D1 0524BA1-GB01

Chassis Dynamometer LPS 3000 for Trucks

Standard Operating Instructions and Users Manual English

LPS 3000 Truck

II D1 0524BA1-GB01

EDITION Version 1 of the operating manual dated 17.1.2005 D1 0524BA1-GB01 Software Version V1.07

MAHA GMBH & CO. KG. All rights reserved. Any reproductions of this document, partial or complete, are only allowed with prior consent of MAHA GmbH & Co. KG.

All rights reserved in cases of patent granting or registration of design.

The contents of this version have been checked with great care. However, errors cannot be fully excluded. Please contact MAHA should you find errors of any kind. Subject to technical change without notice. These instructions are intended for users with previous technical knowledge in the field of vehicle testing technology as well as basic computer knowledge and MS-Windows operating system application.

Windows and Windows for Workgroups is a registered trademark of the Microsoft-Corporation.

MANUFACTURER MAHA Maschinenbau Haldenwang GmbH & Co. KG. Hoyen 20 D-87490 Haldenwang/Allgu

Telephone: 08374 / 585-0 Telefax: 08374/ 585-499

Internet: http://www.maha.de e-mail: maha@maha.de

SERVICE MAHA Maschinenbau Haldenwang GmbH & Co. KG. - Service dept. - Hoyen 20 D-87490 Haldenwang/Allgu

Hotline: 08374 / 585 + extension 260 for brake testers, test lanes 280 for lifting technology 290 for performance testers, exhaust and air condidioning service equipment

Service: 08374 / 585-110 bis - 113, - 115 Telefax: 08374 / 585-491

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TABLE OF CONTENTS

1 Description ............................................................................................................. 1.1 1.1 General Information.................................................................................................................... 1.1 1.2 Technical Data............................................................................................................................ 1.2

1.2.1 Communication Desk .................................................................................................. 1.2 1.2.2 PC Min. Requirements (Status: November 2002) ...................................................... 1.2 1.2.3 Roller Set of Series R200............................................................................................ 1.2

1.3 Noise Emission........................................................................................................................... 1.3 1.4 Keyboard Description ................................................................................................................. 1.4 1.5 Description of the Remote Control ............................................................................................. 1.6 1.6 Description of the Interface Box ................................................................................................. 1.8

1.6.1 RPM Module (Standard) ............................................................................................. 1.9 1.6.1.1 Trigger tongs................................................................................................ 1.9 1.6.1.2 Piezo clamp ................................................................................................. 1.9 1.6.1.3 Clamp W .................................................................................................... 1.10 1.6.1.4 TDC Sensor ............................................................................................... 1.10 1.6.1.5 Light barrier................................................................................................ 1.10 1.6.1.6 Driving Trial................................................................................................ 1.11 1.6.1.7 OBD Module .............................................................................................. 1.11 1.6.1.8 Oil Temperature Probe (Optional) ............................................................. 1.11

1.6.2 Environmental Module (Standard) ............................................................................ 1.12 1.6.2.1 Fuel temperature (Optional) ...................................................................... 1.12 1.6.2.2 Intake air temperature................................................................................ 1.12 1.6.2.3 Ambient temperature ................................................................................. 1.12 1.6.2.4 Air pressure ............................................................................................... 1.12 1.6.2.5 Humidity..................................................................................................... 1.12

1.6.3 OBD Module (Optional)............................................................................................. 1.13 1.6.4 Pressure/Temperature module (Optional) ................................................................ 1.13

1.6.4.1 Pressure 1 + 2 ........................................................................................... 1.13 1.6.4.2 Exhaust Gas Temperature......................................................................... 1.13

1.7 Measurement Program............................................................................................................. 1.14 1.8 Calculation Basis ...................................................................................................................... 1.15

1.8.1 Driving Resistance .................................................................................................... 1.15 1.8.2 Torque....................................................................................................................... 1.16 1.8.3 Projection of the Engine Power with Gasoline Engines............................................ 1.17 1.8.4 Projection of the Engine Power with Diesel-Engines( Suction and/or mech. charger)1.18 1.8.5 Projection of the Engine Power with Turbodiesel Engines ....................................... 1.19 1.8.6 Calculate Engine Factor fm....................................................................................... 1.20 1.8.7 4 Wheel Drive Operation........................................................................................... 1.21

1.8.7.1 Traction Regulation.................................................................................... 1.21 1.8.7.2 RPM Regulation......................................................................................... 1.21 1.8.7.3 Driving Resistance Simulation................................................................... 1.21

2 Safety ...................................................................................................................... 2.1 2.1 Introduction ................................................................................................................................. 2.1 2.2 Safety Regulations for Commissioning ...................................................................................... 2.1 2.3 Safety Regulations during Operation ......................................................................................... 2.2 2.4 Safety Regulations for Service Work.......................................................................................... 2.2 2.5 Attention...................................................................................................................................... 2.2 2.6 Important Information about the Tires ........................................................................................ 2.3 2.7 Safety Instructions for Anchoring Device LPS 3000 Truck ........................................................ 2.3

2.7.1 Lifting Straps (made of synthetic fiber) ....................................................................... 2.3 2.7.2 Sling Chain.................................................................................................................. 2.4 2.7.3 Pit Safety (Optional) .................................................................................................... 2.4

2.8 Further Information ..................................................................................................................... 2.4 2.9 Information about the Eddy Current Brake................................................................................. 2.4

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2.10 Replacing Parts .......................................................................................................................... 2.5 2.11 Safety Features .......................................................................................................................... 2.5

2.11.1 Lockable Main Switch ................................................................................................. 2.5 2.11.2 Warning and Information Labels ................................................................................. 2.5

3 Installation.............................................................................................................. 3.1 3.1 Requirements for the Place of Installation.................................................................................. 3.1 3.2 Safety Measures......................................................................................................................... 3.1

3.2.1 Heat Balance............................................................................................................... 3.1 3.2.2 Exhaust Suction System ............................................................................................. 3.3 3.2.3 Fresh Air Supply for the Test Room............................................................................ 3.4

3.3 Installation and Commissioning.................................................................................................. 3.4

4 Preparations for Testing........................................................................................ 4.1 4.1 Switch on the Dyno..................................................................................................................... 4.1 4.2 Drive on to Dyno/ Lower Lifting Bar............................................................................................ 4.1 4.3 Position Vehicle .......................................................................................................................... 4.1 4.4 Fix Vehicle .................................................................................................................................. 4.2 4.5 Attach Weight Simulator (optional) ............................................................................................. 4.2 4.6 Connect the RPM Sensor........................................................................................................... 4.3 4.7 Connect Oil Temperature Probe ................................................................................................ 4.3 4.8 Attach Exhaust Suction .............................................................................................................. 4.3 4.9 Position Cooling Air Fan ............................................................................................................. 4.3 4.10 Bring the Vehicle up to Operating Temperature......................................................................... 4.4 4.11 Vehicle Ready-for-Testing .......................................................................................................... 4.4

5 Program Structure ................................................................................................. 5.1 5.1 General Information.................................................................................................................... 5.1 5.2 Program Structure ...................................................................................................................... 5.2 5.3 Start Program ............................................................................................................................. 5.3 5.4 Screen Set Up ............................................................................................................................ 5.4

5.4.1 Status line ................................................................................................................... 5.4 5.4.1.1 Symbols in the Status line ........................................................................... 5.5

5.4.2 Main Mask................................................................................................................... 5.6 5.4.3 Button Strip ................................................................................................................. 5.6

5.4.3.1 Button SWITCH OVER................................................................................ 5.6 5.4.3.2 Button INFO................................................................................................. 5.7 5.4.3.3 Button PRINT............................................................................................... 5.7 5.4.3.4 Button ESCAPE........................................................................................... 5.7

5.5 End Program / Switch off Dyno .................................................................................................. 5.7 5.6 Update LPS 3000 Software ........................................................................................................ 5.8

5.6.1 Update USB Driver.................................................................................................... 5.11

6 Measurements........................................................................................................ 6.1 6.1 Load Simulation.......................................................................................................................... 6.1

