Standard Operating

Procedures and User´s

Manual

Roller Brake Tester

IW2 SCREEN/EUROTEST
(4 wheel-drive)
for passenger cars and commercial vehicles of up to 4 t axle load

GV Hoà Höõu Chaán

Version 1a of these Standard Operating Procedures dated 13th February 1995.
Software: from EPROM V 1.19

The contents of these operating instructions have been checked with great care. However, erros cannot
be fully excluded.

The contents of these operating instructions are directed at users with prior technical knowledge in the
field of motor vehicle testing technology

The test stand portrayed on the title page is not standard equipment. See the current price list for
options.

D1 0206BA1-GB01
EU-IW2SCR/EUR
13.02.1995
English

copyright ©
1995 by MAHA Maschinenbau Haldenwang GmbH & Co. KG
D-87490 Haldenwang/Allgäu, Hoyen 20
Telefon : 08374 / 585-0
Telefax : 08374 / 585-499

All rights reserved.

Subject to alterations of a technical or subject-related nature.

GV Hoà Höõu Chaán

 Table of Contents

Chapter 1

Safety Instructions
1.1. Safety Instructions .......................................................................... 1
1.2. Additional Precautions .....................................................................2
1.3. Safety Features ...............................................................................3

Chapter 2

Description
2.1. Usage, Range of Application ...........................................................5
2.2. Equipment Overview .......................................................................6
2.2.1. IW2 SCREEN..................................................................................6
2.2.2. IW2 EUROTEST .............................................................................6
2.3. General Information about Brake Testing ........................................7
2.3.1. Standard Vehicles ...........................................................................7
2.3.2. 4-wheel Drive Vehicles ....................................................................8
2.4. Technical Specifications ................................................................ 11
2.5. Noise Emission.............................................................................. 12

Chapter 3

Installation
3.1. Installation Requirements .............................................................. 13
3.2. Space Requirements ..................................................................... 13
3.3. Installation and Commissioning ..................................................... 13

Chapter 4

Operations
4.1. Input Possibilities........................................................................... 15
4.1.1. Key Description for the MF-keyboard............................................. 16
4.1.2. Key Description of the Remote Cotrol............................................ 16
4.1.3. Printer ........................................................................................... 17
4.2. Short Operating Instructions .......................................................... 17
4.2.1. Without Keyboard or Remote Control ............................................ 17
4.2.2. With keyboard or remote control.................................................... 18

GV Hoà Höõu Chaán I

 4.3. Operations..................................................................................... 19
4.3.1. Preparations for a Brake Test ........................................................ 19
4.3.2. How to Carry out a Brake Test....................................................... 19
4.3.2.1. Roller Resistance Test................................................................... 20
4.3.2.2. Ovality Test (Out-of-round, e.g. due to drum knocking) ................. 20
4.3.2.3. Maximum Brake Force .................................................................. 20
4.3.3. Imbalance Display ......................................................................... 21
4.3.4. Single Wheel Test ......................................................................... 21
4.3.5. 4 Wheel Drive Brake Test (only poss. with 4 wheel drive testers).... 22
4.3.5.1. Preparations for a 4 wheel drive test.............................................. 23
4.3.5.2. Brake Test on the Left Side ........................................................... 23
4.3.5.3. Ovality Test on the Left Side ......................................................... 24
4.3.5.4. Testing the max. Brake Force of the Left Side............................... 24
4.3.5.5. Brake Test on the Right Side ......................................................... 24
4.3.5.6. Ovality Test on the Right Side ....................................................... 24
4.3.5.7. Testing for Max. Brake Forces on the Right Side........................... 25
4.3.6. Positons of the 4 Wheel Drive Switch ............................................ 25
4.3.6.1. Switch Position 0 ........................................................................... 25
4.3.6.2. Switch Position 1 ........................................................................... 26
4.3.6.2.1. Testing of the ASD (Automatic Differential Lock)........................... 26
4.3.6.2.2. Testing of ASR (Automatic Drive Slip Control)............................... 26
4.3.6.3. Switch Position 2 ........................................................................... 26
4.3.6.4. Switch Position 3 ........................................................................... 27
4.3.7. Reviewing of the Test Values ........................................................ 27
4.3.8. Print out of Test Results ................................................................ 28

Chapter 5

Maintenance, Malfunction Diagnosis

5.1. Maintenance of the Roller Set ....................................................... 29
5.1.1. Chain Lubrication .......................................................................... 30
5.1.2. Chain Tension ............................................................................... 30
5.1.3. Greasing or Oiling Sensor Roller Hinge ......................................... 30
5.1.4. Grease Motor Outer Support ......................................................... 30
5.2. Safety Inspection........................................................................... 30
5.3. Malfunction-Check list ................................................................... 31
5.4. Disassembly and Repair of the Test Stand .................................... 32

Chapter 6

Warranty, Service
6.1. Warranty ....................................................................................... 33
6.2. Warranty Exclusion Clause............................................................ 33
6.3. Service.......................................................................................... 34

II GV Hoà Höõu Chaán

Chapter 1 Safety Instructions

Chapter 1

Safety Instructions

1.1. Safety Instructions

Pay close attention to all safety instructions described here to prevent accidents or injury to personnel or
damage to the test stand.
A turning roller is potentially dangerous!
Always pay close attention when passing by the rollers or entering or exiting the vehicle!
No persons are allowed in the vicinity of the brake rollers while brake tests are in progress.
The danger zone should be easily recognizable, if necessary the floor should have colored
indication markers. In addition, a sign should be clearly visible warning all persons that a brake
test is in progress.
If the brake tester is located in an area to which the public has access,additional precautions must
be taken when the brake tester is unattended or not in use. The rollers should be covered or
secured in such a way that no tampering is possible and unauthorized persons do not have
access.

