Car Alternator - new brushes, re-assembling, bench test, (Denso, Jeep Cherokee XJ, ZJ) Part 2 dynoguy 2026-09-27 | Car Alternator - new brushes, re-assembling, bench test, (Denso, Jeep Cherokee XJ, ZJ) Part 2
Weve got a new old Digger ! Kubota KH-90 mini excavator project, Ep# 1, quick test and look around dynoguy 2022-04-15 | We finally found a mini excavator which ticks most of the boxes, it's a rather sad looking Kubota KH90, manufactured from 1984 onward, still trying to find out when it was actually made.It looks really bad, but most things do work, somehow... main issue is a lot of rust, must have been sitting around for a long time. The undercarriage does need quite some work, also some leaks and the usual age related issues.I bought it from pictures and videos as i was away from home and had no chance too look at it, but did not want to miss the deal as they don't come up very often . The seller was, let's say semi-honest, especially regarding some particular details of the undercarriage and a massive oil leak (hole) on one of the bucket hard lines, the rollback of the delivery guy was soaked in oil ...:-)Did i pay too much ? Probably yes, but a 5 hours round trip + fuel is most likely worth the same i could eventually haggled off, so what !Why this one ? Obviously price, budget was limited. It moves on it's own steam, it was not too far away, saving on transport cost. It's big enough to be actually useful, did not want one of these toy diggers as you can't even lift something serious. It has steel tracks (which i wanted) and weighs 3.3 tons, which makes it less interesting for the public as here in the UK, you can't legally tow it with a trailer anymore.The KH-90 is quite similar to KH66, KH91 and KH101, especially most undercarriage parts seem to fit straight away.More to come, new drive sprocket, cylinder seals and hydraulic lines already here, just need the time to fit it .... as you can see at the very end, the Jeep is till on jack stands with no rear axle ....(c) 2022www.dynogouy.co.uk
Very dirty SSD (Parker) 590P, 725A DC Motor Drive, Ep#1 strip down for cleaning dynoguy 2022-02-23 | A very dirty SSD 590P DC drive needed recommissioning, but the drive is extremely dirty, also contaminated with fine metal particles.400V mains voltage together with carbon and metal glitter does almost guarantee for nice fireworks.The only way to ensure it does not go up in flames was a complete strip down and thorough cleaning.It also turned out that the heat sink and fan was so dirty that there was almost no air flow left, if it would not spark straight away, it would most certainly overheat.It became quite a lengthy 2 part video, but the main purpose is to show customers the importance of regular drive maintenance.This is not your average Chinese Huanyang hobby toy, it's a serious piece of kit for powering a big DC motor, see technical data belowDrive data:Make: SSD (Parker)Model: 590PSupply voltage: 220 - 500V AC, 3-phaseMax supply current: 653AMax Armature voltage: 600VMax Armature current: 725APart 2 to follow shortly(c) 2022www.dynoguy.co.uk
Jeep Cherokee XJ, major rust repairs , Ep#1 - looking at the issues dynoguy 2022-01-22 | The Jeep is due for MOT (annual vehicle inspection here in the UK), but it certainly won't pass this time as we have some major rust issues. Mainly boot floor, rear spring mounts and some part of the right sill are eaten away by salty roads in the winter time and our seaside climate.Well, that's what we know so far, but the list will be growing while working on it, ... as with most jobs on an old truck.In this episode we have a quick look at the obvious damage, but there is more ....I do have an original factory boot floor, but that involves a lot of metal in the rear has to be removed to get it fitted properly, and then everything must be welded back on. No other sheet metal parts available in the UK, therefore everything required has to be made from scratch.Also ordered some new springs and shackles as my old ones are over 12 years (and 120k miles) old, showing quite a lot of wear. These were aftermarket parts, not really sagging as the factory set did, but very worn at the edges.(c) 2022www.dynoguy.co,uk
Kearns Richards, Part 3 - Electrical Tests And First Run, S-type horizontal borer dynoguy 2021-12-30 | In this episode, we do some electrical checks and then power up the Kearns for the first time.Some stuff works, but there is also a lot which doesn't work,...and then there was that horrible noise coming from the feed gearbox.... looks like there are quite a few more episodes comingI just found this much desired addition to my workshop, entirely unexpected.Recently been to a customer who was moving premises and seen that old machine sitting there onblocks. Being on the lookout for one of those for quite a while, I could not resist to ask that magic question. Much to my surprise, he was willing to part with it, now see the result in the video ...:-)(c) 2021www.dynoguy.co.uk
Kearns S-Type Horizontal Boring Mill, Part2 - moving it into the shop dynoguy 2021-12-20 | In this episode, we move the Kearns to it's final place in the machine shop, next will be electrical test and first run,.... unfortunately, we found quite a few issues, so please stay tuned for the following episodes.I just found this much desired addition to my workshop, entirely unexpected.Recently been to a customer who was moving premises and seen that old machine sitting there onblocks. Being on the lookout for one of those for quite a while, I could not resist to ask that magic question. Much to my surprise, he was willing to part with it, now see the result in the video ...:-)(c) 2021www.dynoguy.co.uk
More Heavy Old English Iron For The Workshop Followed Me Home.... Kearns Richards S-type, part 1 dynoguy 2021-11-09 | I just found a much desired addition to my workshop, entirely unexpected.Recently been to a customer who was moving premises and i saw that old machine sitting there.Being on the lookout for one of those for quite a while, I could not resist to ask that magic question. Much to my surprise, he was willing to part with it, now see the result in the video ...:-)(c) 2021www.dynoguy.co.uk