6.1.1 Identical Functions ...................................................................................................... 6.2 6.1.1.1 Button description ........................................................................................ 6.2 6.1.1.2 Driving Cycle (Optional)............................................................................... 6.3 6.1.1.3 Evaluation .................................................................................................... 6.4 6.1.1.4 Zoom function .............................................................................................. 6.4 6.1.1.5 Cursor function ............................................................................................ 6.5 6.1.1.6 Insert comment ............................................................................................ 6.5 6.1.1.7 Store ............................................................................................................ 6.6 6.1.1.8 Print.............................................................................................................. 6.6

6.1.2 Constant Traction........................................................................................................ 6.7 6.1.3 Constant Speed .......................................................................................................... 6.9 6.1.4 Driving Simulation ..................................................................................................... 6.10

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6.1.5 Constant Engine RPM............................................................................................... 6.13 6.1.6 Standstill.................................................................................................................... 6.13

6.2 Measure Engine Power ............................................................................................................ 6.14 6.2.1 Display Last Measurement ....................................................................................... 6.14 6.2.2 Continuous Measurement ......................................................................................... 6.14

6.2.2.1 Continuous Measurement with CAR with Automatic Transmission and Converter Slip Measurement..................................................................... 6.16

6.2.3 Discrete Measurement .............................................................................................. 6.18 6.2.3.1 Discrete Measurement for a truck with manual transmission (2nd roll out

trial) ............................................................................................................ 6.20 6.3 Engine Flexibility Test............................................................................................................... 6.22 6.4 Speedometer Check................................................................................................................. 6.23

6.4.1 Vehicle Speed ........................................................................................................... 6.23 6.4.2 Mileage...................................................................................................................... 6.24

6.5 Load Adaption (Optional).......................................................................................................... 6.26 6.5.1 Coefficient Adaption based on ECE.......................................................................... 6.26 6.5.2 Coefficient adaption based on SAE J2264 ............................................................... 6.28

6.6 LUG-Down Test (Option for China and Korea) ........................................................................ 6.29 6.7 Using the Weight Simulator (optional)...................................................................................... 6.29

7 Settings................................................................................................................... 7.1 7.1 Database .................................................................................................................................... 7.1

7.1.1 Identical Functions ...................................................................................................... 7.2 7.1.1.1 Button description ........................................................................................ 7.2 7.1.1.2 Delete........................................................................................................... 7.2 7.1.1.3 Export........................................................................................................... 7.3 7.1.1.4 Import........................................................................................................... 7.3

7.1.2 Performance curves .................................................................................................... 7.4 7.1.2.1 Button description ........................................................................................ 7.4 7.1.2.2 Curve Selection ........................................................................................... 7.6 7.1.2.3 Power correction.......................................................................................... 7.7 7.1.2.4 Load ............................................................................................................. 7.7 7.1.2.5 Excel Export................................................................................................. 7.7 7.1.2.6 P-Drag Wizard ............................................................................................. 7.9

7.1.3 Time Diagram............................................................................................................ 7.10 7.1.4 Vehicle Data.............................................................................................................. 7.11 7.1.5 Load simulation profile .............................................................................................. 7.12

7.1.5.1 Create new profile...................................................................................... 7.12 7.1.5.2 Process Profile........................................................................................... 7.14 7.1.5.3 Export Profile ............................................................................................. 7.14 7.1.5.4 Import Profile ............................................................................................. 7.14

7.1.6 Driving Cycle Data .................................................................................................... 7.14 7.2 Vehicle Data ............................................................................................................................. 7.15 7.3 RPM Setting ............................................................................................................................. 7.16

7.3.1 Driving Trial ............................................................................................................... 7.17 7.4 OBD Settings (Optional) ........................................................................................................... 7.18 7.5 Special Settings........................................................................................................................ 7.19 7.6 Select Dyno Type ..................................................................................................................... 7.19 7.7 Units.......................................................................................................................................... 7.20 7.8 Language.................................................................................................................................. 7.20

8 Diagnosis / Service ................................................................................................ 8.1 8.1 Dyno Status ................................................................................................................................ 8.1 8.2 Drivers Aid Setup(Optional) ....................................................................................................... 8.1

8.2.1 Test Driving Cycle (Optional) ...................................................................................... 8.2 8.2.2 Work Profile................................................................................................................. 8.3 8.2.3 New Profile .................................................................................................................. 8.4 8.2.4 Delete Profile............................................................................................................... 8.4

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8.3 Backup/Restore Database.......................................................................................................... 8.5 8.3.1 Backup Database........................................................................................................ 8.5 8.3.2 Restore Database ....................................................................................................... 8.5 8.3.3 Delete Table................................................................................................................ 8.6 8.3.4 Delete Database ......................................................................................................... 8.6

8.4 Service Menu.............................................................................................................................. 8.6

9 Maintenance and Troubleshooting....................................................................... 9.1 9.1 Maintenance ............................................................................................................................... 9.1

9.1.1 Roller set ..................................................................................................................... 9.1 9.1.2 Eddy Current Brake..................................................................................................... 9.1 9.1.3 Cardan shaft................................................................................................................ 9.2 9.1.4 Roller bearing.............................................................................................................. 9.2 9.1.5 Weight Simulator Hydraulic (optional)......................................................................... 9.2

9.2 Error Remedy ............................................................................................................................. 9.2 9.2.1 Daily Password ........................................................................................................... 9.2

10 Software License Agreement.............................................................................. 10.1 10.1 Software License Agreement ................................................................................................... 10.1

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1 Description

1.1 General Information The chassis dynamometer LPS 3000 consists of ! a communication desk with PC, monitor, keyboard and wheel mouse ! a remote control and ! a roller set

The LPS 3000 is available in various versions for performance testing of trucks. Depending on the version, wheel power from 4000 kW to 660 kW with a max. test speed of 200km/h can be tested. The dyno load simulation is done with an eddy-current brake.

The LPS 3000 enables engine power measurements to be made on trucks with Otto and diesel engines. Testing of four wheel drive vehicles is possible if the LPS 3000 is equipped with the appropriate roller set and the corresponding control electronics.

Optionally available are: ! A cooling air fan which is connected to the communication desk and is operated via the radio

remote control. ! An interface box via which the following modules can be connected:

RPM module Acquisition of engine RPM via Trigger tongs (Otto engine), Piezo clamp sensor (Diesel engine), TDC-sensor (manufacturer-specific, upon request), Diagnostic plug (manufacturer-specific, upon request), Oil temperature probe (up to max. 180C) and much more. Environmental module Acquisition of ambient temperature, intake air temperature, air pressure and humidity, fuel temperature Analog module Acquisition of analog signals OBD module Aquisition of OBD data Pressure/Temperature module Recording of 2 temperatures and 2 pressures each

! To determine performance data of DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001 a barometer and a humidity sensor are installed in the interface box (Graphic package is prerequisite) (*).

! MAHA emission testers, gasoline (MGT5) and diesel (MDO2 and MDO2 LON) which can be connected to the dyno (*).

! DIN A4 ink jet printer, color (*) ! Fuel consumption device for gasoline and diesel engines. (Krupp/AIC) (*) (*

) These options are not connected to the interface box but separately on the dyno.

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1.2 Technical Data

1.2.1 Communication Desk ! Color screen 19 diagonal

(factory recommendation)

! Dimensions communication desk (W x H x D) 600 x 1850 x 800 mm

! Packaging (L x W x H) 2360 x 960 x 870 mm ! Weight incl. packing ca. 250 kg ! Powder paint coating blue, RAL 5010 ! Connection 230 V, 50 Hz ! Multi-processor capability

! Multi-tasking capability

1.2.2 PC Min. Requirements (Status: November 2002) CPU ...............................................................................Processor starting at 800 MHz Motherboard ..................................................................USB connection Working storage ............................................................256 MB Harddrive .......................................................................> 4 GB Drive ..............................................................................CD-ROM > 32x .......................................................................................Disc drive 1.44 Graphic card ..................................................................Resolution 800x600 with 64k colors .......................................................................................Storage 4 MB Operating system ..........................................................Windows XP Professional

1.2.3 Roller Set of Series R200 The LPS 3000 roller sets consist of a sturdy, self-supporting frame construction with powder paint coating and flame sprayed rollers. There are various versions available for the LPS 3000: Roller Set Test Vehicle Comments R200/1 Car/Truck/Van/Bus closed roller set R200/1 Car/Truck/Van/Bus closed roller set

with reinforced eddy current brake R200/2 Car/Truck/Van/Bus Divided roller set R200/2 Car/Truck/Van/Bus Divided roller set

with reinforced eddy current brake

Description LPS 3000 Truck

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The Series R200 roller sets are not suitable for motorcycle testing!