The edges of the installation pit must be clearly visible and painted with a safety coating according
to DIN 4844.

The test stand shoud be turned off and locked when not in use, during malfunctioning or
when repair work is being done! This procedure prevents unauthorized personell from turning
on the test stand or carrying out repair work.

Before opening up the test stand for servicing any electrical components on the test stand
should be disconnected from the power supply. (Turn off main switch and lock it)

Only trained, authorized personell shall be allowed to carry out electrical service work on
the brake tester. Unskilled work on the brake tester can be life threatening!

The main switch also serves as an emergency switch! The switch must be in position 0 in
emergency situations.

All electrical components shall be protected from moisture and humidity.

Test stands which are built over an inspection pit are required to have pit safety systems. A pit
safety system prevents persons from being in the pit area while the brake tester is in operation.
Rotating parts of the vehicle and the tester such as drive shaft, tires and rollers are particularly
dangerous as hair or clothing may get caught.
continued on the next page!

GV Hoà Höõu Chaán 1

Operating Instructions IW2 SCREEN/EUROTEST

All test stand safety devices must be checked before it is commissioned for the first time. Regular
inspection of all safety features is necessary, but at least once every years by trained service
personell. (regular inspections)

Never do calibration or maintenance work while the rollers are running or the test stand is
in operation. Rotating parts of the vehicle and the tester such as drive shaft, tires and rollers are
particularly dangerous as hair or clothing may get caught.

The test stand is only to be used as described in the operating manual. The test stand
serves as brake tester for passenger cars and commerial vehicles up to 4 t axle load.

Never use the roller set drive to start the engine of a vehicle. e.g. when the battery of the
car is dead!
The vehicle can jump out of the test stand when the car is put into gear.

Never park a car on the roller set. The rollers may be arbitrarily set in motion when the main
power is turned on.

Never exit the test stand with a driven axle unless both motors are running and the
"Ready" message appears on the screen.
If this procedure is not closely followed severe damage can be done to the electronics and
mechanics of the roller set and test stand !

Pay close attention to the brake force bar graph! An extreme high bar graph display indicates
lateral starting of one wheel on the wheel deflector or stiff wheels due to jammed brake
components.

Be careful when vehicle engines are running! Exhaust fumes can cause carbon monoxide
poisoning.

Standard brake testers are not explosion proof! Test stands should never be operated in
cofined spaces liable to contain explosive mixtures!

1.2. Additional Precautions

• The main switch and "ON" key should only be turned on when no vehicle is on the rollers and the
sensor rollers are not pressed. If this is not the case no zero point offset can be conducted.

• If a vehicle is on the rollers or the sensor rollers are pressed the white control lamp will blink once
the main switch has been turned on. After the "ON" key has been pressed the white control lamp
will be on continuously and the test stand will automatically begin running after a programmed
start up time has passed.

• ABS-System (Anti-Block-System)
Vehicles equipped with ABS-Systems can be easily tested on the IW2 SCREEN and/or IW2
EUROTEST. Be sure to carefully follow the manufacturers instructions. As the testing speed of the
IW2 SCREEN/EUROTEST does not exceed 5 km/h most ABS-Systems will not be activated.
Vehicle in which the ABS-System becomes activated at this low test speed can only be tested if
the ABS can be swithed off.

• 4 wheel drive vehicle

A brake test on the standard brake tester is only possible if the 4 wheel drive system can be
switched off during the brake test. Otherwise the test stand must be optionally equipped to test 4
wheel drive vehicles.

2 GV Hoà Höõu Chaán

Chapter 1 Safety Instructions

• The test stand rollers should not be running when a 4 wheel drive vehicle exits the test stand.

• Always drive slowly onto the brake tester rollers to avoid unnecessary strain on vehicle and test
stand.

• Operational malfunctions due to improper installation or alterations are not covered by the
warranty. This regulation also applies when the regular warranty period has not yet expired.
The manufacturers CE Declaration of Conformity becomes invalid when improper installation or
alterations have been undertaken on the equipment.

1.3. Safety Features

• Sensor Roller
Each side of the roller set has a sensor roller. The test stand will only turn on if both sensor rollers
are pressed. The sensor rollers turn as the vehicle wheels turn and serve to recognize slip. When
slip occurs between tires and test stand rollers the test stand automatically switches off as the
sensor rollers are no longer turning.

• Lockable main switch

When the test stand is not in use the main switch can be locked to prevent unauthorized use of the
test stand. By pressing the extended nose piece an opening will appear in which a padlock can be
hung and locked preventing any unauthorized usage.

• Pit Safety System

Test stands which are constructed over pits should have a pit safety system which automatically
switches off the test stand if it is activated. (i.e. someone enters the pit while the test stand is in
motion.) MAHA manufacturers several different versions of the pit safety system.