Auction Scores 21-10, Kempi MIG welding torches, switch gear and some random bits dynoguy 2021-11-09 | Nothing super exciting in this lot, but for continuity reasons, i had to upload this before the next one, otherwise the announcement at the end won't make sense anymore2 of the big lights are working so far, The telephone system turned out to be a Panasonic KX-TA624, cleaned ok, but not yet tested.It certainly would be a nice replacement for my 25 year old KX-T616, ... my existing (proprietary) Panasonic system phones will work just fine on that. If it's any good, a testing and programming video will come as soon as i find the time for it.Just noticed that i did not really show the welding rod ovens, it's 21 in total, in various states of deterioration, maybe i'll do a video of fixing those ....(c) 2021 www.dynoguy.co.uk
Air Compressor - Poor Performance - fixing leaking reed valve dynoguy 2021-08-22 | My 10 year old compressor took longer and longer to fill up, so time to have a look what's wrong with it. Turned out to be a leaking intake valve and we found a zero $ solution to fix it.(c) 2021www. dynoguy.co.uk
Auction Scores 07.21 - steel storage rack, raw materials, etc dynoguy 2021-08-21 | Just another auction haul, this time with some bigger and heavier items ... :-)If you watch the video to the end, you can see what Groupie made of the little wooden tool box and also the steel rack at it's final place.The little shed briefly visible at the auction site will be the star of one of the next videos, itcame up for sale right after this pickup and we already made very good use of it.(c) 2021www.dynoguy.co.uk
Samsung SyncMaster 913n Monitor, power supply repair dynoguy 2021-08-20 | In this episode we are fixing a dead computer monitor, it just stopped working at some day. I usually don't throw things away without looking into it, so we had a closer look.It turned out to be repairable with rather little effort.Someone might say it's not worth to fix a 15 year old monitor, but it does exactly the job as good as a new one, so why not ? Certainly better than going to the landfill !I know, the title in the video says 930n, my bad, sorry(c) 2021www.dynoguy.co.uk
Electric Shower leaking inside - quick fix (UK domestic appliance) dynoguy 2021-08-19 | This is one of these cheap power showers, very popular in the UK as in older houses the hot water storage tank is not pressurized, just gravity fed by a cistern in the attic, therefore the hot water pressure is usually not sufficient for a normal shower head.These electric showers are pretty simple, basically just a massive heating element (8 to 12kW) , supplied with cold mains water.Looks a bit scary inside, i personally don't really like the close proximity of mains power and a shower head. But apparently these things are considered to be safe by UK regulations.Please note: Electricity can kill you, in most countries you must be qualified to work on fixed appliances. This video is for entertainment only and by no means an instructable(c) 2021www.dynoguy.co.uk
Volvo V50 D5 EGR Valve positioning fault, diagnosis and repair (codes 4450, 44D0 and limp mode) dynoguy 2021-08-17 | Back again on the Volvo V50 D5 SE. In this episode we trace and repair a fault with the EGR system.It started off with intermittent limp mode (no power, poor acceleration), but over about a week, the fault became permanent and the car was not really driveable anymore. Time to have a closer look.It turned out the EGR valve is mechanically ok, so just another electronics issue.Follow us on the journey to the solution.The procedure as shown does apply to Volvo C30, S40, V50 V70 models with the Euro 4 D5 engine,(5 cyl, 2.4 ltr Diesel with DPF) Depending on engine mapping and transmission, values might be slightly different, but the general principle is exactly the same.This particular car is an RHD 2007 Volvo V50 D5 SE with an AW55-51 automatic transmission,current mileage is around 167000 miles (267200 km)The Volvo V50 Project playlist is here:youtube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2021www.dynoguy.co.uk
Washing Machine Motor, Speed encoder fix (magnet ring falling off) dynoguy 2021-03-27 | A typical (brush - type) washing machine motor has a speed encoder on the back. this relies on a magnet ring, attached to the shaft. due to a bearing failure, the plastic was partially molten and therefore sitting rather loose on the shaft end.The failure symptoms are over speed and/or only short motor movement before showing an errordepends on control logic type and age of machine.Direct drive machines (no drive belt) using a different type of motor, but if the machine has a belt, it's most likely a variant of the motor shown in the videoIn this episode, we show a durable fix, involving some machining on the motor shaft.dismantling of this motor type is here:youtu.be/_7gNiUo6EeQ(c)2021www.dynoguy.co.uk
Tektronix 475 Repair - Ep# 4 - fixing the 110V supply ... but still a lot more work, to come dynoguy 2020-12-27 | Since we now have a trace and the CRT looking really good, it's worth to dig into it further. In this episode we fix an issue with the 110V DC supply,... but it seems there is quite a bit more wrong with it.We got a damaged Tektronix 475 for cheap, the seller stated that it was working before he sent it to the original buyer.Apparently he tried to repair it, but obviously gave up at some point and decided to sell it as it is.On first inspection, we found some damaged pot/switch in the timing circuit and a -8V supply short, but that was not all,... following was quite a lengthy investigation on some mysterious collection of faults. At the end, it turned out to be something rather simple, causing all the confusion and the strange behavior of the circuitry around the channel combiner circuitry.It is also rather unlikely that it was in fully working condition before the transport damage happened as we found a power supply capacitor which was completely dead. Probably would still have displayed a trace, but the scope won't be really usable with that amount of hum on the supply..On powering up after a brief safety inspection, the scope heavily distorted the camera audio. This was either something wildly oscillating, or a hefty dose of X-rays. No trace was visible, only a brief dot in the center, confirming the CRT is most likely working and sweep does not work at all.The scope is already back in working condition, you are invited to follow us over few episodes on the bumpy journey to success. ... so please stay tuned.Part 1 is here youtu.be/McfL-LA2DfIpart 2 hereyoutu.be/iNI0eaQDvWQpart 3 here:youtu.be/h-a5STd3NVE(c) 2020www.dynoguy.co.uk