Roller Set R200/1 R200/1 reinforced R200/2

R200/2 reinforced

Axle load 15 t 15 t 15 t 15 t Length [mm] 4550 4550 2260 per roller 2260 per roller Width [mm] 1100 1100 1100 1100 Height [mm] 625 625 865 865 Weight ca. 2350 kg ca. 2410 kg ca. 1250 kg per roller

ca. 1310 kg per roller

Roller length 900 mm 900 mm 900 mm 900 mm Track min. 820 mm 820 mm 1000 mm 1000 mm Track max. 2620 mm 2620 mm 2800 mm 2800 mm Smallest testable wheel diameter 12" 12" 12" 12"

Roller diameter 318 mm 318 mm 318 mm 318 mm Roller axle separation 565 mm 565 mm 565 mm 565 mm Roller protrusion 45 mm 45 mm -- -- Lifting Bar with roller locking Pneumatic Hydraulic x x x x Electrical Data Eddy current brake data 2 x 200 kW 2 x 330 kW

2 x 200 kW 2 x 330 kW

Power supply 400 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz 400 V / 50 Hz Fuse 35 A slow 63 A slow 35 A slow 63 A slow Display Range Test speed max. 200 km/h max. 200 km/h max. 200 km/h max. 200 km/h Wheel power 30 - max. 400 kW 30 - max. 660 kW 30 - max. 400 kW 30 - max. 660 kW Traction max. 15 kN max. 25 kN max. 15 kN max. 25 kN

RPM 10 10 000 RPM 10 10 000

RPM 10 10 000

RPM 10 10 000

RPM

Measurement accuracy

2 % of Measurement

value

2 % of Measurement

value

2 % of Measurement

value

2 % of Measurement

value

1.3 Noise Emission

Use ear protection! the ear protection should be approved for up to 120 dB (A)

The noise emission value which is reached when the LPS 3000 is in operation is more than 100 dB (A) in the working range of the operational personnel. .

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1.4 Keyboard Description Only the most important key functions are described here which are needed for operating the LPS 3000

Escape ESC Interruption of a function without storing and exiting a menu point.

Function keys F1 to F12 Use function keys F1 to F12 to select various functions.

These functions can also be selected using the F1 to F12 on the remote control.

In the menus there are 4 buttons on the lower screen edge with various functions. These functions are called up with the keys F5 to F8. The key assignment is different in different menus.

Key F2 is used to switch the cooling fan on and off.

Key F3 is used to operate the lifting bar.

Key F4 is used to activate the weight simulator.

Backspace Deletes the character that appears in front of the cursor.

Pos 1 The cursor jumps to the front of the line and erases the previously entered character in this line.

Caps lock Switching over the keyboard to capital (upper case) letters. Press this key again to deactivate the capital locks. ("" key on the remote control)

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Shift (switch over keys) These two keys are used for switching from lower to upper case letters as well as for doubly assigned keys. This function is only possible as long as one of the keys remains pressed.

Alt Gr (Switch over for triply assigned keys) Use this key to activate the keys which have triple assignments. The character in the right hand corner of the respective key is inserted. e.g. @.

Cursor keys (Arrow keys) Selection of the menu point and/or the various options of the menu points..

Digit keys These keys are used to enter numbers.

Return (Confirmation keys) Confirmation of entered data or termination of a menu point. Pay attention to the instructions on the screen!!

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1.5 Description of the Remote Control The functions of the LPS 3000 program can also be selected via the remote control. The remote control can be operated directly from the vehicle.

The signal is transmitted by radio. The reception antenna for the signal is located in the desk. Should several dynos each with its own remote control be operated in one room, the remote controls must be set to different channels. As soon as the remote control is switched on and radio connection to the dyno exists, the green control lamp will light up permanently on the operation desk. The green control lamp will blink briefly each time a key is pressed.

The remote control keyboard consists of two pads: - Function key pad, - Digit pad

Display

Function keys

Digit pad

Connection for Pedal force

sensor

When not in use the remote control should always be stored in the re-charging box to avoid a total discharging of the battery. The re-charging box is equipped with a re-charge overload protection. The re-charging time for a fully discharged battery is about 12 to 14 hours. During the re-charging procedure the red LED on the re-charging box will light up and Battery recharging appears on the display of the remote control.

To switch on the remote control press the ON-key. The remote control has an automatic switch off (Timeout) which can be variably set. The remote control switches off when no key has been pressed during this time.

The letters on the remote control can be selected by pressing the SHIFT-key. Press again to return to the normal operation mode. The display "SHIFT" appears in the window when the SHIFT-key has been pressed.

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The following key assignments are used

Key Function

-

Function keys F5 F8 In some menus special functions can be called up. The key assignments vary in the different menus. 4 boxes are located on the lower screen edge in these menus with diverse functions. These options are selected with the function keys F5 to F8 on the remote control. If the button strip has other levels these can be displayed using the cursor keys and . The function keys F5 to F8 on the keyboard can be used for selection.

Cooling fan on - / off: (F2 key on the keyboard)

Activate lifting bar (Key F3 + Cursor keys on the keyboard) The lifting is activated with this key. The lift can then be operated using the cursor keys and .

Activate weight simulator (only trucks) (key F4 + Cursor keys of the keyboard) The weight simulator is activated with this key. Then the weight simulator can be operated with the cursor keys and .

Activate the roller set adjustment for 4 wheel drive dynos (only via the remote control). The roller set adjustment is activated with this key. The roller set adjustment can then be operated using the cursor keys and .

Deletes an entire line

Comma key: input of a comma

ON-key: switch on remote control

ESCAPE-key: exiting a program part

CURSOR-key: Selection of a menu point (In combination with the function key F5 and the cursor keys target values can be increased or decreased in some menus.

DELETE-key: - Deleting the character before the cursor position - Throwing out input (corresponds with the Backspace-key on the keyboard )

SHIFT-key: switch over to letter mode

CONFIRMATION-key: confirmation of inputs (corresponds with the Return-key of the keyboard)

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1.6 Description of the Interface Box The interface box records engine RPM, environmental data, OBD data, temperatures, pressures and analog signals. This is done via modules. A max. of 4 modules can be installed in the interface box.

Additional modules can be installed in a second interface box which is connected parallel and if desired, adapted to customer wishes.

As standard equipment, the interface box 1 has an RPM and environmental module.

Dimensions (H x W x L) approx. 120 x 170 x 160 mm Weight approx. 1.0 kg

Display interface box assignment:

1 The assignments of the interface box appears using the keys + .

2 Use or to exit this screen..

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1.6.1 RPM Module (Standard) The RPM module is used to record the RPM and oil temperature (Insert card CAN DRZ). Following RPM sensors/RPM sources can be changed:

1.6.1.1 Trigger tongs

The RPM signal is picked up at the ignition cable (spark plug or distributor ignition coil) with the trigger tongs. The trigger tongs should be placed as closely as possible to the spark plug and as fars possible from the next ignition cable. The tripper tongs take up the high voltage signal inductively which is conducted from the distributor to any random cylinder. The impulse is relayed from the trigger tongs to the test box where it is converted to an RPM signal.

The LPS 2000 trigger tongs cannot be used for the LPS 3000..

ATTACHMENT: ! Position (D) on the interface box.

(see Chapter 1, paragraph Description of the interface box).

1.6.1.2 Piezo clamp

Piezo clamp is only used with diesel engines. The piezo clamp consists of a piezo element which recognizes pressure differences at the lead-in and then converts them into electric pulses. It is important that the piezo clamp which is used is suitable for only one diameter of the fuel line and should only be placed at a straight section of the line at any cylinder (attach ground clamp on the same injection line).

ATTACHMENT: ! Position (A) or (B) on the interface box (see

Chapter 1, paragraph Description of the interface box ).

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1.6.1.3 Clamp W

The alternator RPM is ascertained through the clamp W. The number of pulses per rotation at the alternator (proportional to the crank shaft RPM) should be known or must be determined by an external measuring device. This is necessary because individual vehicle models have different transmissions between crank shaft and alternator. The RPM determination at the clamp W is only used with diesel engine vehicles.

