MAHA ZW 500 Operating Instructions Manual

ZW 500

Power Take-off Dynamometer

Original Operating Instructions

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Contents

1 Safety ...................................................................................................................... 5

1.1 Introduction ......................................................................................................................................... 5

1.2 Safety Information .............................................................................................................................. 5

1.3 Safety Information about the Eddy Current Brake ............................................................................. 6

1.4 Further Information ............................................................................................................................. 6

2 Description .............................................................................................................. 7

2.1 General Information............................................................................................................................ 7

2.2 Specifications ..................................................................................................................................... 7

2.2.1 Brake Unit with Trailer ........................................................................................................................ 7

2.2.2 Performance Table (without Gear) ..................................................................................................... 8

2.2.3 Hand Terminal .................................................................................................................................... 8

3 Installation ............................................................................................................... 9

3.1 Requirements for the Place of Installation ......................................................................................... 9

3.2 Technical Safety Measures in Test Rooms........................................................................................ 9

3.2.1 Exhaust Suction System .................................................................................................................... 9

3.2.2 Fresh Air Supply for the Test Room ................................................................................................... 9

3.3 Preparations for a Performance Test ............................................................................................... 10

4 Operation .............................................................................................................. 11

4.1 Radio Hand-Held Terminal ............................................................................................................... 11

4.1.1 Keyboard Assignment ...................................................................................................................... 12

4.2 Program Structure ............................................................................................................................ 14

4.3 Start- / Print Menu <F2> ................................................................................................................... 14

4.3.1 Vehicle Data Entry ............................................................................................................................ 15

4.4 Main Menu <F3> .............................................................................................................................. 15

4.4.1 Constant RPM .................................................................................................................................. 17

4.4.2 Constant Torque ............................................................................................................................... 18

4.4.3 Discrete Measurement ..................................................................................................................... 19

4.4.4 Warm-up Drive ................................................................................................................................. 21

4.5 Setting Menu <F1> ........................................................................................................................... 22

4.5.1 Set Contrast ..................................................................................................................................... 22

4.5.2 Set Date and Time ........................................................................................................................... 23

4.5.3 Program Address ............................................................................................................................. 24

4.5.4 Program Variables ............................................................................................................................ 24

4.5.5 Print Configuration ............................................................................................................................ 26

4.6 Short Operating Instructions for Vehicle Test .................................................................................. 27

4.6.1 Constant RPM or constant Torque ................................................................................................... 27

4.6.2 Discrete Measurement ..................................................................................................................... 27

4.6.3 Warm-up Drive ................................................................................................................................. 27

5 Maintenance.......................................................................................................... 28

5.1 Annual Inspection ............................................................................................................................. 28

5.2 Care Instructions .............................................................................................................................. 28

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5.3 Maintenance by the Operator ........................................................................................................... 28

5.3.1 Bearing Positions ............................................................................................................................. 28

5.3.2 Screw Connections .......................................................................................................................... 28

5.3.3 Eddy Current Brake .......................................................................................................................... 28

5.3.4 Trailer ............................................................................................................................................... 28

5.4 Spare Parts ...................................................................................................................................... 29

6 Dismantling ........................................................................................................... 29

7 Disposal ................................................................................................................ 29

8 Contents of the Declaration of Conformity ............................................................ 29

9 Company Information ............................................................................................ 30

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1 Safety

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1.1 Introduction

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Thoroughly read this manual before operating the equipment and comply with the instructions.
Always display the manual in a conspicuous location.

Personal injury and property damage incurred due to non-compliance with these safety

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instructions are not covered by the product liability regulations.

Important safety instructions. Failure to comply with instructions could result in personal injury or
property damage.

Important information.

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Carefully observe all safety instructions. They are provided to warn of dangers and help prevent
personal injury and property damage.

It is the operator’s responsibility to comply with the applicable accident prevention regulations
and to bring them up to date continually.

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1.2 Safety Information

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Safety information is provided to warn about dangerous situations and help prevent damage to
equipment and injury to persons.

• The test equipment may only be used and operated for its intended purpose and within its
stated performance limits!

• The dynamometer may only be operated by trained, authorized personnel

• Explosion protection! The dynamometer may not be installed and operated in explosion

endangered rooms! Standard serial dynamometers have no EX protection.