Lansing Bagnall FODR6 , transmission leaks, brakes, This old forklift Ep#6 dynoguy 2020-12-27 | In this episode we continue to get the 1977 Lansing Bagnall FODR 6 forklift into reasonable shape. Please also watch the other episodes of this series, link to the playlist is at the bottom of this text.Looking into the brakes was a real surprise, it turned out to be most probably the only thing being in reasonable condition, brake shoes looked almost new and drums are pretty good as well. The video shows only the right hand side, but the other side was as equally good.The real purpose of this day's action was actually to stop some transmission leaks as it was constantly dripping ATF. Looks like it was satisfactory at the end, no more dripping, at least not from the transmission ....Still a lot more to do as this forklift has been neglected for many years, looks like pretty much no serve has bee done whatsoever, so stay tuned for upcoming episodesThe Lansing Playlist is here:https://www.youtube.com./playlist?list=PLJ5sckhk3nikP7WldJR0s_3keByT2RW7g(c) 2020www.dynoguy.co.uk
Solartron 7060 Bench Multimeter, fault finding and repair dynoguy 2020-12-26 | One of my trusty old Solartron 7060 Bench Multimeters suddenly stopped working. These meters are quite large for what they do, but also very accurate and usually pretty reliable.Features like auto ranging and GPIB remote control were state of the art in 1980. It also has low pass filters and plenty of digits. Once on the shelf, the size does not really matter anymore, that's why i have 2 of them in use on pretty much anything which needs accuracy and/or precision.I also like the timeless design (probably quite futuristic then) of Solartron gear of this era, it just never looks old ...Apart from size, it can still compete with a lot of modern gear, not bad for 40 years of age.The fault appeared to be a rather typical capacitor issue, but that was not all, so always worth looking twice before you call it repaired .... (c) 2020www.dynogu.co.uk
Volvo V50 D5, Wheel stuck on hub, replacing rear wheel bearing, brakes and suspension components. dynoguy 2020-12-26 | Back again on the Volvo V50 D5 SE. In this episode, we change the rear wheel bearing, shock absorbers and one of the control arms, also new brake discs and pads. We also had to deal with a badly stuck aluminium rim due to dissimilar metal corrosion between wheel and hub., looks like it has not been off for years.Nothing particular exciting, but maybe of help for someone.Unfortunately, 2500 miles later, both (new) rear shock absorbers started leaking, the seller has sent some new ones, we'll see if they last any longer once they fitted. We'll have a closer look at these in another video.The procedure as shown does apply to Volvo C30, S40, V50 models, also some Ford Focus and Mazda models. Depending on engine and transmission, dimensions might be slightly different, but the general principle is exactly the same.This particular car is an RHD 2007 Volvo V50 D5 SE with an AW55-51 automatic transmission,current mileage is around 157000 miles (251000 km)The Volvo V50 Project playlist is here:youtube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk
We have a trace ! Tektronix 475 Oscilloscope Repair - Ep# 3 - ... but still a lot more work, too dynoguy 2020-12-13 | We got a damaged Tektronix 475 for cheap, the seller stated that it was working before he sent it to the original buyer.Apparently he tried to repair it, but obviously gave up at some point and decided to sell it as it is.On first inspection, we found some damaged pot/switch in the timing circuit and a -8V supply short, but that was not all,... following was quite a lengthy investigation on some mysterious collection of faults. At the end, it turned out to be something rather simple, causing all the confusion and the strange behavior of the circuitry around the channel combiner circuitry.It is also rather unlikely that it was in fully working condition before the transport damage happened as we found a power supply capacitor which was completely dead. Probably would still have displayed a trace, but the scope won't be really usable with that amount of hum on the supply..On powering up after a brief safety inspection, the scope heavily distorted the camera audio. This was either something wildly oscillating, or a hefty dose of X-rays. No trace was visible, only a brief dot in the center, confirming the CRT is most likely working and sweep does not work at all.The scope is already back in working condition, so please follow us over few episodes on the bumpy journey to success.In this episode, we re-assemble the (sort of) repaired switch board for testing,.... and we've got a trace !.But there is quite a bit more to do before we can call it really a working scope ... so please stay tuned.Part 1 is here youtu.be/McfL-LA2DfIpart 2 hereyoutu.be/iNI0eaQDvWQpart 4 hereyoutu.be/g6_wFnkwcnI(c) 2020www.dynoguy.co.uk
Tektronix 475 Repair Ep# 2 - removing the timing switch board dynoguy 2020-12-13 | part 2 of the Tek 475 Story, in this episode, we removing the timing switch board, to get access to the destroyed pot.We recently found a transport damaged Tektronix 475 for cheap, the seller stated that it was working before he sent it to the original buyer.Apparently he tried to repair it, but obviously gave up at some point and decided to sell it as it is.On first inspection, we found some damaged pot/switch in the timing circuit and a -8V supply short, but that was not all,... following was quite a lengthy investigation on some mysterious collection of faults. At the end, it turned out to be something rather simple, causing all the confusion and the strange behavior of the circuitry around the channel combiner circuitry.It is also rather unlikely that it was in fully working condition before the transport damage happened as we found a power supply capacitor which was completely dead. Probably would still have displayed a trace, but the scope won't be really usable with that amount of hum on the supply..On powering up after a brief safety inspection, the scope heavily distorted the camera audio. This was either something wildly oscillating, or a hefty dose of X-rays. No trace was visible, only a brief dot in the center, confirming the CRT is most likely working and sweep does not work at all.The scope is already back in working condition, so please follow us over few episodes on the bumpy journey to success.Part 1 is here youtu.be/McfL-LA2DfIpart 3 is hereyoutu.be/h-a5STd3NVE(c) 2020www.dynoguy.co.uk