1.6.1.4 TDC Sensor

The TDC sensor is always manufacturer-specific, i.e. depending on the vehicle manufacturer the corresponding diagnostic plug is used for the RPM signal pick up.

The TDC sensor pick up offers an extremely accurate RPM measurement. Once fmax is reached, an RPM of 12000 rot/min-1 is displayed.

The level must be between 30 mV and 30 V so that an RPM impulse is recognized

ATTACHMENT: ! Position (A) or (B) on the interface box (see Chapter 1, paragraph Description of the

interface box).

1.6.1.5 Light barrier

Light barrier is used when no direct way of determining the RPM at the engine is possible. The light barrier must be positioned in such a way that via a reflector which is attached either to the vibration absorber, drive belt, or cardan shaft, the RPM can be picked up free of any interfe-rence (no vibration influence etc.). Ratio to engine RPM must be 1:1, enter transmission ratio with cardan shaft in the range of 0.5 and 2.

ATTACHMENT: ! Position (A) or (B) on the interface box (see

Chapter 1, paragraph Description of the Interface Box ).

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1.6.1.6 Driving Trial

If none of the above mentioned alternatives is available for determining an RPM measurement a driving trial can be used to do the same. The RPM is converted from the dyno roller speed (see paragraph Driving Trial in Chapter Settings).

At the beginning of a test a pre-determined RPM value must be approached (Test gear /Gear transmission close to 1:1) while in a specific gear. This RPM value will be stored.

During the performance test the LPS 3000 software will convert the rollers momentary RPM into engine RPM. (Attention: The calculated RPM will only correspond if the vehicle is driven in the test gear.)

Automatic transmission vehicles without converter bridging cannot use the drive trial method because the engine RPM deviates due to the converter slip.

1.6.1.7 OBD Module

The RPM is read out of the OBD data (see Paragraph OBD Settings in Chapter Settings).

1.6.1.8 Oil Temperature Probe (Optional) Driving trials on the LPS 3000 should only be done when the engine is warmed up to operational temperature. The oil temperature meter is used to determine the oil temperature and to monitor it during the testing procedure.

Oil temperature probe for car and truck, length variable (100 to 1500 mm) with closing plug and 6 m line.

ATTACHMENT: ! Position (C) on the interface box (see

Chapter 1, paragraph Description of the Interface Box).

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1.6.2 Environmental Module (Standard) The environomental module is used to record the environmental data (insert card CAN PTH). ! Fuel temperature (Optional) ! Intake air temperature ! Ambient temperature ! Air pressure ! Humidity

1.6.2.1 Fuel temperature (Optional) The fuel temperature is recorded using the interface box and the fuel consumption device and and can be used as additional information for the fuel consumption measurement.

1.6.2.2 Intake air temperature

The intake air temperature is recorded using the interface box and is used for projection of the engine performance based on DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001.

1.6.2.3 Ambient temperature

The ambient temperature is recorded using the interface box.

1.6.2.4 Air pressure

The air pressure is recorded using the interface box and is used for projection of the engine performance based on DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001.

1.6.2.5 Humidity

The humidity is recorded using the interface box and is used for projection of the engine performance based on DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 or JIS D1001.

The current air temperature , ambient pressure and relative humidity is included in the calculation with the given standards (DIN 70020, EWG 80/1269, ISO 1585, SAE J1349 and JIS D1001)

Description LPS 3000 Truck

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1.6.3 OBD Module (Optional) The OBD module is used for recording the OBD data (insert card CAN OBD Module). This OBD data is different depending on the vehicle manufacturer.

ATTACHMENT: ! Position (OBD) on the interface box (see

Chapter 1, paragraph Description of the Interface box).

1.6.4 Pressure/Temperature module (Optional) The pressure/temperature module is used to record 2 temperatures and 2 pressures (insert card CAN P2T2).

1.6.4.1 Pressure 1 + 2

Pressure 1 +2 is user specific. The test range stretches from 0.9 to + 4,0 bar and can for example be used to determine the intake pressure, turbocharger pressure, etc.

1.6.4.2 Exhaust Gas Temperature

The exhaust gas temperature is used as monitor check of the combustion process and to judge its quality.

The high temperature sensor consists. of a Ni-Cr-Ni thermo element with compensation line.

The measurement range stretches from 0 to 1000C.

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1.14 D1 0524BA1-GB01

1.7 Measurement Program The chassis dyno LPS 3000 provides an exact simulation of defined driving conditions on the dyno.

Fuel consumption measurement and exhaust analysis, as well as serial monitoring of vehicles can be carried out.

The following operation modes can be selected for conducting the various measurement tasks:

! LOAD SIMULATION

The user can pre-select from various load conditions which make possible the determination of e.g. a specific engine diagnosis or vehicle climbing power. Depending upon need, various load conditions can be simulated such as constant traction, a constant speed, a constant RPM or a driving simulation. (see Chapter 6, paragraph Load Simulation).

! MEASURE ENGINE POWER

Use this menu point to determine the vehicles engine power (continuous and discrete measurement) (see Chapter 6, paragraph Measure engine power).

ROLL OUT TRIAL 2 (Optional) In order to achieve an even more accurate measurement result, a 2nd roll out trial is needed in truck range.

! PROJECTION of the engine power (Optional)

Projection of the engine power based on DIN 70020, EWG 80/1269, ISO 1585, JIS D 1001, SAE J 1349.

! FLEXIBILITY TEST

The engine flexibility can be checked using this menu point. Once the flexibility test has been called up the vehicle mass and driving resistance must be entered as in the driving simulation test. (see Chapter 6, paragraph Flexibility Test).

! SPEEDOMETER TEST

The vehicles speedometer can be tested using this menu point. The speeds are tested for this: (see Chapter 6, paragraph Speedometer Check).

! ROAD LOAD ADAPTION (Optional)

Various dyno coefficients can be determined using this menu point. The iterative coefficient adaption can be done based on ECE or SAE J2264 standard. (see Chapter 6, paragraph Load-adaption).

! LUG-DOWN TEST (Optional only for foreign countries)

Use this menu point to do a diesel exhaust measurement under full load. (see Chapter 6, paragraph LUG-Down Test).

Description LPS 3000 Truck

D1 0524BA1-GB01 1.15

1.8 Calculation Basis

1.8.1 Driving Resistance Equation

m a v

3,6 P

v

v 3,6 P

v

v 3,6 P F

ref

Roll2ref

Flex3ref

2Air

x +

+

+

=

with ! vref Reference speed for resistance performance values - normally 90 km/h. ! v Driving speed ! Pair Air resistance performance [kW] ! Pflex Flex performance [kW] ! PRoll Roll resistance performance [kW] ! a.m Vehicle mass

v ) v (v A c 0,5 P 20FrontWAir += 1 Air resistance power P-Air [kW]

The air resistance power is proportional to the surface of the vehicle front and air resistance coefficient cw.

with e.g. ! Air density (rho) = 1.1 kg/m3 ! air resistance coefficient cW = 0.38 ! Front surface (VEH-width x Height) AFront = 1.7 m 1.47m = 2.5 m2 ! Driving speed v = 90 km/h = 25 m/s ! Head wind speed v0 = 0 m/s results: ! Pair = 0,5 1,1 0,38 2,5 252 25 = 8.164 kW at 90 km/h

v g m P wFlex = 2 Flex power P-Flex [kW]

Flex power or resistance is defined as the power loss which occurs due to the flexing of the tire on the road surface and/or roller.

Generally speaking the flex power does not have a relevant influence on the test results due to the minimal flex resistance coefficient.

LPS 3000 Truck Description

1.16 D1 0524BA1-GB01

v g m P rRoll = 3 Roller Resistance Power P-Roll [kW]

The rolling resistance power arises from tire and road surface deformation as a function of speed:

with e.g. ! Roll resistance coefficient of the

tires r = 0.012

! Vehicle mass m = 950 kg ! Gravitation constant g = 9.81 m/s2 ! Driving speed v = 90 km/h = 25 m/s the result is: ! PRoll = 0.012 950 9.81 25 = 2.79 kW Since this value only represents a small fraction of the total driving resistance it is entered as a fixed standard value on our dynamometers: for steel belted radial tires approx. 2.5 kW, for winter tires approx. 3.75 kW. Setting of the vehicle mass, the aerodynamic drag power and the rolling resistance power is absolutely necessary for driving resistance simulation and stop watch tests, in order to simulate the vehicle under the correct driving resistances.