• In case of emergency turn the main switch (the Emergency-Off switch) to 0.!

• No persons are allowed in the danger zone surrounding the dynamometer!

Rotating or moving parts are dangerous. (e.g. connection shaft) .

• Use ear protection! The ear protection must be suitable for the noise level.

• Pay close attention when engines are running. Running vehicle engines represent potential

carbon monoxide poisoning.

• Before doing any repair / maintenance / set up work turn off the main switch and secure it
against tampering.

• Secure the dynamometer against unauthorized usage by locking the main switch.

• All work done on electrical parts of the equipment is to be carried out by trained, qualified

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electricians.

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1.3 Safety Information about the Eddy Current Bra k e

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The eddy current brake can heat up significantly during long lasting usage (> 500 °C). The
brake rotors may become red hot.
After a long lasting measurement under load, the eddy current brake should continue to be
rotated without load by the vehicle at a speed of 600…800 rpm for 3…5 minutes.
The rotating rotors suck cooled air from the side and throw it radially off. The eddy current brake

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1.4 Further Information

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is thereby effectively cooled preventing heat build-up at the rotors damaging the coil insulation.

During installation:

• Noise protection! Use noise protection in the work areas near the dynamometer !

During operation:

• Please read the operation & maintenance manual thoroughly. If damage or service costs are
incurred due to non-compliance with these instructions, MAHA is not liable for the damage
and/or service costs will not be covered.

• Carefully observe all accident prevention regulations!

• Adjustment and maintenance work may not be done when the dynamometer is switched on!

• The test vehicle must be road worthy!

• The dynamometer and work area must be kept clean at all times.

• The dynamometer may only be operated within its stated performance limits!

• The dynamometer should be cordoned off or covered if it is located direc t l y in the work shop

or in an area to be which the public has access.

• Work on pulse sensors and proximity switches may only be done by trained, skilled
electricians.

• Never operate the dynamometer without the pr otec t ive grat ing.

• Turn off dynamometer and vehicle when mounting and dismantling the connection shaft.

• Use power take-off shafts which correspond with the performance ranges.

• If the dynamometer is located outdoors both ventilators must be covered.

• Pay attention that the hand terminal is always well.charged. Maximum operating time is 4-5

hours without re-charging.

• The hand terminal can also be operated with the mains power supply.

• When transporting power take-off shafts in the dynamometer house pay close attention to

the maximum load capacity and if necessary, weigh.

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2 Description

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2.1 General Information

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Following measurements are possible:

• Measurement of the motor performance on the power take-off shaft

• Measurement of the performance with constant RPM via automatic RPM regulation

• Measurement of performance with constant torque via automatic RPM regulation

• Discrete performance measurement possible

• Performance warm-up drive program

• Emission measurement (optional)

• Consumption measurement (optional)

• Pressure-temperature-measurement (PC version optional)

The dynamometer consists of:

• A hand terminal with LCD display, keyboard and printer, radio transmission

• Load unit with two eddy current brakes

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• PC or Laptop (optional)

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2.2 Specifications

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2.2.1 Brake Unit with Trailer

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Dimensions ( W x H x L) (2080 x 1515 x 3580) mm
Torque max. 6600 Nm
Test RPM (Direct drive) max. 2500 min
Measurement system Electronic strain gauge technology
Power connection 400V, 50/60 Hz, 16 A
Weight (with trailer) ca. 1300 kg
Support load 75 kg
Rated current 15 A
Fuse 16 A time-delay

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2.2.2 Performance Table (without Gear)

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Length of time With performance n
1 Minute 500 kW
3 Minutes 450 kW
6 Minutes 320 kW
9 Minutes 280 kW
12 Minutes 220 kW

power take off shaft

1000 min-1

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2.2.3 Hand Terminal

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* Dependent upon environmental influences

Dimensions of hand terminal (W x H x D) 125 x 56 x 250 mm
Weight approx. 1 kg
Connection battery 15 V
Power consumption 150…500 mA
Working temperature 0…+50 °C
Storage temperature -20…+60 °C
Display 2 x 16 digits
RS232 interface 9600 Baud,1Start-/ 1Stopbit, 8 Databit

Paper width 58 mm
Type of paper Wood-free
Roller diameter 50 mm max.