Tektronix 475 Oscilloscope Repair Ep# 1 - powers on but no trace. dynoguy 2020-12-13 | We found a transport damaged Tektronix 475 for cheap, the seller stated that it was working before he sent it to the original buyer.Apparently he tried to repair it, but obviously gave up at some point and decided to sell it as it is.On first inspection, we found some damaged pot/switch in the timing circuit and a -8V supply short, but that was not all,... following was quite a lengthy investigation on some mysterious collection of faults. At the end, it turned out to be something rather simple, causing all the confusion and the strange behavior of the circuitry around the channel combiner circuitry.It is also rather unlikely that it was in fully working condition before the transport damage happened as we found a power supply capacitor which was completely dead. Probably would still have displayed a trace, but the scope won't be really usable with that amount of hum on the supply..On powering up after a brief safety inspection, the scope heavily distorted the camera audio (the sequence is only about 20 seconds to show what happened) . This was either something wildly oscillating, or a hefty dose of X-rays. No trace was visible, only a brief dot in the center, confirming the CRT is most likely working and sweep does not work at all.The scope is already back in working condition, so please follow us over few episodes on the bumpy journey to success.Part 2 is hereyoutu.be/iNI0eaQDvWQ(c) 2020www.dynoguy.co.uk
Auction Bargains 11.20 - Steel, Aluminium, etc, pipe fittings, electrical bits + bobs dynoguy 2020-11-29 | We did it again,....another auction haul, ...this time just some cheap boxes full of random stuff, which at the end, turned out to be a real bargain.The repair of the 2 multimeters found in one of the boxes comes towards the end of the video.The company made camshafts, so some of the steel might be something better than just mild steel.(c) 2020www.dynoguy.co.uk
Auction Haul 09.20b, Part 2, welding equipment, electronic components, etc dynoguy 2020-11-26 | Another auction haul with some rather interesting stuff, this is part 2 of 2We bought a few assets of a closed down specialist welding machines company.In this episode, we have just a brief look at the things, the next episode shows a few more details.The highlights are certainly the 2 large TIG welders and a welding positioner which we will have a closer look in part 2.The blue test rig turned out to be a source of very nice parts, dismantling comes also in part 2.Meanwhile, i searched for information about the Hitachi machine, not much found really, just a spec sheet in Japanese saying it is rated at 500A.But according to Google, it was quite popular in Aerospace, probably around 15 years old. If anyone got a service manual, a copy would be much appreciated.The welding positioner needs a bit of work, so that's going to be a separate video.part 1 is here:youtu.be/gmdiOFTRTf4(c)2020www.dynoguy,co.uk
Auction Scores 09.20a, Part 1, TIG welding equipment, etc dynoguy 2020-11-23 | Another auction haul with some rather interesting stuff, this s part 1 of 2.We bought a few assets of a closed down specialist welding machines company.In this episode, we have just a brief look at the things, the next episode shows a few more details.The highlights are certainly the 2 large TIG welders and a welding positioner which may need a bit of work.The blue test rig turned out to be a source of very nice parts, dismantling comes in part 2.Meanwhile, i searched for information about the Hitachi machine, not much found really, just a spec sheet in Japanese saying it is rated at 500A.But according to Google, it was quite popular in Aerospace, probably around 15 years old. If anyone got a service manual, a copy would be much appreciated.part 2 is here:youtu.be/kjtS8TzNeGY(c)2020www.dynoguy,co.uk
Eddy Current Dyno Output Stage Repair (Coil driver module for engine dynamometer) dynoguy 2020-11-07 | In this episode we are repairing a power output module (coil driver stage) for an eddy current dynamometer. If you not interested in electronic circuit talk, this video might be rather boring as there is no fire, bang or explosions, not even smoke ....Now for the interested audience,... these module are essentially controlled rectifiers, directly powered by mains voltage, therefore lethal voltages inside.A current demand is applied to the input and the output current is following pretty linear via a closed loop current regulator. The output is a DC current with 100Hz ripple. (on a 50Hz mains)An eddy current dyno is essentially just a big inductor, obviously inheriting a time constant, back emf issues, etc, which the circuitry has to deal with as well, The trigger circuit for the output bridge is a rather unusual design, so it's certainly worth a video.And so was the fault, rather obvious what's wrong, but it took quite a while to get to the bottom of it.The main purpose of the video is actually showing the customer what has been done, sorry for the shaky camera but the main focus has been on doing the job, the video is just a by product, as with most of my videos.(c) 2020www.dynoguy.co.uk
Volvo V50 Front Suspension, Ep#5 , finally putting it back together dynoguy 2020-11-06 | Episode 5 of the Volvo V50 front end rebuild, this episode covers the final reassembling.In this series, we change major components of the front suspension, including drive shafts.Episode 1 shows dismantling, following episodes are wishbone replacement, shock absorbers, brakes and drive shafts.The procedure as shown does apply to Volvo C30, S40, V50 models, also some Ford Focus and Mazda models. Depending on engine and transmission, dimensions might be slightly different, but the general principle is the same.This particular car is a 2007 Volvo V50 D5 with automatic transmissionVolvo Project Playlist is hereyoutube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk.