GV Hoà Höõu Chaán 3

Operating Instructions IW2 SCREEN/EUROTEST

4 GV Hoà Höõu Chaán

Chapter 2 Description

Chapter 2

Description

2.1. Usage, Range of Application

The IW2 SCREEN/EUROTEST (4 wheel drive) brake tester serves as a brake test stand for passeger
cars and commercial vehicles up to 4 t axle load. It belongs to the roller test stand group of testers. This
class includes two different measuring methods to record brake force: testing of drive torque or drive
power. The former is applied in the IW2 SCREEN/EUROTEST (4 wheel drive).
A brake test supplies exact results about the braking effectiveness of each wheel. but cannot replace a
visual inspection of the individual brake parts.
The IW2 SCREEN/EUROTEST (4 wheel drive) consists of our proven roller set and electronics which
can be easily augmented. The basis of the electronic is a processor mother board with its own operating
system. A color monitor provides a fast and clear display of the brake test results. (including 4 wheel
drive and single wheel tests)
The brakes of 4 wheel drive vehicles can only be tested on the standard brake tester if the 4 wheel drive
system can be disabled. Otherwise the brake tester must be equipped with the optional 4 wheel drive
system from MAHA.
The only difference between the IW2 SCREEN and IW2 EUROTEST is in their various equipment.
These operating instructions describe the brake tester with 4 wheel drive version. The operational
instructions for the communication desk is described with the keyboard and remote control.
Test stands which are not equipped with keyboard or remote control need only the section of the manual
dealing with an actual vehicle test. Status and diagnostic menu descriptions can be disregarded.

GV Hoà Höõu Chaán 5

Operating Instructions IW2 SCREEN/EUROTEST

2.2. Equipment Overview

2.2.1. IW2 SCREEN

• Color screen with graphic and digital display

• Stainless steel casing for monitor with wall attachment
• Elektro-control cabinet (lower cabinet)
• Roller set with steel rollers-synthetic rollers available upon request
• Electronic start up monitoring and exit assistance
• Single wheel switch on and delayed automatic start-up
• Automatic switch off after exiting the test stand
• Automatic slip switch off with test resutls display and re-start automatic
• Electronic strain gauge measurement system
• Self-supporting enclosed roller set
• Powder paint coating blue, RAL 5010
• Painted control cabinet, gray RAL 7042

2.2.2. IW2 EUROTEST

• Control, display and print out via the EUROTEST 2000 communication desk
• Electronic start up monitoring and exit assistance
• Single wheel switch on and delayed automatic start-up
• Automatic switch off after exiting the test stand
• Automatic slip switch off with test resutls display and re-start automatic
• Electronic strain gauge measurement system
• Self-supporting enclosed roller set
• Powder paint coating blue, RAL 5010

Standard equipment subject to change without notice!

See the current price list for equipment and options.
In addition to standard versions MAHA Maschinenbau Haldenwang offers diverse expansion possibilities which are listed in the current
price list.

6 GV Hoà Höõu Chaán

Chapter 2 Description

2.3. General Information about Brake Testing

It is important that the respective brake forces of wheels on one axle are the same to avoid skidding.
Just as important is the minimum brake moment for each individual wheel so that when braking no
vehicle brake is overburdened. Consequently, each wheel is measured individually on a brake tester.

For measuring brake force, a static and a dynamic method are available.
With the static method, the force is determined that is necessary to rotate a wheel, which is positioned in
a stationary state on a plate, when the brakes are applied.
With the dynamic method -practical experience orientated- the wheel is brought up to a specified speed
by the motor-driven rollers and then the brakes are applied.
A slip bar directly measures the wheel revolutions. From the comparison of drive roller with the slip bar
revolutions, the amount of slippage can be determined. For safety reasons, the brake test is
automatically interrupted on MBH brake testers with a slippage of approximately 30% or more.

The measuring principle is the same for both methods of testing. The drive motor is supported in a
rotary fashion; without any additional support, the drive shaft and the housing would counter-rotate when
under load, depending on the force distribution. This additional support consists of a beam on which the
housing is placed. The steel beam bends corresponding to the torque produced by the motor which the
beam has to resist; the torque is zero when beginning the static method of brake testing and, with the
dynamic method, is just as high as necessary in order to bring the drive rollers and wheel in motion when
the brakes are applied.

A wire strain gauge (DMS) is mounted on the transverse beam, which converts the force into a usable
electrical value.

A roller brake tester based on the dynamic mode is used for the IW2 E (4wd) EUROTEST brake tester,
as this will yield the most accurate readings and as there is no other alternative for brake tests of 4-wheel
drive vehicles.

2.3.1. Standard Vehicles

Drive wheel axle to be tested onto the roller set. This will push both sensors rollers down to measure the
wheel speeds. Slowly accelerate both drive motors of the roller set to nominal speed, turning both
vehicle wheels forward. When nominal speed of the drive motors has been reached, a comparison is
made between the drive roller nominal speed and the sensor roller speed in order to be able to switch off
when approximately 30% slip of the drive motors is exceeded (to protect the drive motors against
overload and the tyres against bursting or excessive wear .).

The READY indicator will light signaling that the rig is ready to start the brake test. During brake tests the
vehicle is decelerated to the pointthat at least one sensor roller will exceed 30% slip and the drive motors
will switch off.

GV Hoà Höõu Chaán 7

Operating Instructions IW2 SCREEN/EUROTEST

2.3.2. 4-wheel Drive Vehicles

In 4-wheel drive vehicles in which the 4-wheel drive can be disabled, the brakes are tested with the 4-
wheel drive switched off, as with standard vehicles. If the 4-wheel drive of a vehicle cannot be switched
off, such vehicles can only be tested after an assurance has been given that no brake torque will be
transferred from one vehicle wheel to the other. This is guaranteed if no torque is applied to the drive
shaft of the differential. To prevent transfer of torque, the drive shaft of the differential may be removed
(high labor costs).

If torque is applied to the drive shaft, either through the torque of the vehicle engine or of the test rig
drive motors, this torque will be evenly distributed to all four wheels, i.e. a quarter of the total torque will
be applied to each wheel.