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3 Installation

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3.1 Requirements for the Place of Installation

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The dynamometer can be operated outdoors as well as in enclosed rooms.
If the dynamometer is operated in an enclosed room, this must be in accordance with the

statutory regulations for work places. An adequate fresh-air supply and an exhaust shaft should

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3.2 Technical Safety Measures in Test Rooms

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3.2.1 Exhaust Suction System

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also be available.

The following technical safety precautions must be observed by the customer at all times.
Disregarding these precautions can be life-threatening even for those who enter the room for

only a very short period.

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As a safety precaution it is recommended that a CO warning device be installed in the test
room.

The exhaust discharge for the auto exhaust can be done with suction hoses or with suction

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3.2.2 Fresh Air Supply for the Test Room

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flaps.

According to currently effective regulations in the Federal Republic of Germany, the air must be
renewed 10 to 15 times per hour in closed testing rooms with a surface area up to 100 m².

The air must be renewed 5 to 8 times per hour in rooms over 100 m².
An air throughput of approx. 5000 m³/h is required for a surface area of 100 m².

An inadequate fresh-air supply increases the burden on the test personnel and distorts the test
results.

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3.3 Preparations for a Performance Test

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1 Position the trailer with the dynamometer on a suitable, level surface.
2 Pull on the hand brakes.
3 Pull out the supports of the trailer to prevent any swinging movements:

- Lower the trailer forward over the support wheel

- Lower the support foot in the rear and fix it

- Raise the trailer over the support wheel (ca. 10 cm)

- Lower the support foot in the front and fix

- Slightly loosen the support wheel( 1 rotation)

4 Open front flap.
5 Mount the power take-off shaft so that it is aligned with the vehicle.

Switch off the dynamometer and the vehicle when mounting and removing the connection shaft.

Use a suitable power take-off shaft depending on the performance range!
Pay attention to the rotation direction of the shaft.
The rotation direction of the dynamometer shaft must show in direction of the drawbar!
The dynamometer will not brake if the rotation direction is wrong!

6 Chain on the protective sheathing for the power take-off shaft.
7 Connect dynamometer to power supply.
8 Switch on the main switch.
9 Activate the hand terminal using any key.
10 Optional: Connect consumption measurement device, see Chapter Main menu.
⇒ The dynamometer is now ready for testing. The performance measurement is done after the

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vehicle is warmed-up.

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4 Operation

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4.1 Radio Hand-Held Terminal

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The dynamometer can be operated via the hand-held terminal. Data or instructions can be
entered via the keypad.

The terminal is used for:

• Printout

• Data on the LCD display

A Printer mechanism
B 2-line LCD display
C Not used
D Re-charging plug

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E Keypad

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A

B

C

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D

E

C

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4.1.1 Keyboard Assignment

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A B F E

C

D

G

H

I

O

N

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M

L

J

K

P

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The hand-held terminal can be switched on with any key.
If the hand-held terminal is not used for longer than 20 minutes, it switches off automatically

(battery saving mode). The switch-off time is adjustable.

Key Description

A Open setting menu
B Start menu, open printer menu
C Open main menu with test mode
D Switchover between shaft rpm and motor rpm (V1.11 or higher)
E Reduction of the target value (rpm / torque)
F Increasing the target value (rpm / torque)
G Enter key, confirm selection menus and/or entries
H Delete

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I Switch forward display window of menu and measurement values

J Switch back display window of menu and measurement values
K Digit block for numerical input or menu selection (if available)
L Space key, paper feed for printer

M Comma for numerical input
N Termination of current measurement, complete printout, change between the menus
O Keypad for text input

Switchover between PS and kW; available if measurement not yet started (V1.11 or

P

higher)

N+A+G

Switch off ⇒ If the hand-held terminal is connected to the power unit, it cannot be

switched off.

Some keys have a double allocation for text entries. Press twice quickly to type the character
shown as a small symbol on the key.

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2x A = Ä ; 2x O = Ö ; 2x U = Ü ; 2x . = / ; 2x S = ß

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4.2 Program Structure

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Use function keys <F1>, <F2> and <F3> to open the appropriate menu. Use the arrow key to
change to the sub-menus and select using the <*> or <ENTER> key. The description of the

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4.3 Start- / Print Menu <F2>

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sub-menus can be found in the following chapters.

The power take-off shaft can measure, short-term, up to 500 kW with 1000 min-1. Performance
input is reduced to ca. 220 kW with measurements over 12 minutes (continuous performance).