Diesel Space Heater, fault finding and repair + some auction finds dynoguy 2020-11-01 | Here we looking into a iarge (43kW) diiesel fired space heater. It arrived dismantled and without any information why it has been taken apart.It's basically a standard Riello oil burner, just firing into a big cone.The only modification to the standard oil burner is a little circuit which keeps the motor running for a while after the burner has shut down. Seems that's just for cooling down the hot parts of the burn chamber.Apparently some electrical "expert" had his fingers on the wiring, probably trying to find whats wrong with it. I think the main fault was the oil supply issue as outlined in the video, the control relay was probably damaged by the wizzard while messing around.(c) 2020www.dynoguy.co.uk
Volvo V50 Front Suspension, Ep# 4, Shock absorbers, top strut bearings dynoguy 2020-10-17 | Episode 4 of the Volvo V50 front end rebuild, this episode covers front shock replacement, top strut bearings and the creeping camber issue with these cars.In this series, we change major components of the front suspension, including drive shafts.Episode 1 shows dismantling, following episodes are wishbone replacement, shock absorbers, brakes and drive shafts.The procedure as shown does apply to Volvo C30, S40, V50 models, also some Ford Focus and Mazda models. Depending on engine and transmission, dimensions might be slightly different, but the general principle is the same.This particular car is a 2007 Volvo V50 D5 with automatic transmissionVolvo Project Playlist is hereyoutube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk.
Pipe Hawk II GPR repair - Part 1, the dismantling challenge (Ground Penetrating Radar) dynoguy 2020-08-29 | Here we are looking into a faulty PipeHawk II ground penetrating radar, recently acquired at an auction as non-working, no further description from the seller.It was a bit of a gamble, but the asking price was so low that i simply could not resist bidding on it, plan B would stripping it for parts, but we obviously try to fix it first.It was quite challenging to get it apart for gaining access to the electronics compartment, required to get the internal PC back to life.Quite a clever design and not exactly obvious how things came together at the factory, it almost appears that someone tried to prevent the untrained folk to get the thing apart.Meanwhile, we already got some life back into it, just waiting for some parts to get my trial fix right, then sorting out some other minor issues, thereafter we'll check it with some real (known) underground pipework and see how it performsThe next episode shows how we finally got it up and running, also going through some issues which were most likely the case that this equipment got abandoned.(c) 2020www.dynogy.co.uk
Auction Scores 08.20, Eisele VMS metal saw, PipeHawk II GPR (Ground Penetrating Radar) , etc dynoguy 2020-08-29 | Look what followed me home from an Industrial auction ....Eisele VMS II PV300 semi automatic metal chop saw, a brief check shows no major faults, mainly wear and pneumatic issues, more to come on this.The PipeHawk was a bit of a challenge, multiple faults, but basic functionality is already restored, more to come on that soon as well.(c) 2020www.dynoguy.co.uk
Tektronix 464 oscilloscope repair, channel off screen/large offset and other issues dynoguy 2020-08-16 | The trusty Tek 464 suddenly lost channel one, it turned out that the channel was still there but way off screen to the negative. It also had some other faults which are inconvenient but don't make it unusable, therefore i just lived with it until now, Since we had to go into it, we addressed most of these as well. This episode shows the fix of the non working channel, the following episode covers some of the other issues and a rather surprising performance test.The Tek 464 is a 100MHz analogue storage scope which utilizes a variable persistance CRT, that means everything is done with the CRT, no digital electronics involved whatsoever.The CRT actually writes and stores everything in real time.List price in the 1978 Catalogue is $4120 plus $125 for option 07 (12V DC supply option ).Being a Tek scope from the good old days (made in 1978) it well exceeds the specs, as we show in the next episode. (c) 2020www.dynoguy.co.uk
Volvo V50 Front End - Ep#3, The drive shaft drama, or why you should always check your spare parts dynoguy 2020-08-06 | Episode 3 of the Volvo V50 front end rebuild, this episode covers the drive shafts and some issues with suppliers, one delivering entirely wrong parts and the other one supplied a part which was not fit for purpose.In this series, we change major components of the front suspension, including drive shafts.Episode 1 shows dismantling, following episodes are wishbone replacement, shock absorbers, brakes and drive shafts.The procedure as shown does apply to Volvo C30, S40, V50 models, also some Ford Focus and Mazda models. Depending on engine and transmission, dimensions might be slightly different, but the general principle is the same.This particular car is a 2007 Volvo V50 D5 with automatic transmissionVolvo Project Playlist is hereyoutube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk.
Volvo V50 Front Suspension - Ep#2, wishbones (front lower control arms) replacement dynoguy 2020-08-02 | Episode 2 of the Volvo V50 front end rebuild, this episode covers the lower control arms (wishbones)In this series, we change major components of the front suspension, including drive shafts.Episode 1 shows dismantling, following episodes are wishbone replacement, shock absorbers, brakes and drive shafts.The procedure as shown does apply to Volvo C30, S40, V50 models, also some Ford Focus and Mazda models. Depending on engine and transmission, dimensions might be slightly different, but the general principle is the same.The wishbones are a rather simple job, but if you got Xenon lights, there is a feature at the front right lower arm which is quite important.Volvo Project Playlist is hereyoutube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk.
Volvo V50 Front Suspension Rebuild, Ep#1 dismantling - shocks, drive shafts, brakes dynoguy 2020-08-02 | In this series, we change major components of the front suspension, including drive shafts and brakes.Episode 1 shows dismantling, following episodes are wishbone replacement, shock absorbers and drive shafts. Rear shocks, brakes and a wheel bearing also will be changed.This acar is a 2007 V50 D5, but the procedure as shown does apply to most Volvo C30, S40, V50 models, also some Ford Focus and Mazda models. Depending on engine and transmission, dimensions might be slightly different, but the general principle is the same.Unfortunately, the driveshafts were are rather painful journey, because the first supplier did send both sides wrong, replaced one which then finally had the right dimensions, but with the other side they said they have only the one they sent and it would fit auto and manual transmission, which is absolutely not the case.So i decided to order it elsewhere, but it turned out that was not a direct fit either.Finally decided to make a custom part to ensure it fits correctly.Volvo Project Playlist is hereyoutube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk.