[N] a m F = 4 Mass m = Vehicle mass [kg]

This value is needed in order to attain a proportional traction F via the eddy-current brake from the vehicle determined acceleration.

1.8.2 Torque Equation

[U/min] n9549 [kW] P

M =

Description LPS 3000 Truck

D1 0524BA1-GB01 1.17

1.8.3 Projection of the Engine Power with Gasoline Engines

! DIN 70020 5,0

293[K] T

[mbar] p1013

Ka

=

! EWG 80/1269 [ ]6,01,2

298[K] T

mbarp990

Ka

=

! ISO 1585 [ ]6,01,2

298[K] T

mbarp990

Ka

=

! SAE J1349 [ ]6,01,2

298[K] T

mbarp990

Ka

=

! JIS D1001 [ ]6,01,2

298[K] T

mbarp990

Ka

=

with ! Ka correction factor ! p Atmospheric pressure at the dyno in mbar (1 mbar = 0.001 bar) ! T Air temperature at the dyno in Kelvin (0C = 273 K) e.g. ! ambient air pressure p = 936 mbar ! ambient temperature T = 17C = 290K ! based on DIN 70200 the result is: Ka = 1.07671

LPS 3000 Truck Description

1.18 D1 0524BA1-GB01

1.8.4 Projection of the Engine Power with Diesel-Engines( Suction and/or mech. charger)

! DIN 70020 [ ]5,0

293[K] T

mbarp1013

Ka

=

! EWG 80/1269 [ ]fm

=

7,0

298[K] T

mbarp990

Ka

! ISO 1585 [ ]fm

=

7,0

298[K] T

mbarp990

Ka

! SAE J1349 [ ]fm

=

7,0

298[K] T

mbarp990

Ka

! JIS D1001 [ ]fm

=

7,0

298[K] T

mbarp990

Ka

with ! fm Engine factor (Standard = 0.3)

Description LPS 3000 Truck

D1 0524BA1-GB01 1.19

1.8.5 Projection of the Engine Power with Turbodiesel Engines

! DIN 70020 [ ]5,0

293[K] T

mbarp1013

Ka

=

! EWG 80/1269 [ ]fm

=

5,10,7

298[K] T

mbarp990

Ka

! ISO 1585 [ ]fm

=

2,10,7

298[K] T

mbarp990

Ka

! SAE J1349 [ ]fm

=

5,10,7

298[K] T

mbarp990

Ka

! JIS D1001 [ ]fm

=

5,10,7

298[K] T

mbarp990

Ka

with ! fm Engine factor (Standard = 0.3)

The projection equation for Turbodiesel engine in the ISO 1585 only applies to air cooled charger cooling. The following equation applies to water cooled charger cooling.:

! ISO 1585 (Water cooled) [ ]

fm

=

7,00,7

298[K] T

mbarp990

Ka

LPS 3000 Truck Description

1.20 D1 0524BA1-GB01

1.8.6 Calculate Engine Factor fm In most cases fm = 0.3 applies but this value can be changed. The following equations are used:

Engine factor fm based on ISO 1585:

652,37 r

q 14,1.036,0 =

r

qfm

2,37r

q 2,1=fm

Engine factor fm based on EWG 80/1269, SAE J1349 and JIS D1001:

6540 r

q 14,1.036,0 =

r

qfm

40r

q 2,1=fm

Pressure behavior of the supercharging:

E

L

PP

r =

Specific fuel consumption based on SAE J1349:

4-stroke engine nD

Fq

= .120000

2-stroke engine nD

Fq

= .60000

with ! fm Engine factor ! r Pressure behavior of the supercharging ! q Specific fuel consumption based on SAE J1349 ! pL Absolute boost pressure ! pE Absolute pressure in front of the compressor ! F Fuel flow (mg/s) ! D Cubic capacity volume ! n Engine RPM

Description LPS 3000 Truck

D1 0524BA1-GB01 1.21

1.8.7 4 Wheel Drive Operation

1.8.7.1 Traction Regulation

The traction target value is divided in the front and rear as a function of the support roller RPM..

Fx n n

n Fx

h-Stv-St

v-Stv +=

Fx n n

n Fx

h-Stv-St

h-Sth +=

with ! Fxv

Traction front ! Fxh

Traction rear ! nSt-v

Support roller RPM front ! nSt-h

Support roller RPM rear ! Fx Traction total

1.8.7.2 RPM Regulation

The variable (control of the eddy current brake) is divided between the front and rear axle. This happens again as a function of the support roller RPM.

y n n

n y

h-Stv-St

v-Stv +=

y n n

n y

h-Stv-St

h-Sth +=

with ! yv

Variable front ! yh

Variable rear ! nSt-v

Support roller RPM front ! nSt-h

Support roller RPM rear ! y Variable total

1.8.7.3 Driving Resistance Simulation

The traction target value which is calculated from the individual driving resistances, is divided between the front and rear axle as with the normal traction regulation.

LPS 3000 Truck Description

1.22 D1 0524BA1-GB01

LPS 3000 Truck

D1 0524BA1-GB01 2.1

2 Safety

2.1 Introduction Please read the standard operating procedures and users manual thoroughly and carefully before commissioning the machinery and comply with the instructions. The operating manual should always be conveniently stored to be readily available at all times.

Injury to persons incurred due to non-compliance with these operating instructions are not covered by the product liability regulations.

MAHA is not liable for damage to the dyno and/or vehicles incurred due to non-compliance with these operating instructions.

A warning means that instructions that are not complied with or incompletely complied with can endanger persons.

Attention means that instructions that are not complied with or incompletely complied with can lead to equipment damage.

Notes provide additional information.

Safety information is provided to warn about dangerous situations and help prevent damage to equipment and injury to persons. For your own safety it is imperative that all safety regulations included in these instructions be carefully observed.

Carefully observe all federal and international safety guidelines for work place protection. Every user is responsible for observing all regulations which apply to his workplace and is obliged to integrate any new regulations that may be initiated.

2.2 Safety Regulations for Commissioning ! The MAHA chassis dynamometer LPS 3000 may only be commissioned by MAHA Service

technicians or those authorized by MAHA as service partners. ! All electrical parts of the testing machinery must be protected from moisture and humidity. ! The MAHA chassis dynamometer LPS 3000 may not be installed and operated in explosion

endangered rooms or wash halls.

LPS 3000 Truck Safety

2.2 D1 0524BA1-GB01

2.3 Safety Regulations during Operation ! The MAHA chassis dynamometer LPS 3000 may only be used and operated for its intended

purpose and within its stated performance limits. ! The MAHA chassis dynamometer LPS 3000 may only be operated by trained, authorized

personnel. The test lane and the surrounding work area must be kept clean. ! The dyno must be switched off when not in use and the main switch secured against

tampering with a padlock. ! No persons are allowed in the MAHA chassis dynamometer danger zone. Rotating or

moving parts are dangerous. (e.g. dyno rollers) ! In case of emergency turn the main switch (the EMERGENCY OFF switch) to 0. ! Running vehicle engines present potential carbon monoxide poisoning. The operator/owner

is responsible for providing for sufficient air ventilation. ! Use ear protection! The ear protection must be suitable to protect working areas around the

dyno from noise pollution! ! Pay attention to the official accident prevention regulations.

2.4 Safety Regulations for Service Work ! Adjustment or maintenance work should not be done on running rollers. ! Service work such as installation, maintenance or repair work on the chassis dynamometer

LPS 3000 may only be done by MAHA service technicians or authorized service partner technicians.

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

! Before doing any repair- / maintenance- / set up turn off the main switch and secure against tampering.

2.5 Attention ! Do not climb onto the roller sets and lifting bar at any time, not even when locked. ! Avoid any quick steering motions during the test. ! Check the attachment screws of the cover plate regularly to make sure they are tight. ! Avoid any unnecessary strain to the vehicle and test stand. Drive the vehicle slowly onto the

test stand. ! Damage to low lying vehicles is not covered by the warranty. ! Dynos with working pits, no person is allowed in the pit below the vehicle while its wheels

are rotating on the roller set.