Switch on the device by pressing any key.
After switch on, the following messages appear on the display one after the other:

LPS ZW-500

V 1.0

The operating hours appear on the operating hours counter based on battery capacity.

Menu item Function
New measurement A new measurement is started
Print copy A copy of the last printout is printed
Print memory Select and print measurement based on date and time

Accu-capacity

<ЧЧЧЧЧЧЧЧЧЧЧЧЧ>

New Measurement

Start with <*>

Delete measurement Select and delete measuremt. based on date and time (V1.11 or higher)
Delete memory Delete all measurements in the memory (maximum of 11 possible)
Memory to PC Data transmission per radio to PC

A) Using the <ENTER> key to start a new measurement, see Main menu <F3>.
Occurs once after switch-on, otherwise select new measurement mode via main menu!

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BA060801-en

B) Select menu item of printer menu using the arrow keys. Confirm with <ENTER>.

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4.3.1 Vehicle Data Entry

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Vehicle data entry via print menu with <F2> and <ENTER>. Following boxes are available:

15

• Make

• Model

• Operating hours (optional)

• Customer name

Setting of vehicle data in Variable 4: see section "Operation / Setting Menu <F1> / Program
Variables".

Use the keypad for data entry.
Confirm with <ENTER> .

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4.4 Main Menu <F3>

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The following measurement methods can be selected:
Display Mode Entry values

• Constant n

• Constant Md

max. 24 characters, alpha-numeric
max. 24 characters, alpha-numeric
max. 24 digits, numeric
max. 24 characters, alpha-numeric

Make

--

Constant RPM - Target RPM
Constant engine torque - Target RPM

• Discrete n

Discrete RPM
measurement

- RPM Start

- RPM Stop

- RPM Step

- Waiting time

• Warm-up drive

Constant power at

- Warm-up power
constant RPM and p.t.o
shaft torque

With V1.11 or higher, the measurements can
be performed using the engine RPM or the
engine torque. To do this, enter the trans-

0.0 Nm →

0.0 kW 0 rpm

mission ratio engine/p.t.o. shaft using <F4>.
All display and input values bearing this factor are marked with an asterisk on the display.

First the measurement method [constant n] is
displayed:

Measurement with
constant n <*> →

Key <+> or <-> Change to a different measurement method
Key <ENTER> Select desired measurement method

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16

To open the main menu, an active connection to the dynamometer must exist.
For safety reasons, the measurement methods are only selectable with RPM n = 0.

Consumption Measurement (Optional)

The fuel consumption measurement device
AIC is connected to the switch box in order to
conduct fuel consumption measurements.

After confirmation of a target value ca. 5 s will pass until the fuel consumption is shown on the
display. Beforehand, the display -,- l/h appears.

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4.4.1 Constant RPM

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1 Select suitable transmission/RPM range of the power take-off shaft, switch on p.t.o. shaft.

17

2 Select measurement method and confirm with <ENTER>.

Measurement with
constant n <*> →

3 Enter value for target RPM using digit keys.
4 Use <ENTER> key for confirmation.

If a torque value < 20 % of the current RPM is entered, an error message appears: "RPM too
low" (V1.11).

5 Press the accelerator. When the target RPM is reached, regulation is automatically done.

Regulate power and engine torque using the accelerator.

6 Display of the target values:

Use the arrow keys to switch between the displays:

• P.t.o. shaft performance

• P.t.o. shaft torque

• P.t.o. shaft performance

• P.t.o. shaft RPM

• P.t.o. shaft torque

• P.t.o. shaft RPM

Target RPM
2500 min

-1

<*>

0.0 Nm

0.0 kW 00 min

P 0.0 kW
Md 0.0 Nm

P 0.0 kW
n 0.0 min

-1

Md 0.0 Nm
n 0 min

-1

-1

• P.t.o. shaft consumption

• P.t.o.f shaft RPM

Reducing the target value by 1 min-1 (basic setting) <F5>
Increasing the target value by 1 min

Setting the increment in Variable 1: see section "Operation / Setting Menu <F1> / Program
Variables".

7 Printing the current measurement data using the print

menu.
8 Enter vehicle data.
9 Printing the current measurement values. <ENTER>
10 Cancel printout. Signature and stamp are printed. <ESC>

After measurement, continue driving the p.t.o. shaft without load to cool down the brake.