Air compressor tank testing, Getting a new life into an old air compressor, part 1 dynoguy 2020-05-13 | In this series, we restoring an old air compressor, Ep #1 starts with pressure testing the tank.This compressor has been sitting unused for almost 10 years, so it's probably not a good idea to fire it up without knowing the air tank is safe to use.Before filling it with water, we looked into it with an inspection camera, but the footage was only glare, perhaps we repeat that in a later episode.For your own safety, never ever test an air tank with air, always use water !This unit is a 90 liter, 3kW 3-phase version, made by Kaeser in 1982(c) 2020www.dynoguy.co.uk
Mitsubishi GDI fault code P0190 and how to fix it, 4G94 engine, 2.0 GDI, Shogun Pinin dynoguy 2020-05-13 | Mitsubishi GDI engines are rather sensitive when it comes to fuel system issues.The P0190 error code can be misleading at first sight, therefore it is important to go through the whole fuel system and make sure everything is in order. Changing random components is certainly not the right way to get to the bottom, especially if it is a sporadic fault.The official description for this fault code is "Fuel pressure sensor circuit malfunction" but does not necessarily mean the sensor is faulty, a clogged filter can cause the same code, because the fault condition is a rather simple range check. Low pressure, e.g because of blocked filters, etc may trigger it as wellThis video shows inspection and diagnosis, resulting in a $40 fix, rather than a new high pressure pump which is often suggested as a solution.This particular car is a Shogun Pinin with the 2.0 GDI . 4G94 engine which was also used in other Mitsubishi Models, therefore the same principle will apply. To my knowledge this even applies to other GDi variants as well, including some GDI 6 cylinders.(c) 2020www.dynoguy.co.uk
Mitsubishi GDI, EGR + intake cleaning, part 2 (2.0 GDI engine, 4G94, Shogun Pinin, iO, Montery) dynoguy 2020-05-12 | This is part 2 of the intage/EGR system cleaning on the Mitsubishi.Link to part 1 is at the bottom of this text.Mitsubishi GDI engines (as most other Gasoline DI engines) suffer from coked + gunked up intake systems, some more, some less, but it always happens. Sooner or later, the engine will loose power and fuel consumption is getting worse .The only solution is cleaning the entire intake and EGR system, this is usually done with some sort of sand blaster, but using walnut shells as a blasting media, because any remains will go into the cylinders and sand is the last thing you want there.A we don't have the equipment, we came up with another solution, takes a bit more time, but the result is good.Part 1 shows dismantling the entire thing, part 2 will be cleaning and re-assembling.The Mitsubishi 4G94 2.0 GDI Engine is used in many Mitsubishi cars, the 1.8 version was also used in Volvo S40 Models.This one is a 2002 Mitsubishi Shogun Pinin Mirage with an Aisin AW4 automatic transmission. In some countries this was sold as a Mitsubishi "iO" alo as "Montery"The high pressure fuel sensor fault ( P0190 ) fix comes after this one in a separate video.Part 1 is here:youtu.be/k3GemLazJmA(c) 2020www.dynoguy.co.uk
2 sick Westwood garden tractors , Part 2 - the final result (T1200 lawn mower, ride on mower) dynoguy 2020-05-03 | This episode #2 shows the final result of the story below ....I needed some spare parts for my Westwood D1200 lawnmower and a friend needed an engine. Most obvious place to go is ebay, so i was bidding on 2 machines rather close to me. Mine is a diesel, so the petrol engine was useless to me but the other parts are the same.Got the first one rather cheap and forgot about the other bid. A few days later i got an email that i won the second ones as well, this one had a sick engine.So change of plans, we'll keep the good bits, my friend gets the working Briggs engine and we'll see if we can fix the second one and flogg it.It was a bit of work, but we got it back to life, fixed the engine, welded the cutting deck, replaced some rollers and tided up the messy electrics.This part shows some more fixes and the final result.This was filmed some time ago, still at the old premises.The Westwood playlist is here:youtube.com/playlist?list=PLJ5sckhk3nil3XSHXSRKx5EQVZNWLlLoI(c) 2020www.dynoguy.co.uk
Two sick Westwood T1200 garden tractors + interesting faults, Part 1 (lawn mower, ride on mower) dynoguy 2020-04-26 | I needed some spare parts for my Westwood D1200 lawnmower and a friend needed an engine. Most obvious place to go is ebay, so i was bidding on 2 machines rather close to me. Mine is a diesel, so the petrol engine was useless to me but the other parts are the same.Got the first one rather cheap and forgot about the other bid. A few days later i got an email that i won the second ones as well, this one had a sick engine.So change of plans, we'll keep the good bits, my friend gets the working Briggs engine and we'll see if we can fix the second one and flogg it.It was a bit of work, but we got it back to life, fixed the engine, welded the cutting deck, replaced some rollers and tided up the messy electrics.This part shows arrival and some fault finding, part 2 will show some more fixes and the final result.This was filmed some time ago, still at the old premises.The Westwood playlist is here:youtube.com/playlist?list=PLJ5sckhk3nil3XSHXSRKx5EQVZNWLlLoI(c) 2020www.dynoguy.co.uk
Coal mining - Mitsubishi 2.0 GDI EGR de-coking - Part 1, tear down and inspection, 4G94 engine dynoguy 2020-04-19 | Mitsubishi GDI engines (as most other Gasoline DI engines) suffer from coked + gunked up intake systems, some more, some less, but it always happens. Sooner or later, the engine will loose power and fuel consumption is getting worse .The only solution is cleaning the entire intake and EGR system, this is usually done with some sort of sand blaster, but using walnut shells as a blasting media, because any remains will go into the cylinders and sand is the last thing you want there.A we don't have the equipment, we came up with another solution, takes a bit more time, but the result is good.Part 1 shows dismantling the entire thing, part 2 will be cleaning and re-assembling.The Mitsubishi 4G94 2.0 GDI Engine is used in many Mitsubishi cars, the 1.8 version was also used in Volvo S40 Models.This one is a 2002 Mitsubishi Shogun Pinin Mirage with an Aisin AW4 automatic transmission. In some countries this was sold as a Mitsubishi "iO" alo as "Montery"Part 2 is here:youtu.be/lE3FafoBBS8(c) 2020www.dynoguy.co.uk