If one brake of the 4-wheel drive vehicle is removed, leaving only one brake on the axle to be tested and
if the brake is tested in the test rig without eliminating torque from the drive shaft, the wire strain gauges
of the left-hand and right-hand drive motors will display the same brake torque during a brake test. This
would lead to error readings of a faultless brake if one was not aware that one brake had become
ineffective. During correct testing one motor should therefore not display a brake torque (the motor with
the disabled brake), with the other motor displaying the actual brake torque applied by the wheel. The
reason for both motors displaying the same brake torque is the 4-wheel drive concept, distributing the
torque evenly to the vehicle wheels. The brake torque is distributed by the drive shaft.

If both vehicle wheels of the axle to be tested are allowed to rotate forward during a brake test, the
vehicle will push out of the test rig, as the torque is transferred to the wheels of the other vehicle axle by
the drive shaft. Pushing the vehicle from the test rig will be prevented if one vehicle wheel is driven in
forward direction and the other in reverse, eliminating torque building up in the differential against the
drive shaft.

Fig. 2-1: Reversed rotational directions

8 GV Hoà Höõu Chaán

Chapter 2 Description

The brake moment can only be conclusively measured by a vehicle wheel rotating forward, as the brake
characteristics will change depending on the direction. (The brake pads and brake drums are only
machined in forward direction, resulting in different brake characteristics when braking the wheel rotating
in reverse direction.) For this reason the brake test will have to be repeated for each wheel to rotate each
wheel once in forward direction when measuring its brake torque.

In order to obtain a comparison of the brake torques of the wheels on a vehicle axle, the same pedal
force will have to be applied to both wheels of the vehicle during brake tests, as the brake torque of the
left-hand and right-hand wheel can only be measured in sequence (left-hand forward alternating by right-
hand forward). For this purpose a pedal force load cell will be connected to the brake pedal, or the
control pressure of the hydraulic brake will have to be measured by a pressure sensor to obtain the same
pedal force for both measuring cycles.

Fig. 2-2: Pedal force meter

4-wheel drive vehicles either have a drive shaft to the differential which can be disabled, a VISCOSE
clutch (VC) in the drive shaft to the differential, or the drive shaft between the two differentials is rigidly
connected.

More rotation (soft VISCOSE clutch) or less rotation (hard VISCOSE clutch) may be applied to the
VISCOSE clutch, transferring no torque to the other wheels when the drive shaft speed is low.

Fig. 2-3: Viscose-clutch

GV Hoà Höõu Chaán 9

Operating Instructions IW2 SCREEN/EUROTEST

Brake tests of 4-wheel drive vehicles are feasible if no brake torque is transferred to the drive shaft
and/or if no brake torque is transferred from the differential to the drive shaft. This is achieved if the left-
hand wheel of the vehicle is rotated at the same speed as the right-hand wheel. The speed of the two
drive motors should mostly differ, as in fact the left-hand wheel has a different circumference from the
right-hand wheel. This is due to the different depths of sections and the air pressure of the tyres.
Therefore the drive motors must control the wheel speed required to obtain the same speed for both
wheels.

Approximately the same speed of the roller set drive motors will be sufficient for a 4-wheel drive vehicle
having a soft VISCOSE clutch in the drive shaft as no torque and/or brake torque is transferred by the
VISCOSE clutch when the drive shaft speed is low. Therefore the speed control of the drive motors
alone will not be sufficient in this case.

Contrary to this, when testing the wheels of 4-wheel drive vehicles having a hard VISCOSE clutch in the
drive axle, both vehicle wheels must rotate synchronously during the brake test, as the clutch viscosity is
so low that even the lowest speed of the drive axle will transfer torque and/or brake torque to the other
wheels through the VISCOSE clutch.

In order to control synchronous rotation of the wheels, the wheels are equipped with reflective strips
triggering signals of two photo-electric cells arranged on the roller set side.

A Reflective strips
B Licht barrier

Fig. 2-4: Reflection strips

The principle of measuring the position of the reflective strips on the vehicle wheels will now also
facilitate a brake test of 4-wheel drive vehicles having a rigid front axle and rear axle drive shaft. With a
rigid drive axle of the 4-wheel drive vehicle to be tested, the wheels may no longer be rotated in opposite
directions. If one vehicle wheel in the roller set is rotated forward, the other wheel will be reversed in a
synchronous angle. If the wheel is rotated forward or reverse by several centimeters, one will note that
the other wheel has not yet started to rotate. This is due to gear play (profile play) of the differential.

A Gear differential play

Fig. 2-5: Gear play of the differential gear

10 GV Hoà Höõu Chaán

Chapter 2 Description

To perform a brake test on a 4-wheel drive vehicle having a rigid drive shaft, the wheels must be
controlled in such a way that no brake torque can be transferred by the drive shaft. This is achieved by
maintaining the gear play of the wheels of the 4-wheel drive vehicle during the brake test, with the
differential being in "balance" to prevent brake torque being transferred to the drive shaft. Therefore gear
play is initially assessed in learning mode.

Initially this will require acceleration of the left-hand wheel to nominal speed (with the right-hand drive
motor disabled) with the left-hand wheel coupled to the right-hand wheel. The two sections of the
differential are therefore touching on one side. Now the first limit position of the gear play may be
measured by the reflective strip of the photo-electric cells, followed by disabling the left-hand drive motor
and accelerating the right-hand drive motor to nominal speed. Now the right-hand wheel will be coupled
to the left-hand wheel, with the two sections of the differential touching on the other side. The second
limit position of the gear play may now be measured by the reflective strips of the photo-electric cells.
The position of the drive play center line will be calculated from these two limit positions, and the brake
test will be controlled based on this gear play center position.

During brake tests of 4-wheel drive vehicles the drive motors are accelerated to test speed. One vehicle
wheel will rotate forward, the other in reverse direction. As soon as this happens, with no brake torque
being transferred to the drive shaft, brake testing may begin.