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-1

(basic setting) <F6>

<F2>

Consumpt. -,- l/h
n -- min-1

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18

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4.4.2 Constant Torque

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1 Select suitable transmission/RPM range of the power take-off shaft, switch on shaft.
2 Select measurement method and confirm with <ENTER>.

3 Enter value for target torque using digit keys.
4 Use <ENTER>-key for confirmation.

5 Press the accelerator. Target torque is regulated over the

entire RPM range.

Regulate power and engine torque using the accelerator.
6 Display of the target values:

Use the arrow keys to switch between the displays:

• P.t.o. shaft performance

• P.t.o. shaft torque

• P.t.o. shaft performance

• P.t.o. shaft RPM

• P.t.o. shaft torque

• P.t.o. shaft RPM

• P.t.o. shaft consumption

• P.t.o. shaft RPM

Measurement with
constant Md <*> →

Target torque

0.0 Nm

0.0 Nm →

0.0 kW 0 U/m
P 0.0 kW

Md 0.0 Nm
P 0.0 kW

n 0.0 min

-1

Md 0.0 Nm
n 0 min

-1

Consumpt. -,- l/h
n -- min-1

Reducing the target value by 1 min-1 (basic setting) <F5>
Increasing the target value by 1 min

Setting the increment in Variable 2: see "Operation / Setting Menu <F1> / Program Variables".

7 Printing of the current measurement data using the print

menu.
8 Enter vehicle data.
9 Printing the current measurement values. <ENTER>
10 Cancel printout. Signature and stamp are printed. <ESC>

After measurement, continue driving the p.t.o. shaft without load to cool down the brake.

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-1

(basic setting) <F6>

<F2> and <ENTER>

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4.4.3 Discrete Measurement

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Pre-defined points in relation to the RPM are measured in the discrete performance measure­ment. The start and end RPM as well as the increment are defined by the operator.

1 Select suitable transmission/RPM range of the p.t.o. shaft, switch on the shaft.

19

2 Select measurement method and confirm with <ENTER>.

Measurement with
Discrete n <*> →

3 Enter value for RPM start using the digit keys.
4 Use <ENTER> key for confirmation.

5 Enter value for RPM stop using the digit keys.
6 Use <ENTER> key for confirmation.

7 Enter value for RPM step using digit keys.
8 Use <ENTER> key for confirmation.

9 Enter value for waiting time using the digit keys.
10 Use <ENTER> key for confirmation.

During the waiting time the approached RPM is held constant to keep a stable measurement
point. A waiting time of at least 10 s is recommended. Please pay attention to the vehicle
manufacturer’s instructions.

The printout starts automatically with the printing of the header data. This message appears:
"Please wait, printing data". During the measurement the current measurement values are
printed.

11 Press the accelerator to full throttle.

The first measurement point entered is approached with full throttle.
The eddy current brake hold the RPM constant based on the pre-selected waiting time and
files the measurement of this point. Then the brake is released and the next measurement
point is approached. The operator presses the accelerator during the entire test.

Example of measurement value entry:

RPM Start

- min-1
RPM Stop

- min-1
RPM Step

- min-1
Waiting t ime

10 s

Sequence of the measurement values RPM measurement values - example
Minimum to maximum 500 600 700 800 900 1000
Maximum to minimum 1000 900 800 700 600 500

With V1.11 or higher, the start value can be set automatically during measurements from high to
low:

1 Enter "0" as start value, then the lower end value, step and waiting time.
2 Raise the RPM to the desired start RPM. This must be greater than stop RPM + step.
► <*> appears on the display.
3 Press the <*> key to select the current RPM as start value.

BA060801-en

20

The upper left part of the display shows in what range the RPM is:

• If the flashing square is within the limits, the RPM is within
the tolerance corridor.

• If the square is located to the left of the limit, the RPM is
too low. The vehicle cannot approach the next target RPM.
Cancel the test with <ESC>. This case may occur if an
exaggerated target RPM was entered, e.g. tractor has

= 1050 min-1, and U

U

max

= 1200 min

tar

-1

was entered.