Safety LPS 3000 Truck

D1 0524BA1-GB01 2.3

2.6 Important Information about the Tires ! Check the tire pressure and do a visual damage control of the tires. ! To avoid damage, we recommend using test tires during a performance test. ! Never test a vehicle which has snow, race, retreated or new tires! ! Pay close attention to the highest permissable speed for tires! ! Check the balancing weights on the rim before each test to make sure they are securely

fastened. ! Pay attention to tire size. Do not test tires below 12 !

2.7 Safety Instructions for Anchoring Device LPS 3000 Truck The additional anchoring device is a supplement to the hydraulic load device on the LPS 3000 Truck. Anchoring devices are divided into two groups: ! Lifting straps / Tension belts (made of synthetic fiber) ! Sling chain

2.7.1 Lifting Straps (made of synthetic fiber) 1 tension belt (50 mm width) Tensile strength 2000 kg, Length 4m or 1 Polytex lifting strap 2-straps with ring and load hooks, ML 2 m, load capacity with 45 to 60 inclination angle 2000 kg

Before using each time pay attention to the following:

! Only authorized and trained personnel are allowed to use it ! Lifting straps should be checked for damage and safety before using ! Do not exceed permissable load capacity. Place the straps so that the load is distributed

across the entire width ! Use only suitable anchoring positions ! Only use undamaged lifting straps / tension belts with identifiable tension labels ! Do not knot or twist the lifting straps and do not tie together to extend them ! Wind the straps a min. of 1.5 times and a max.of 3 times around the ratchet. ! Only use lifting bands with protective edges when loads have sharp edges ! Do not put stress on the tip of or up to the bending point of fixed parts ! Operating temperature: -40C to +100C ! Load capacity reduction with:

- non-symmetric (unbalanced) load - usage in tightening process only with permissible end loop reinforcement

! May not be used in lye ! Usage forbidden when there are mechanical damages, deformation or damages to any

safety features. ! Inspection and maintenance after one year only by skilled technicians

LPS 3000 Truck Safety

2.4 D1 0524BA1-GB01

2.7.2 Sling Chain Sling chain (two parts) NL 1 m, with KHS-hooks. Load capacity with 45 to 60 inclination angle 2000 kg.

Before using each time pay attention to the following

! Usage only by authorized, trained personnel. ! Inspect the sling chain for damage of any kind and other safety application before

commissioning; do not use if there is mechanical damage, deformations, stretching of the chain or an individual link, or reduction in the thickness.

! Do not exceed permissible load capacity. ! Use only suitable tie down positions. ! Use only sling chains with readable marking tag. ! Do not knot or twist the chain and do not place over sharp edges. ! Operating temperature: -40C to +200C ! Load capacity reduction when there is:

- non-symmetric (unbalanced) load - usage in tightening process.

! May not be used in acid or lye. ! Usage forbidden when there is mechanical damage, deformation or damage to safety

features. ! Do not load the hooks at the tip. ! Inspection and maintenance only by trained technicians after one year, and every 3 years a

special chain check for fracture detection.

2.7.3 Pit Safety (Optional) Light barrier or Infra-red motion sensors. An acoustic and visual signal is provided if persons are in the pit.

2.8 Further Information Cleaning with high pressure or steam pressure cleaners can lead to damage to the dyno. Do not use any cleaning agents that attack the paint, coatings or sealing material on the equipment

2.9 Information about the Eddy Current Brake The eddy current brake can heat us significantly during long lasting usage. 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 approx. 50 80 km/h.

The rotating rotors suck cooled air from the side and throw it radically off. The eddy current brake is thereby effectively cooled preventing heat build up at the rotors damaging the coil insulation.

Safety LPS 3000 Truck

D1 0524BA1-GB01 2.5

2.10 Replacing Parts Only original MAHA spare parts may be used to guarantee the reliable functioning of and thereby the safety of the MAHA LPS 3000. Original MAHA spare parts are manufactured under the highest quality standards for material and production procedure.

2.11 Safety Features The safety features should be checked regularly by an authorized service technician (recommended interval: 12 months). Pay attention to statutory requirements. The dyno may not be operated with defective safety features.

2.11.1 Lockable Main Switch Serves as a normal On and Off switch for the chassis dynamometer LPS 3000 as well as an EMERGENCY-OFF switch.

The switch can be protected from unauthorized switch on by locking with a padlock.

2.11.2 Warning and Information Labels Warning and information labels are attached to the MAHA dyno. The labels may not be changed or removed. Defective warning and information labels must be replaced.

LPS 3000 Truck Safety

2.6 D1 0524BA1-GB01

LPS 3000 Truck

D1 0524BA1-GB01 3.1

3 Installation

3.1 Requirements for the Place of Installation The room in which the dyno is to be operated must satisfy all official regulations for the operation of equipment in the workplace.

An adequate fresh-air supply and an exhaust shaft should also be available.

3.2 Safety Measures 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.

3.2.1 Heat Balance Rough calculation for diesel and Otto engines

The available energy in fuel is taken as standard. This is specified as fuel power with 100 % and is divided as follows: P1 29 % = Engine power (mechanical)

Degree of effectiveness over the entire RPM range P2 23 % = Heat flow over the engine block surface and engine components. P3 20 % = Coolant heat flow (is transmitted via the vehicle cooler) P4 14 % = Heat flow via the surface of the vehicle exhaust system P5 14 % = Heat flow of the exhaust Heat volume in the test room

P1 + P2 + P3 + P4 P1 : Is converted to heat by the air cooled eddy current brake and normally emitted into the test room. P5 : This energy is suctioned out with the exhaust suction system and does not contribute to heat volume in the test room.

Generally speaking the engine power to be measured is known. If this is specified with 1, the following factors are given: P1 Engine power 1 P2 Heat flow surface engine block 0.8 P3 Coolant heat flow 0.7 P4 Heat flow vehicle exhaust system 0.5 The heat volume in test room is then: 1 + 0.8 + 0.7 + 0.5 = 3

This means that the energy quantity of the engine power multiplied by 3 is the volume of heat energy in the test room.

P1 Engine power = 100 kW

P2 Heat flow surface engine block 0.8 x 100 = 80 kW

P3 Coolant heat flow 0.7 x 100 = 70 kW

Example 1

P4 Heat flow vehicle exhaust system 0.5 x 100 = 50 kW

Heat burden on the room = 300 kW

LPS 3000 Truck Installation

3.2 D1 0524BA1-GB01

Separate suction of the heat energy P1 converted by the eddy current brake can considerably lower the burden on the room.

The heat volume in the test room would then be: + 0.8 + 0.7 + 0.5 = 2

This means that the energy quantity of the engine power multiplied by 2 is the volume of heat energy in the test room.

P2 Heat flow surface engnine block 0,8 x 100 = 80 kW P3 Coolant heat flow 0,7 x 100 = 70 kW

Example 2

P4 Heat flow vehicle exhaust system 0,5 x 100 = 50 kW Heat burden on the room = 200 kW

! Time period An LPS 3000 performance test takes, on the average: CAR 1.5 minutes TRUCK 3 4 minutes A short working break follows (vehicle change, set up work, etc.)

! Ventilation concept criteria The following points must be considered for the ventilation concept: - Engine power - Frequency of measurements - Room temperature increase allowed by operator - Room size - Energy storage volume of the walls

Experiences of MAHA Maschinenbau Haldenwang

Cooling air is of special importance as modern engine management systems are equipped with control systems which reduce the engine power when intake temperatures are too high. The full engine power is however to be measured on the dyno.

Do not fall below the following values when testing vehicles under full load:

- Air power > 25 000m/h - Flow speed > 90 km/h - Securing of under body flow (catalytic converter)

Installation LPS 3000 Truck

D1 0524BA1-GB01 3.3

3.2.2 Exhaust Suction System The exhaust quantity depends upon the test vehicle.The factors which are most influential are the engine cubic capacity and RPM as well as the combustion process (spark ignition or spontaneous ignition).