The drive motors are switched off during excessive slip for the same reasons as for the standard vehicle.

2.4. Technical Specifications

IW2 SCREEN/EUROTEST (4 wheel drive)

Mechanical Data IW2 SCREEN IW2 EUROTEST

perm. axle load 4t

Track width min. 780 mm, max 2200 mm

Dimesions control cabinet 800 x 950 x 195 mm 675 x 2025 x 680 mm

(WxHxD)

Dimesions of roller set 240 x 680 x 2320 mm

(HxWxL)

Roller diameter 202 mm

Roller axle separation 400 mm

Roller friction value steel dry ca. 0,9; wet ca. 0,7

Roller friction value plastic dry ca. 0,8; wet ca. 0,7

Test speed 5 km/h

Display unit Color monitor 52 cm diagonal

Test value display range 0 - 6 kN

Test accuracy grouping 2,5 (error smaller than 2 % of scale end value)

Continuation⇒
Continuation⇓

GV Hoà Höõu Chaán 11

Operating Instructions IW2 SCREEN/EUROTEST

Test accuracy grouping 2,5 (error smaller than 1 % of scale end value)

Imbalance display range 0 - 70 %

Ovality measurement unit kN or %

Operating temperature -10°C to +40°C

Elektrical Data

Power supply 3 x 400 V, 50 Hz

Fuse 25 A slow

Drive power 2 x 3 kW

Measurement system Strain gauge system

Technical data subject to change without notice.

2.5. Noise Emission

The noise emission caused by the test stand is less than 70 dB (A) in the area around the test stand in
which operational personell are required to work.
Test conditions: Test stand is occupied by a vehicle (passenger car); Test point: driver at head level in
the drivers seat with open window and running rollers.

12 GV Hoà Höõu Chaán

Chapter 3 Installation

Chapter 3

Installation

3.1. Installation Requirements

The IW2 SCREEN/EUROTEST brake tester is not to be installed in washing halls, high humidity areas,
hazardous locations or out in the open. Dirt and humidity may impair the precise operation of the brake
tester.
The minimum concrete grade must be at least B 25.
The floor unevenness must be smaller than 3 mm/m². Pay close to the MAHA foundation plans when
installing the foundation.

The buyer is to provide for the following power supply connections:

Power supply 3 x 400 V + N + PE, 25 A slow / 5 x 6 mm².

A suitable location for the installation of the brake tester is to be chosen by the buyer.

3.2. Space Requirements

Pay close attention to the foundation plans when planning the space distribution. Make sure that enough
space remains on all sides of the roller set for an escape route if it ever becomes necessary to quickly
leave the test room.

The electro control cabinet / communication desk should be positioned in such a way that the main
switch is always easily accessible.

The edge of the installation pit should be clearly visible and marked (painted) with a safety coating
based on regulation (DIN 4844).

3.3. Installation and Commissioning

The test stand may only be installed and commissioned by the manufacturer's trained authorized
personell or other qualified technicians of MAHA dealers or representatives.
Authorized service technicians have technical handbooks and other documents at their disposal when in-
stalling or dismantling the test stand.

• Operational malfunctions of the test stand due to improper installation or alterations are not
covered by the warranty. This regulation also applies when the regular warranty period has not yet
expired.
The manufacturers CE Declaration of Conformity becomes invalid when improper installation or
alterations have been undertaken on the equipment.

GV Hoà Höõu Chaán 13

Chapter 4 Operations

Chapter 4

Operations

4.1. Input Possibilities

The standard version of the IW2 SCREEN normally does not require an input device. The testing
procedure is fully automatic. Optionally available are a MF-keyboard with 102 keys, and 2 remote control
units; the "COMMANDER" and the "Tele-EURO".
The IW2/SCREEN EUROTEST has a 102 MF keyboard but can optionally be supplied with the "Tele-
EURO" remote control.

Each input device has its own operating manual which should be carefully read before use. The
operational instructions for using the keyboard are included in the operations manual for the
"SCREEN/EUROTEST 2000" communication desk.

GV Hoà Höõu Chaán 15

Operating Instructions IW2 SCREEN/EUROTEST

4.1.1. Key Description for the MF-keyboard

The keyboard is described in detail in the "Communication desk SCREEN/EUROTEST 2000" operations
manual. The following only describes the specific keys needed for the brake test itself.

Function keys for the keyboard

The following keys are important for the IW2 SCREEN/EUROTEST brake test:

Start a print out/ Bar diagram

Once the operator is in the Status-Menu a print out can be started directly
after calling up the print program. This key serves to display various test
resuIts when in the "Test values" menu point: the bar diagram of a brake test
in kN, assuming test values are available, as well as a display of ovality in kN,
differential values of all test in %, the weight in kg and the deceleration in %.
Pedal-Graphic
The progress of the brake force over the pedal force value in menu point "test
values" can be viewed assuming a pedal force meter was connected during
testing.
Difference- Graphic
The deviation of the kN-Brake values in % during the total test can viewed in
menu point "Test values".

BT-BC-Graphic
When in menu point "Test values" the brake corridor shows the difference in
% of the brake forces of both sides as a green curve between the lineals.
Depending on the set deviation in % the lineal leg will be more or less split
apart. (country specific settings).
Manual Ovality Test
While this key is pressed during the brake test, the test stand will show the
ovality. It is not necessary to brake into the braking range. The brake force
during an ovality test should be minimal. A second test person is needed
when an ovality test is done using the keyboard.
Maximum Values
The max. values of the individual tests can be viewed during the test using
this key.