• If the square is located to the right of the limit, the RPM is
too high. In this case, the dynamometer can no longer
regulate the RPM, because the performance range of the

>  < 0.0 Nm

0.0 kW 0 min-1
 > < 0.0 Nm

0.0 kW 0 min-1

> <  0.0 Nm

0.0 kW 0 U min-1

brakes is exceeded. This message appears: "Error Brake 1
100% performance".

A printout is automatically created with a discrete measure­ment. After the discrete measurement has been completed, the
program returns automatically to the measurement display of

0.0 Nm →

0.0 kW 0 min-1

the main menu. There, using <F3>, a different measurement
method can be selected or a new menu opened once the
power take-off shaft has come to a standstill.

In the event of overload the measurement value "− −" is shown.
After measurement, continue driving the power take-off shaft without load to cool down the

brake.

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4.4.4 Warm-up Drive

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1 Select suitable transmission/RPM range of the power take-off shaft., switch it on.

21

2 Select measurement method and confirm with <ENTER>

3 Enter performance target value using digit keys.
4 Confirm with <ENTER> key.

5 Press accelerator.

If there is no RPM signal, this message appears:

The following display appears with applied RPM signal

Note: keep motor RPM constant.

4 When desired RPM is reached, confirm with <ENTER> .

With constant motor RPM, the pre-set target performance
remains constant.

Limits to the LPS

Measurement with→
Warm-up drive <*>

Target performance
20 kW <*>

Bring Motor up to
RPM

Warm-up. RPM
too small

RPM OK? <*>
n = 500 min-1

Hold Motor RPM
constant

381.9 Nm
20,0 kW 500min-1

If the max. torque is exceeded, the following display appears:
No measurement values are recorded by the dynamometer,
the RPM continues to be displayed.

If the brake is overloaded (warmed up), the following display
appears:

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-- .-- Nm

-- -- kW xxmin-1

Error Brakes 1
100% driven

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22

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4.5 Setting Menu <F1>

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Enter the setting menu using the <F1> key in the measurement

menu. (display to the right)

The following points are found in the setting menu:

• Switch off

• Set contrast

• Set clock

• Program address

• Program variables

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4.5.1 Set Contrast

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• Configuration print out

Setting of the display contrast if the display is too light or too dark. The LCG display contrast is
dependent upon the environmental temperature.

0.0 Nm →

0.0 kW 0 U/m

Key Description
<-> Reduce contrast
<+> Increase contrast
<ENTER> Accept contrast. By accepting the set contrast, it is automatically stored and

<ESC> Return to setting menu without storing the changes.

1 Select menu point and confirm with <ENTER>.
2 The black bar in line 2 stands for the intensity of the display

contrast. If the bar fills out the entire line, this is the max.
contrast setting.

3 Change the contrast with the arrow keys. The new contrast

can be seen directly on the display.

4 Confirm with <ENTER>.

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returned to the setting menu.

Set contrast →
Start with <*>

- <= OK<*> => +
>ЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧЧ

×<

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4.5.2 Set Date and Time

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The terminal’s date and time can be set or checked.

23

1 Select menu point, confirm with <ENTER> .

2 Enter new date using the digit keys.

Confirm with <ENTER>. The cursor jumps to the next line
for time entry.

3 Enter the new time using the digit keys and confirm with

the <ENTER> key.

4 Exit menu point with <ENTER>-key.

The date entry must be done in format day, month and year.
Time entry must be done completely in hours and minutes.

A digit entered incorrectly can be deleted with the <CLEAR> key.
Use <ESC> key to exit the menu point without storing.

Key Description
<0> ..<9> Entry of the current time/date.
<CLEAR> Correcting the entry.
<ENTER> Confirming the entry of time/date.

Ending the date/time reading.

Set clock →
Start with <*>

Date: 12.10.99
Time: 14:13:04

<ESC> Exit date entry without storing. Exit time entry without storing. End entry of

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date/time reading.

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24

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4.5.3 Program Address

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The address of the heading is entered for the print out. Four lines each one with 24 letters are
available. Entry is done using the digit and letter keys.

1 Select menu point, confirm with <ENTER>.
2 Enter the address line by line.

Change into the next line with <ENTER>.

