown on the calibration machine indicator is greater than the rated dynamometer load Move the bracket away from the center of the unit if the load shown on the calibration machine indicator is less than the rated dynamometer load Repeated this procedure until the unit is spanned 6b Tighten the zero adjustment bracket cap screws to 144 8 inch pounds torque 7T Linearity adjustment procedure Slight adjustments can be made to the midrange readings of the dynamometer 8a Loosen the two dial retaining screws Load the dynamometer until the pointer and the one half of rated capacity division mark are aligned Shift the bottom of the dial to the right if the load shown on the calibra tion machine indicator is greater than the half scale dynamometer load Shift the bottom of the dial to the left if the load shown on the calibra tion machine indicator is less than the half scale dynamometer load 8b Tighten the two dial retaining screws and recheck the span adjustmen
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