Online Print out

Use this key to print out the current brake and imbalance values of the
respective axles during the brake test itself.

4.1.2. Key Description of the Remote Cotrol

Note: The following description applies only to test stands or test lanes which have
been supplied with a remote control as an accessory.

The key assignments for the "Tele-EURO" remote control are described in the instructions titled "Remote
Control Tele-EURO" and applies to the test lane EUROTEST 2000 as well as the SCREEN-version.

16 GV Hoà Höõu Chaán

Chapter 4 Operations

The key assignments for the "Commander" remote control are described in the instructions titled
"Remote Control Commander SCREEN". The "Commander" remote control is only available as an
accessory in the SCREEN-version.

4.1.3. Printer
A short description of the DIN A4-printer "CITIZEN SWIFT 200" can be found in the "Communication
desk SCREEN/EUROTEST 2000" operating instructions.

Note: The printer has its own operating instructions.

4.2. Short Operating Instructions

4.2.1. Without Keyboard or Remote Control

Pay close attention to the operating instructions! The instructions in this chapter contain
important information.

Fig. 4-1: Short operating instructions for the brake test without keyboard or remote control

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Operating Instructions IW2 SCREEN/EUROTEST

4.2.2. With keyboard or remote control

Pay close attention to the operating instructions! The instructions in this chapter contain
important information.

Fig. 4-2: Short operating instructions for a brake test with keyboard or remote control

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Chapter 4 Operations

4.3. Operations

4.3.1. Preparations for a Brake Test

The 4 wheel drive switch should be positioned at 0. The testing of 4 wd vehicles is described at a later
point in this chapter.
Turn on the main switch on the communication desk. Follow the procedure described in the operating
instructions from the "Communication desk SCREEN/EUROTEST 2000".

• Only turn on the main switch and "ON" key if no vehicle is on the rollers i.e. the sensor rollers are
not pressed. Otherwise the test stand cannot conduct a zero point calibration.

=> The test stand is now ready for operation!

4.3.2. How to Carry out a Brake Test

Drive the vehicle onto the rollers with the first axle and put the vehicle into neutral.

• Drive slowly onto the rollers so that no unnecessary strain is placed on the vehicle or the test
stand.

Select "N" on vehicles with automatic gear shift. After a brief time both motors will start up separately.
Should both motors switch off again immediately this is an indication that the start-up monitoring was
activated preventing any damage to the vehicle or its tires. One or both wheels may be jammed. (seized
bearings, jammed brake pads, etc.) The start-up monitoring is also activated if, when the motors are
started, the brakes are applied.

The following screen display will appear:

Wait until both motors have started and the screen display "Brake within arrows. Ovality" appears. Now
the brake test can start.

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Operating Instructions IW2 SCREEN/EUROTEST

4.3.2.1. Roller Resistance Test

Before the brake pedal is applied, the roller resistance appears on the screen. (i.e. the diagram bars are
not exactly at 0). The roller resistance can have various values depending on type of vehicle and load:
For a passenger car it is between ca. 0.1 to 0.6 kN.

The left-hand roller resistance should be approximately the same value as the right-hand resistance. If
large differences exist, a bearing might be faulty or a brake be jammed. The green middle bar shows the
difference between the right and left side. If the roller resistance of one or both wheels is excessive, and
if damage to the wheel by the rollers may be anticipated or if the brake pedal has been depressed, the
start-up monitor will be enabled when the wheel is started, immediately switching the test rig off.

4.3.2.2. Ovality Test (Out-of-round, e.g. due to drum knocking)

Apply moderate brake force to the brake pedal until the brake force indicator is between the green
marks. Maintain constant brake force while the green arrow is blinking and the screen message shows
the ovality test is completed. In case of ovality, the bar will move up and down, despite constant pedal
force. The difference between the maximum and minimum display is ovality in kN. This will be displayed
on the screen.

Fig. 4-3: Out-of-round on a drum brake

4.3.2.3. Maximum Brake Force

When the screen indicates "Ready", apply the brake pedal slowly and evenly.

On test rigs equipped with an acceleration limiter (optional) the screen

will show an error message if the brake pedal is depressed too fast.
In this case the brake test will have to be repeated.

Observe the brake force bars on the screen. The diagram bars of the brake torque needles should rise,
based on the pedal force applied. The differential between the left-hand and right-hand brake force will
be shown on the differential display (if available). As soon as the wheel has reached a slip of 30%, both
rollers will be switched off. Now the maximum brake force has been reached. This value will be
displayed on the monitor until the motors are restarted (needles stopped). Should the motor not switch
off inspite of maximum pedal force, the brake force reached at maximum pedal force is the maximum.

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Chapter 4 Operations

The test results are automatically stored after the test is completed.
After all the axles have been stored, the communication desk program will return to the Status-Menu.
It is also possible to return to status menu by pressing the 'STATUS' key on the remote control or the
'F10' key on the keyboard.

Never exit the test stand with a driven axle unless both motors are running and the
"Ready" message appears on the screen.
If this procedure is not closely followed severe damage can be done to the electronics and
mechanics of the roller set and test stand as the rollers are then being driven by the vehicle!

• The difference between the two brake forces should not exceed 30%!
The ratio of max. brake force of the service brake to the weight of the vehicle should not be less
than 0.4 (40%)!

4.3.3. Imbalance Display

The imbalance display shows the difference between the right and left hand brake force value in
percentage. (%) The diagram bar moves into a green, orange or red range depending on the imbalance
value. These ranges can be freely set by the service technician.
The imbalance display is triggered when a pre-set total brake force is reached.