3 Confirm with <ENTER>.

Key Description
<A>..<Z>

<0>..<9>
<·/> <+> <->

<SPACE> Entry symbol: space
<F1> Switching between upper and lower case letters.
<CLEAR> Delete entered symbol
<ENTER> Accept entry line. When accepting the fourth address line, the complete

<ESC> Return to setting menu without storing. The completed entries are thrown

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Prog Address . →
Start with <*>

Entry symbols for the address.

address is automatically stored and returned to the setting menu.

out.

4.5.4 Program Variables

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Setting the variables

1 Select menu item, confirm with <ENTER>.
2 Enter value using digit keys.

If necessary, correct input using <CLEAR> key.

3 Use <ENTER> to confirm input.

Key Description
<+> Display next variable
<-> Display previous variable
<0>...<9> Enter new variable value
<ENTER> Confirm entry of the new variable value
<CLEAR> Correct entries which are not correct (previous symbols are deleted)
<ESC> Cancel entry (variable remains unchanged) or

Return to setting menu.

Prog Variable . →
Start with <*>

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25

The following variables can be set:

Variable Designation Description Default Unit
1 Single step RPM Increment of the RPM 1

(1...2000)

2 Single step Trq Increment of the power take-off torque 1

(1...9999)

3 Warm-up

performance

4 Vehicle data entry Activation or deactivation of the vehicle

Warm-up performance standard value 20

(1...9999)
15

data entry and the print out

(0…15)
1 = Make
2 = Model
4 = Operating hours
8 = Customer name
The setting is generated by adding up
the desired digits.
e.g.: Print model and customer name:
Variable value is 10 = 2 + 8

5 Autom. printout 0 = No print out is done during the

measurement. The print out is created

1

(0...1)
using the print out menu <F2> .

1 = A print out is created during the
measurement. A copy can be created in
the print out menu <F2>

min-1

Nm

kW

6 Switchover PS/kW Switchover via software by pressing

<P> key in the measurement menu.

10 Pulses per litre Resolution of the consumption meter.

The number of pulses per litre of the
consumption meter are given.

11 Consumption

measurement time

Measurement interval of the
consumption measurement with
constant RPM or constant torque.

12 Consumption

measurement
delay

Time delay until the consumption
values are recorded. Is added to
holding time with discrete
measurement.

13 Stamp size Number of empty lines at the end of a

print out to use a stamp

14 Switch-off time Time after which the hand terminal

switches off automatically. The switch­off time is reset if any key is pressed or
an RPM is recognized.

15 Radio channel Radio channel of the radio transmission

module
0 = Data transmission per cable
1-3= Radio transmission

0

(0...1)

2000

(1...9999)

5,00

(0,01...

99.99)

0,00

(0…99.99)

5

(0…99)

20

(0…999)

2

(0…3)

pulses/l

s

s

Lines

Minutes

Channel
no.

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26

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4.5.5 Print Configuration

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If a malfunction occurs on the dynamometer, always print out the configuration.

Select menu point, confirm with <ENTER> .
The printout is automatically started.
Cancel the printout with <ESC>.

Following message appears:

The print outof the configuration contains all settings

• the terminal

• the RG240 PCB

• the radio module (terminal and RG240)

Version number

The version number of the software appears briefly on the
display of the hand terminal after the test stand has been
switched on.

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Print config. →
Start with <*>

Please wait...
print Data

LPS ZW-500

V 1.01

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4.6 Short Operating Instructi ons f or Vehicle Test

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Operate the dynamometer only with open flaps!
Switch off dynamometer and vehicle when mounting and disassembling the connection shaft.

Select desired measurement method. Press the <F3> key to get into the selection menu. The

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4.6.1 Constant RPM or constant Torque

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dynamometer must be in standstill position.

Please see section "Op er at ion / Main Me nu <F 3 >".

1 Enter target value.
2 Select printout using key <F2> .
3 Approach the entered target value, print with <ENTER> .
4 Enter new target value using digit block or cancel the test with <ESC>.
5 Release the accelerator, stop p.t.o. shaft after brake has cooled down.

27

4.6.2 Discrete Measurement

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Please see section "Operation / Main Me n u <F 3 >".

1 Enter data for start and stop RPM, increments and waiting time.

With the discrete measurement, the printout is automatically started and all approached
measurement points printed.

2 Once the start RPM is reached, the eddy current brake holds the RPM constant for the set

holding time and the measurement is filed. After the holding time the brake releases again
the next measurement point is approached. During the entire test, use full throttle and hold.