Volvo V50 alternator pulley change - The Volvo V50 D5 Project, Part 6 dynoguy 2020-04-18 | Working on the Volvo V50 D5 again. In this episode we changing the faulty alternator free wheeling pulley (sprag clutch).A faulty pulley clutch can cause many issues, worst case with this particular engine is that it can cause a catastrophic cam belt failure.Sound strange at first, but looking at the chain of events it boils down to a simple design flaw.,... if one of the drive belts goes flying, it can sling around the crank pulley and rip the cam belt off, the plastic cam cover is just too weak. Therefore it is important to keep an eye on these belts and accessories.These sprag pulleys are easily forgotten in maintenance schedules, but with modern turbo charged engines, producing large crank speed amplitudes , it's essential to keep them in good working order. Worst case is a (self) unscrewed pulley, but premature belt failures or poor idle are other common issues and if a whistling sound comes from your alternator, it's most likely time to change the pulley.Volvo Project Playlist is hereyoutube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk
Hydraulic cylinder repairs/assembling, This old forklift Ep#5, Lansing Bagnall FODR6 tilt cylinder dynoguy 2020-04-04 | In this episode we continue with the Lansing tilt cylinder repair. Please also watch the other episodes of this series, link to the playlist is at the bottom of this text.Almost every part had lots of dings and dents from previous repairs over the last 40+ years of it's life, so we spent quite a bit of time inspecting everything, machine and hone as required.It paid off at the end, everything fits nicely and the cylinder now works as it should.While testing, it turned out that the other tilt cylinder has extensive play on the bottom pin, need to take it out anyway as it's leaking as well, just not as bad as this one did.As soon as time allows, we'll have a look into that one. too.The Lansing Playlist is here:youtube.com/playlist?list=PLJ5sckhk3nikP7WldJR0s_3keByT2RW7gSeals suppler:thepartscentre.co.uk(c) 2020www.dynoguy.co.uk
Hydraulic cylinder tear down, This old forklift Ep#4, Lansing Bagnall FODR6 tilt cylinder dynoguy 2020-04-03 | Tn this episode we strip down the left tilt cylinder and found some rather nasty surprises. It was extremely difficult to get the gland plug out, so we had to apply some rather unusual methods to get it apart. On inspecting everything, it was obvious that this guy with only a hammer in his toolbox was there before and left some obvious traces of his destructive skills. Not exactly unexpected as it fits the big picture of this 40+ years old truck.As almost always with this forklift, a 3 hours seal change job turns into a much longer journey, therefore this became a 2 part video.Almost any part of this cylinder will need some rework, so that's coming in the next episode.With the correct seal kit and not been messed around with before, this cylinder would be very easy to repair, because it is a split piston design, so no trouble to get the piston seals on.At least the seal kit seems to be a perfect fit ....The Lansing Playlist is here:youtube.com/playlist?list=PLJ5sckhk3nikP7WldJR0s_3keByT2RW7gSeals suppler:thepartscentre.co.uk(c) 2020www.dynoguy.co.uk
Westwood 42 Cutting Deck repair (T1200 Diesel Ride-on mower, garden tractor) dynoguy 2020-03-27 | This is the counter rotating 42" deck, fitted to the Westwood Diesel mowers in the 1980s. It has interfering blades, therefore these are timed with a tooth belt (timing belt)If the right blade hits something very hard,. the belt usually snaps.That's exactly what happened, so we had to fix it.This was filmed in September 2019, The Westwood plalist is here:youtube.com/playlist?list=PLJ5sckhk3nil3XSHXSRKx5EQVZNWLlLoI(c) 2020www.dynoguy.co.uk
Diesel injector fix - This Old Forklift, Ep#3, Lansing Bagnall FODR6 , Perkins 4.203 dynoguy 2020-03-26 | I this episode we pulling the injectors and test them. As expected, they were in rather poor shape.Time for some good old fashioned injector service.The actual rebuild is covered in the video just before this one, here we show only removal, initial test and dismantling the first one, also the result once fitted back in the engine.If you follow this series, you may notice that some work has been done which is not published right now, the reason is that it might not yet be finished, but it will certainly come in later episodes once the job is completed.The good news is that i found 2 complete seal kits for the tilt cylinders, so that's coming soon as well.The Lansing Playlist is here:youtube.com/playlist?list=PLJ5sckhk3nikP7WldJR0s_3keByT2RW7g(c) 2020www.dynoguy.co.uk
Diesel Injector repairs + pressure setting, Perkins 4.203 engine (CAV injectors) dynoguy 2020-03-25 | These are the injectors of my Perkins 4.203 forklift engine with CAV injectors, the engine was smoking badly and misfiring sometimes, too.Time for the 500 hour maintenance as i think that no one looked at these for a long time. It turned out that 2 were leaking badly and nozzles were stuck, the #3 pintle was a real challenge to get out, so we applied some rather unusual method to get it out. Another one was a different type and all were low on opening pressure. one as low as 95 bar,Standard setting for this engine should be 120bar.All 4 now performing reasonably ok and the engine runs much better.Episode #3 of the forklift story (coming soon) will show dismantling the first injector, this video shows cleaning, re-assembly and pressure setting.The engine is not the best anymore, producing a lot of blowby, so every little helps, but sooner or later, i will need to rebuild it anyway.Therefore i am happy with the result, even the injectors would need new nozzle kits to make them perfect.The Lansing Playlist is here:youtube.com/playlist?list=PLJ5sckhk3nikP7WldJR0s_3keByT2RW7g(c) 2020www.dynoguy.co.uk