4.3.4. Single Wheel Test

In order to conduct a single wheel test on test stands without remote control the single wheel switch must
be positioned at the side to be tested before the vehicle drives onto the rollers. If for example the switch
is set at L (left), then only the left rollers will start up when the vehicle drives onto the rollers. The max.
value of the test will be automatically stored and displayed together with the values from the other side
once the test has been completed. The switching from L (left) to R (right) should be done by a second
operator personnel which is stationed at the communication desk. The switch over from L to R should be
done in one smooth action avoiding a catch at position 0. If a second person is not available to do the
switching then the inspector must leave the vehicle to do so.

Running rollers are potentially dangerous!

When walking by, entering and exiting the vehicle pay close attention to the rollers!

When the single wheel test is completed the single wheel switch must be returned to position 0. After a
brief time both rollers will start up and the vehicle can exit the rollers.

Never exit the test stand with a driven axle unless both motors are running and the
"Ready" message appears on the screen.
If this procedure is not closely followed severe damage can be done to the electronics and
mechanics of the roller set and test stand !

To do single wheel test using the remote control drive onto the rollers as when doing a normal brake test
and wait for the rollers to start up. (assuming automatic start up is set. Now use the "Left-off" or "right off"
to switch off one side of the roller set.
If only one side is running apply the brake until roller set switches off. If the slip switch off is not reached,
the test stand "remembers" the max. value attained. Switch off this side after the test is completed. Now
the other side must be switched on separately with the remote control. Now this side will be tested. If the
slip switch off is not reached this side will have to be switched off.

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Operating Instructions IW2 SCREEN/EUROTEST

Use the "Confirmation" key to store the test values when both sides have been tested. If the values of
just one side are unintentionally stored then the entire test must be repeated.

Never exit the test stand with a driven axle unless both motors are running and the
"Ready" message appears on the screen.
If this procedure is not closely followed severe damage can be done to the electronics and
mechanics of the roller set and test stand !

• If it is not possible to start both roller sets using the "Left ON" or "right ON" keys (e.g. accident
vehicle) the vehicle will have to be removed from the rollers using outside assistance.

When the single wheel tests are completed, i.e. both sides have been stored via the "Confirmation" key,
the motors of both sides will be automatically turned on. The message "Single wheel mode END; motors
automatic".

4.3.5. 4 Wheel Drive Brake Test (only possible with 4 wheel drive test stands)

Generally the brakes of a 4 wheel drive vehicle can only be tested using a 4 wheel drive test stand. 4
wheel drive vehicles with a variable 4 wheel drive i.e. which are equipped with a differential between
front and rear axle, can be tested on a standard brake tester once the 4 wheel drive has been de-
activated.

During four-wheel drive tests the pedal force meter should be connected
at the interface of the remote control for comparison of pedal forces with
brake forces.

The velcro band should be placed over the foot so that the pedal force meter is centrally positioned on
the brake pedal.

When operating the brakes, hold remote control in the direction of the
communication desk, as otherwise the pedal force and/or brake data will
not be transferred. The acceptance of the command will be confirmed by
flashing of the green indicator on the front side of the pult.

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Chapter 4 Operations

4.3.5.1. Preparations for a 4 Wheel Drive Test

a) Main switch to off

-> Set selector to four-wheel drive (Switch position 2 oder 3).

b) Main switch to on

c) Wait for initializing. Press 'Confirmation' or '*' key. Wait for message "Test lane ready for testing".

d) Drive vehicle in front of roller. Attach reflector strips to all wheels at the same level as the photo-
electric cell. Ensure all surfaces are clean before reflector strips are attached. If, in 4-wheel drive
mode 3 (see 2.7.4) a 4-wheel drive vehicle with soft VISCOSE clutch is tested, no reflector strips
are necessary. If there is doubt as to which type of clutch is present, reflector strips should be
used.

e) Connect pedal force meter to "Telecom-EURO" remote control and before pressing the brake
pedal connect it under the foot.

f) Switch remote control on.

Press "ON" pushbutton on remote control. There will be a zero calibration and a display test.
After the display test the measured pedal force will be indicated. If no force is exerted on the
pedal force meter, the display will show 000 (and/or 005-010 due to the deadweight of the
pedal). Now the remote control and the pedal force meter are ready for operation. When the
test rig receives the signals from the remote control, the green indicator will light. The
connection is interrupted if this light is off.

g) Drive vehicle including axle to be tested onto the roller set. As soon as the vehicle is on the
roller set, release brake and switch gear lever to idle or "N" (neutral) for automatic
transmissions.

h) Maximum readings which have already been measured can be displayed on the screen by
pressing the "ON" key on the roller set.

• If the vehicle is on the rollers and the 'Return' (#) key is pressed, all test data of the currently
tested axle will be deleted!

4.3.5.2. Brake Test on the Left Side

Press left "ON" button on "Telecom-EURO". The roller sets will be started. The left-hand arrow (rotation)
will light on the screen. The 'Ready' message will only switch on after the motors have reached their
steady state.
Now the brake test may commence. Due to the rolling resistance of the wheels, there will be a display on
the diagram bars without the brake being operated.

Pay close attention to the brake force bar graph! An extreme high bar graph display indicates
lateral starting of one wheel on the wheel deflector or stiff wheels due to jammed brake
components.

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Operating Instructions IW2 SCREEN/EUROTEST

4.3.5.3. Ovality Test on the Left Side

To test ovality (out-of-round) of the brake disc or drum, apply approximately half of the maximum brake
force.
This value should be maintained for at least one rotation of the wheel, simultaneously pressing the "oval"
button. The blue Status line will indicate that ovality is being measured. Now release the "Oval" button.

Recommendation: Note the pedal force which is displayed on the remote control or the
screen. To compare the left and right-hand brakes, it is important that
the ovality on both sides is measured with the same pedal force.