3 After the last measurement point has been approached, the test is automatically finished and

the printout completed.

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4.6.3 Warm-up Drive

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4 Release accelerator, stop the p.t.o. shaft after the brake has cooled down.

Please see section "Operation / Main Me nu <F3 > / Constant Torque".

1 Enter the target performance.
2 Drive the target RPM and hold it constant. The performance is calculated from the constant

RPM and the applied torque.

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3 Release accelerator, stop p.t.o. shaft after brake has cooled down.

BA060801-en

28

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5 Maintenance

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5.1 Annual Inspection

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• The maintenance interval prescribed by the manufacturer is 12 (twelve) months.
This maintenance interval refers to normal workshop usage. If the equipment is used more
frequently or under severe operating conditions (e.g. outdoors), the interval must be reduced
accordingly.

• Maintenance work shall be done only by authorized and trained service technicians provided
by the manufacturer, licensed dealers or service partners.

• In case of non-compliance the manufacturer's warranty becomes void.

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5.2 Care Instructions

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• Periodically clean the equipment and treat it with a care product.

• Repair damage to the paintwork immediately to prevent corrosion.

• Usage of caustic cleaning agents or high pressure and steam jet cleaners may lead to

equipment damage.

Regular care and maintenance is the key condition for functionality and long life expectancy of
the equipment!

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5.3 Maintenance by the Operator

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5.3.1 Bearing Positions

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The bearings of the brake housing are equipped with lubricating nipples. Lubricate once a year

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5.3.2 Screw Connections

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5.3.3 Eddy Current Brake

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5.3.4 Trailer

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using a grease gun (qty. required: 1…2 strokes).

Periodically check the screw connections for tight fit.

The eddy current brakes are maintenance-free.

Periodically check the pressure of the trailer tyres. Rated pressure: 4.5 bar.

BA060801-en

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5.4 Spare Parts

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To ensure safe and reliable operation, only use original spare parts supplied by the equipment

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manufacturer.

6 Dismantling

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Decommissioning and dismantling of the equipment may be done only by specially authorized

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and trained personnel provided by the manufacturer, licensed dealers or service partners.

7 Disposal

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If you want to dispose of the equipment, please contact your MAHA dealer or the following
address, indicating equipment type, date of purchase and serial number:

MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany

Phone: [phone]
Fax: [phone]

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Email: [e-mail]
Alternatively, you may take the equipment to a specialised waste management plant to ensure

that all components and operating liquids are properly disposed of.

29

8 Contents of the Declaration of Conformity

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MAHA Maschinenbau Haldenwang GmbH & Co. KG

herewith declares as a manufacturer its sole responsibility to ensure that the product named
hereafter meets the safety and health regulations both in design and construction required by
the EC directives stated below.
This declaration becomes void if any change is made to the product that was not discussed and

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approved by named company beforehand.

Model: ZW 500 / W 500 / MZW 300 / HZW 300
Designation: Power Take-off Dynamometer
Directives: 2006/42/EC; 2004/108/EC
Standards: DIN EN ISO 12100:2011; DIN EN ISO 13849-1; DIN EN ISO 13857;

DIN EN 349; DIN EN 60204-1

BA060801-en

30

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9 Company Informati on

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© MAHA Maschinenbau Haldenwang GmbH & Co. KG

Legal notice based on ISO 16016:
The reproduction, distribution and utilization of this document as well as the communication of
its contents to others without explicit authorization is prohibited. Offenders will be held liable for
the payment of damages. All rights reserved in the event of the grant of a patent, utility model or
design.

The contents of this edition have been checked with great care. However, errors cannot be fully
excluded. Subject to technical change without notice.

Document

Document №: BA060801-en
Approval Date: 2013-09-30

Manufacturer

MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany

Phone: [phone]
Fax: [phone]
Fax Parts: [phone]
Internet: http://www.maha.de
E-Mail: [e-mail]
Hotline: [phone] for Brake Testers and Test Lanes
[phone] for Automotive Lifts
[phone] for Dynamometers and Emission Testers

Service

=== Ende der Liste für Textmar ke Inhalt == =

BA060801-en

AutomoTec GmbH
Maybachstraße 8
87437 Kempten
Germany

Phone: [phone]
Fax: [phone]
Internet: http://www.automo-tec.com
E-Mail: [e-mail]