HP5328B Frequency Counter, tear down, inspection and repair (Hewlett Packard test equipment) dynoguy 2020-03-23 | In this episode, we looking into an Hewlett Packard HP 5328B frequency counter. Acquired cheaply on a local surplus auction because it was dead, together with another 5238 (512MHz only) and a HP5345.Counter which might be featured in another video.What makes this example particular interesting is the heated high stability time base and the 1.3GHz option, also HPIB, these specs don't turn up for sale very often on these. It has the one piece front panel with the black stripe, so it guess it is a later model.List price in the 1991 catalogue for this particular model and options was a whopping $ 8745 ....It had a rather stupid man-made fault, so the symptoms did not really make sense at first sight. Once i found the issue, it was a rather easy fix.It's now working fine and already found a place in the lab.My problem with HP gear is that i just can't resist if it comes up cheaply, this score increases my number of various HP5328 models to a total of 4 ....:-)(c) 2020www.dynoguy.co.uk
Auction scores March 2020, ....finds from a local surplus auction dynoguy 2020-03-23 | Just some random finds from a local surplus auction.Various electronic test gear and other stuff, enjoy !(c) 2020www.dynoguy.co.uk
This Old Forklift, Ep#2, restoring a very tired Lansing Bagnall FODR6 2.0 dynoguy 2020-03-10 | In this episode we address a few of the most important issues to get it moving and lifting at least.Transmission and hydraulic tank were almost dry, after topping up it drives and lifts ok. Leaking fuel pump fix comes in the next episode.Obviously, the more i look at it, the more issues become apparent..Just noticed that one of the mast pins is really beaten up and not centered. Looks like a job for the lathe.We just had a new battery, ignition barrel and starter motor delivered, so some work on the electrics will be coming soon, tooSee also the description in part 1 of this series.The Lansing Playlist is here:youtube.com/playlist?list=PLJ5sckhk3nikP7WldJR0s_3keByT2RW7g(c) 2020www.dynoguy.co.uk
This Old Forklift, Ep#1, restoring a very tired Lansing Bagnall FODR6 2.0 dynoguy 2020-03-10 | Following the (again) popular slogan 'buy British', an old Lansing Bagnall FODR6, made in the mid 1970's, followed me home.Found it on ebay, not exactly the cheapest but with the right specs, which are: big wheels, diesel, min 2 ton, short mast and under £1500 (USD 2000).The seller was not exactly honest and it has a lot more issues than he was telling. The irony is that this came from a classic car restoration business, i wonder how their cars look under the shiny paint ...:-)But it did run (barely) on it's own steam, so it was not too difficult to move, Most forklifts have hydraulic steering, that means no steering without a running engine.Tires are air inflatet (not solids) , old but some thread left and do hold pressure reasonably ok. It was only 60 miles away, so transport cost was reasonable ( £260, about $300)The engine is a Perkins 4 cylinder Diesel, either a 4.192 or a 4.203, i could not yet find the engine number, but it's probably around 60hp. Transmisson is a Warner 10-10 single speed industrial with torque converter, no clutch, just throttle and (non working) brake.It was leaking like a sieve. pouring out twice as much Diesel than it actually burned, the engine smokes a fair bit and all fluid levels were all below registration on the dipsticks. Electrics are a rats nest, nothing apart from the (pretty worn out) starter works, battery was dead. The fuel system is completely messed up, no filter, piping completely wrong, original fuel tank is present and not leaking but for some reason, the previous owner fitted an old oil can as a tank ... Tilt cylinders are squirting oil, lift cylinder looks fairly ok, steering cylinder is wet but not dripping.Service brake does not work because it is disconnected entirely, parking brake works somewhat.Engine is wetter than sardines in oil, but a head cover gasket and a crank pulley seal should stop most of it, these old Perkins Diesels always mark their territory a bit.Lots of other issues, but we'll fix them as time and budget allows.Since major engine and transmission issues are fixed already, it is now usable with caution, next episode to come soon In 1989, Lansing Bagnall was acquired by Linde, therefore information and specific parts are hard to come by nowadays.Very little to find on the internet and i have not seen one of those in real for years.If someone has documents regarding the FODR6 series (or FOPR6, FOGR6, same truck but different engines), please let me know.Luckily, they used many generic parts so it should not be too difficult to keep it going. Engine parts are easy to get, Perkins still sells parts for those, lots of aftermarket parts available, tooThe Lansing Playlist is here:youtube.com/playlist?list=PLJ5sckhk3nikP7WldJR0s_3keByT2RW7g(c) 2020www.dynoguy.co.uk
Volvo V50, cracked headlight fix, changing front glass on a sealed unit dynoguy 2020-01-10 | Working on the Volvo V50 D5 again. In this episode No.5 we trying to fix a broken headlight. Replacing the entire unit would be 3 minutes job due to Volvo's ingenious mounting system. The bigger issue is that these HID units super expensive, even second hand these are demanding silly prices. The cheapest i could find was around $200 (used)So i decided to buy a dirt cheap H7 unit at the breaker yard and just swap the front glass. ($30 used).The housing and front glass are pretty much identical, but the internals are obviously quite differentNot normally designed to be replaced, but with some care and a heat gun, it is actually doable and the result looks almost as good as new. Volvo Project Playlist is hereyoutube.com/playlist?list=PLJ5sckhk3ninv5WtcdeannTCT0JQ9sm3f(c) 2020www.dynoguy.co.uk