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

Equation for dimensioning of exhaust suction systems (see TRGS 554 also paragraph 4.7.4.3 paragraph 2)

V = Vh x n x 0,0363 x 1,2

V = necessary suction volume flow (m/h) Vh = cubic capacity of the test vehicle (l) n = RPM of the test vehicle (rot/min) 0.0363 = proximity value 1.2 = fresh air share of 20 %

Experimental values based on BG-BIA / ASA recommendations *:

CAR workshop Service/Repair

CAR-Workshop Test room + AU

TRUCK-Workshop Service/Repair

TRUCK Workshop Test room + AU

350 450 m/h 700 1200 m/h 700 1200 m/h 1700 2800 m/h

hose - hose - hose - hose -

100 mm 150 mm 125 150 mm 200 mm

* Measurement point: interface recording element-exhaust hose

Pay attention to temperature consistency. The respective exhaust suction system must be adapted to the needs of the operator.

It is recommended that exhaust suction system not be combined with a welding smoke suction system and then connected to a ventilator. It is possible that a combustible or explosion-endangered mixture may be created based on the ZH 1/454-vehicle maintenance guideline.

Example for calculation based on the equation V = Vh x n x 0,0363 x 1,2 Example 1 Example 2 CAR with 3.0 Liter cubic capacity, Service work with up to middle RPM of 3000 rot/min

TRUCK 12.0 Liter cubic capacity, Service work with middle RPM of 1500 rot/min

V = 3.0 x 3000 x 0. 0363 x 1.2 V = 12.0 x 1500 x 0. 0363 x 1.2 V = 392.04 m/h V = 784.08 m/h

The exhaust discharge for the auto exhaust can be done with suction hoses (air throughput flow > 3000 m/h) or with suction flaps (air throughput flow approx. 10000 m/h) .

LPS 3000 Truck Installation

3.4 D1 0524BA1-GB01

Example to calculate for chassis dynamometers Vt = Vh x (t in C:273 Kelvin) x = supply degree of 0.85 (without Turbocharger) approx. 1.9 (depending on motor and manufacturer)

Example 1 Example 2 Car-LPS-Stand, Engine 5.547 Liter, RPM 5000 rot/min, Temperature 500C, = 1.0

Truck-LPS-Stand, Engine 18.273 Liter, RPM 2300 rot/min, Temperature 500C, = 1.5

Vt = 5.547 x 5000 x 0. 0363 x 1.2 x 500/273 x 1.0

Vt = 18.273 x 2300 x 0,.0363 x 1.2 x 500/273 x 1.5

Vt = 2212.71 m/h Vt = 5029.49 m/h

3.2.3 Fresh Air Supply for the Test Room 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 m.

The air must be renewed 5 to 8 times per hour in rooms over 100 m.

An air throughput of approx. 5000 m/h is required for a surface area of 100 m.

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

3.3 Installation and Commissioning Only authorized service technicians from MAHA Maschinenbau Haldenwang may install the machinery and commission it.

If necessary, the operator of the LPS 3000 must offer any equipment needed for installation assistance.

LPS 3000 Truck

D1 0524BA1-GB01 4.1

4 Preparations for Testing

4.1 Switch on the Dyno 1 Switch on the chassis dynamometer using the main switch on the communication desk.

2 After the PC booting, Windows is started. Depending upon the setting, the program is started either automatically, or by calling up the start group or double clicking the Icon. After program start the start screen with MAHA-Logo appears.

4.2 Drive on to Dyno/ Lower Lifting Bar

Particles on the tires such as small stones caught in the tire tread, may come loose and fly off due to the rotation of the rollers. The tires should be checked and any particles removed before driving the vehicle on to the rollers. Otherwise, danger of injury! Always wear protective glasses. Check the balancing weights on the rims for tightness before testing.

1 Check the tire tread for any particles which may fly off and cause injury before driving onto the dyno.

2 Activate the lifting bar and raise it with the cursor keys using the function key F3 of the keyboard or remote control. The lifting bar moves up and the dyno roller are blocked.

3 Drive on to the lifting bar with the driven axle of the test vehicle, the dyno driving direction. Drive the vehicle slowly and straight onto the dyno and position the vehicle in the center.

4 Activate the lifting bar using the function key F3 of the keyboard or the remote control and lower it using the cursor keys. The lifting bar lowers and the dyno rollers are free again.

4.3 Position Vehicle 1 Place the gear in idle or to position NEUTRAL with automatic vehicles and release the

emergency brake.

2 Place the wheels of the front axle straight on in driving direction. The steering wheel lock may not be locked!

LPS 3000 Truck Preparations for Testing

4.2 D1 0524BA1-GB01

4.4 Fix Vehicle

Trucks must always be fixed on the rear axle.

1 Attach the tension straps to the towing hook or to the rear axle of the vehicle.

The anchoring must sit tightly but not pull down the vehicle.

If tension straps are used for anchoring, pay close attention that the loose ends of the tension straps are not in the vicinity of the tires and rollers. This is particularly important if the fan is switched on.

4.5 Attach Weight Simulator (optional) 1 Pull the tension straps through the loops on the hydraulic

cylinders.

2 Then place the straps around the vehicle axle and pull moderately tight by moving the handle up and down.

As soon as the straps are properly placed and checked, the weight pull-down can begin.

Improper placement of the straps can lead to damage on the axle and/or other parts. Only trained personnel should attach the straps.

Any loose ends of the straps should not be in the vicinity of the tires and rollers.

Preparations for Testing LPS 3000 Truck

D1 0524BA1-GB01 4.3

4.6 Connect the RPM Sensor 1 Connect the RPM sensor in the engine room. The procedure depends upon the type of

sensor. Please pay attention to the detailed description of the various RPM sensors in Chapter 1, paragraph RPM sensor. Set the RPM sensor device using the selection list in window "RPM Sensor" in the menu "RPM Settings"

2 The RPM sensor device is connected to the interface box. Other data recorders which may be needed during the test should be connected according to the interface assignment plan for the interface box. Connect all needed measurement value sensors to the vehicle.. Use the menu "RPM Settings" to check whether all connected measurement sensors are functioning correctly.

It makes no sense to do the RPM determination via driving trial with vehicles which have automatic transmission without converter by-pass coupling because the engine RPM deviates due to converter slip.

4.7 Connect Oil Temperature Probe 1 Remove the oil measurement dip stick from the engine.

2 Adjust the length of the oil temperature probe to the length of the original dip stick by using the cone plug.

A unsuitable length adjustment of the oil temperature probe can lead to engine damage!

3 Replace the oil dip stick with the oil temperature probe. Close the oil measurements sleeves with the cone plug.

4.8 Attach Exhaust Suction 1 Place the exhaust suction device close to the exhaust pipe and switch it on.

A certain distance should be maintained from the vehicle because of possible heat accumulation in the exhaust suction unit which may cause damage to vehicle or paint.

4.9 Position Cooling Air Fan 1 Position the cooling air fan in front of the vehicles engine cooler.

2 To make sure that the fan remains in place during operation, use the fixing levers on the steering rollers of the fan.

3 Switch on the air cooling fan.

LPS 3000 Truck Preparations for Testing

4.4 D1 0524BA1-GB01

Cable and tightening straps can get between tires and rollers due to the air flow.

4.10 Bring the Vehicle up to Operating Temperature This can be done using the load simulation, e.g. with a constant traction (see Chapter 6, paragraph Load Simulation).

4.11 Vehicle Ready-for-Testing The vehicle is ready for testing when all the preparation steps for testing have been completed.

LPS 3000 Truck

D1 0524BA1-GB01 5.1

5 Program Structure

5.1 General Information The program runs under the operating system Windows XP Professional The chassis dynamometer LPS 3000 program is menu-oriented. Data or instructions can be entered via the PC keyboard. The remote control is used for the set up operation, for e.g. wheelbase setting, starting and stopping of the pre-selected driving cycle.

The program main menu is divided into several sub-menus which are called up as follows:

Wheel-Mouse: with mouse click

Keyboard: select with the Cursor-keys and call up with the key.

During the program procedure follow the instructions in the status line!

The program description is in the following chapters, i.e. in the sequence of the menu points for easy access to information.

The following is described in the instructions:

Program structure

Starting the program

Operation and explanation of the main masks and button strip

End program / switch off dyno

LPS 3000 Truck Program Structure

5.2 D1 0524BA1-GB01

5.2 Program Structure

Me

asu

rem

ent

s

Me

asu

re e

ngin

e p

ow

er

Spe

ed

om

ete

r Che

ck

Loa

d S

imul

atio

n

Loa

d A

da

ptio

n (O

ptio

nal)

Fle

xibilit

y M

ea

sure

me

nt

co

nst.

trac

tion

co

nst.

spe

ed

Driv

ing

Sim

ula

tion

co

nst.

Eng

ine

RPM

Con

tinuo

us m

ea

sure

me

nt

Disc

rete

Mea

sure

me

nt

Sta

ndst

ill

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Program Structure LPS 3000 Truck

D1 0524BA1-GB01 5.3

5.3 Start Program

1 Switch on the performance dyno via the main switch on the communication desk.

2Windows is started after the PC is booted. Depending on setting, the program is started either automatically, or by calling up the start group or by double clicking on the icon.

The start screen appears with the MAHA-Logo and version number:

The following screen appears which shows the connected PCB.

3 Confirm the release of the individual dyno components with the button.

Use to start a software-Update of the individual dyno components.

The number of modules (PCBs) depends upon the options that have been ordered!

After a few seconds the main menu appears:

LPS 3000 Truck Program Structure

5.4 D1 0524BA1-GB01

5.4 Screen Set Up Generally the screen is divided up into the following areas:

STATUS LINE

MAIN MASK

BUTTON STRIP

5.4.1 Status line The user is constantly being informed about the current status of the program in the status line guiding the user through the program and providing info about the proper keys to use. Further, fault and error messages are shown.

In the status line the dyno type, the operational and functional status of the various devices is displayed.

The various symbols are described in the following paragraph.

The messages and information in the status line should generally be adhered to!

Program Structure LPS 3000 Truck

D1 0524BA1-GB01 5.5

5.4.1.1 Symbols in the Status line

Symbol Description

Dyno OK (green) The connection to the various dyno components (e.g. eddy current brakes, interface box, etc.) are working trouble-free.

An error has occurred, but it is possible to continue! (yellow)

An error has occurred, and continuation is not possible! (red)

Communication status to OBD (red: communication error green: communication OK ) See paragraph OBD-Setting in Chapter Settings.

Dyno is set for CAR (green).

Dyno is set for TRUCK (green).

Dyno is set for motorcycles (green).

Fan (red: switched off (green: switched on )

Activate lifting bar After activation, the lifting bar can be raised/lowered using the cursor keys.

(red: lifting bar up green: lifting bar down yellow: lifting bar moves up or down)

Activate weight simulator After activation the weight simulator can be moved up or down using the cursor keys

(red: weight simulator up green: weight simulator down)

LPS 3000 Truck Program Structure

5.6 D1 0524BA1-GB01

5.4.2 Main Mask Here menu points can be selected or measurement variables displayed.

Dark colored boxes are not active!

OPERATING THE MAIN MASK

There are the following possibilities to select a menu point from the main mask:

1. Select the menu point with the cursor keys and/or with the key and confirm with .

or

2. Click on the desired menu point with the left-hand mouse key.

5.4.3 Button Strip Here are additional important functions. The assignment of buttons to in the button strip can vary. The individual buttons are labelled with the respective function and function key. The button assignments are explained later in the respective menu points as they appear.

The button strip assignments are dependent upon the respectively active screen! Dark buttons are not active!

Following diagram shows the screen range in which the button strip is designated: Example:

USING THE BUTTON STRIP:

1. Use the function key of the desired button or

2. Click the desired button using the left-hand mouse key.

3. For arrow buttons use the or , the scrolling wheel of the mouse or the left hand mouse key to switch over the strip.

5.4.3.1 Button SWITCH OVER

If the highlighted display appears in front of the arrow keys, this means the button strip has additional functions and can be switched over with the respective arrow button, with the or button or with the scrolling wheel of the mouse; i.e. additional button levels can be displayed.

Program Structure LPS 3000 Truck

D1 0524BA1-GB01 5.7

5.4.3.2 Button INFO

Use this button to call up various dyno information.

Currently not active!

5.4.3.3 Button PRINT

Use this key or the key to start a print out from every screen in which this button is active.

5.4.3.4 Button ESCAPE

Use this button or key to exit the active mask.

5.5 End Program / Switch off Dyno

First end the program and then shut down the computer properly. Improper termination can cause a system crash and data loss!

1 Exit the menu point with .

2 As soon as you are in the main menu, end the program with the key.

3 End Windows and shut down the computer properly.

4 Switch off the main switch at the communication desk.

LPS 3000 Truck Program Structure

5.8 D1 0524BA1-GB01

5.6 Update LPS 3000 Software

1 Insert LPS 3000 InstallationsCD . The automatic set-up starts.

2 Select language.

3 Confirm with button Next .

4 Select Update an existing version.

5 Use the button Browse to search for the existing path., e.g. C:\MAHA\LPS3000.

Check the Installation path. Some earlier version were installed under C:\MAHA\LPSEuro3 . If necessary, change the installation path with Browse.

Program Structure LPS 3000 Truck

D1 0524BA1-GB01 5.9

6 SQL Server selection If an SQL-Server is already installed on the computer (e.g. from an existing LPS 3000 Version or from another program) point 2 must be selected.

At many (larger) companies, an SQL Server is usually installed on another computer in the network. If LPS 3000 accesses this server, point 3 must be selected and the name of the SQL Servers must be inquired with the database administrator.

7 Selection of the components

If Docu remains marked, depending upon the installation language, Acrobat Reader is automatically installed too in English or German. The can be prevented by clicking on the Plus symbol (+) and deleting the check in front of the Acrobat Reader.

8 Autostart connection

If yes is confirmed, LPS 3000 starts automatically when Windows is started.

9 Hardlock driver installation

The Hardlock driver can be installed again even with an existing LPS 3000.

10 Lon-Network driver installation

LPS 3000 communicates with the dyno via the Lon Network. After selection of yes, the LON set-up starts.

LPS 3000 Truck Program Structure

5.10 D1 0524BA1-GB01

The Update is complete when the message Update completed appears.

11 Use the button Ende.

It starts the copying of the files. The update stalls for a longer period due to the copying of the files.

To complete the installation the following screen appears.

12 Use the button Finish.

Program Structure LPS 3000 Truck

D1 0524BA1-GB01 5.11

5.6.1 Update USB Driver

If the following error message appears when starting the LPS 3000 software, the USB-LON driver must be updated.

1 Use the Ja button.

2 End the LPS 3000 Program with .

1 Open the device manager:

Start settings Control Panel

System Hardware.

2 Select USB-Controller, i.e. click on the Plus symbol (+) and double click USB-LON.

LPS 3000 Truck Program Structure

5.12 D1 0524BA1-GB01

3 The USB-LON-driver must be updated. Use the button Update Driver.

The following screen appears.

4 Select point Install from a list or specific location.

5 Confirm with button Next .

6 Select point Dont search. I will choose the driver to install.

7 Confirm with button Next .

Program Structure LPS 3000 Truck

D1 0524BA1-GB01 5.13

8 Select USB-LON .

9 Use the button Have Disk.

10 Use the button Browse and manually select the appropriate driver from the CD directory.: Driver_usblon XP-2000-Me usblon32 usblon32.inf

11 Use the button Next and continue the installation with instructions.

LPS 3000 Truck Program Structure

5.14 D1 0524BA1-GB01

The following screen appears.

12 Use the button Continue Anyway.

Confirm File Replace

13 Use button Yes , appropriate files will be overwritten.

14 Confirm the screen with Finish.

The driver installation is herewith completed.

LPS 3000 Truck

D1 0524BA1-GB01 6.1

6 Measurements

6.1 Load Simulation The load simulation menu enables the user to preselect various load conditions which, for example, make possible targeted engine diagnosis or determination of the climbing performance of a vehicle. After selecting the menu point the following simulation selection screen appears. The individual menu points can be selected with the cursor keys or the mouse. The menu points are explained below.

Example:

1 Engine cutout at 80 km/h in 3rd gear during acceleration. Inspection of the ignition and fuel injection diagrams with the engine tester in the partial and full load range at a target value of 80 km/h.

2 Emission tests at predetermined RPMs and in various load ranges.

3 Examination of catalytic converter for pollutant emission and lambda control function.

LPS 3000 Truck Measurements

6.2 D1 0524BA1-GB01

6.1.1 Identical Functions

6.1.1.1 Button description

LEVEL 1

! The target value can be changed and confirmed during the measurement using