4.3.5.4. Testing the max. Brake Force of the Left Side

Apply the brakes until the maximum brake force is reached.

There are two possibilities:

a) The rollers will switch off when a slip of 30% is reached.The maximum value will be shown on
the display.

b) The rollers will not be switched off. Release brake and press red "Off" push button on
"Telecom-EURO". The rollers will be switched off. The maximum values will remain on the
screen.

4.3.5.5. Brake Test on the Right Side

Press right "ON" button on "Telecom-EURO". The roller sets will be started. The right-hand arrow
(rotation) will light on the screen. The "Ready"- message will only switch on after the motors have
reached their steady state.
Now the brake test may commence. Due to the rolling resistance of the wheels, there will be a display on
the diagram bars without the brake being operated.

Pay close attention to the brake force bar graph! An extreme high bar graph display indicates
lateral starting of one wheel on the wheel deflector or stiff wheels due to jammed brake
components.

4.3.5.6. Ovality Test on the Right Side

To test ovality (out-of-round) of the brake disc or drum, apply approximately half of the maximum brake
force. (The maximum brake force will differ from one vehicle to the next.) This value should be
maintained for at least one rotation of the wheel, simultaneously pressing the "oval" button.

Note: Ensure that you made a note of the pedal force during the ovality test of
the left-hand side. To ascertain whether the brake effect is actually
roughly the same on both sides, this test should be carried out with the
same pedal force, if possible. Observe display on remote control (pedal
force) and the analogue display on the test rig.

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Chapter 4 Operations

4.3.5.7. Testing for Max. Brake Forces on the Right Side

Apply brake pedal until the maximum brake force is reached.

There are two possibilities:

a) The rollers will switch off when a slip of 30% is reached.

b) The rollers will not be switched off. Release brake and press red "Right Off" button on "Telecom
EURO". The rollers will then be switched off.

Before allocating the test data to an axle and storing them, it is advisable to check them once again by
pressing the "ON" button. Whilst pressing the "ON" pushbutton, the test rig will display the maximum
brake forces. If one side is missing, the test was not completed properly and will have to be repeated for
the missing side.

The display will now show the maximum brake forces of both sides.

Brake tests of the rear axle and handbrake will be carried out in the same way.

The blue Status line at the bottom of the screen , shows the respective status of the test.

• Except for a few special cases attach pedal force meter to the handbrake with the enclosed strap
when testing the handbrake.

• The test stand rollers need not be running when a 4 wheel drive vehicle exits the rollers.

4.3.6. Positons of the 4 Wheel Drive Switch

The 4- wheel drive functions described below apply only to test stands i.e. test lanes which have 4-wheel
drive brake testing capabilities.

If the 4 wheel drive can be switched off on a vehicle then this should be done simply to save time and
the the brakes should be tested while in normal drive.
The 4 wheel drive switch positions described below should only be altered while no vehicle is on the
rollers.

4.3.6.1. Switch Position 0

The "0" position (left side of the communication desk) is used for normal operation (no 4 wheel drive
vehicle or the 4 wheel drive has been turned off). The brake test can be carried out exactly as in point
"Conducting a brake test".

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Operating Instructions IW2 SCREEN/EUROTEST

4.3.6.2. Switch Position 1

Select this switch position to test an automatic differential lock (ASD) or a drive slip control (ASR) as to
their functions.

The automatic differential lock will be engaged when a certain slip between the wheels is reached if an
ASD is available.
In contrast, the ASR will only apply as much force on the drive wheel as could be transferred to the road
surface.

4.3.6.2.1. Testing of the ASD (Automatic Differential Lock)

Drive axle to be tested onto roller set. Select roller to be decelerated by remote control (right "on" button
for the right side, left "on" button for the left side). The selected roller will be decelerated as soon as the
vehicle wheels start rotating, with the other roller running idle (this will result in slip between the drive
wheels). Put into first gear and accelerate drive rollers with vehicle engine (speed < 15 km/h). As soon as
the wheels start rotating the "ready" indicator will light. If the automatic differential lock (ASD) is
functioning, the vehicle will be lifted from the rollers (Exit assistance) and/or the decelerated roller will
display a high torque. If it is not OK, the wheel which is not decelerated will rotate at a higher speed than
the decelerated wheel. As soon as the 15 km/h limit is reached, the "ready" lamp will extinguish. Repeat
the test on the other wheel by pressing the left "off" and/or right "off" pushbuttons, followed by switching
on the other side.

4.3.6.2.2. Testing of ASR (Automatic Drive Slip Control)

Proceed as described in Point 2.7.2.1 to test the balancing function for slip differential. In addition, the
engine throttle with the full rotation of drive wheels can be tested. To do so press left "off" and right "off"
pushbuttons. Accelerate vehicle in the first gear. Initially the "ready" indicator will switch on. If the vehicle
engine is not throttled, the "ready" indicator will extinguish after 15 km/h are reached and the engine slip
throttle is not OK. If it is OK, the engine will be throttled before a speed of 15 km/h is reached.

Set switch to 0 before driving vehicle off the rollers.

4.3.6.3. Switch Position 2

This switch position is used for brake tests on vehicles having a permanent four-wheel drive. Use remote
control as described in Point 2.5 "Individual wheel tests by remote control". Drive axle to be tested onto
the roller set. Attach reflector strips to both wheels at the same level as the photo-electric cell.

Attention: Ensure that reflector strips are attached on the same level as the photo-
electric cell for proper functioning of the control. This will be confirmed
when the "ready" indicator is on.

The test rig is now in learning mode, in which play of the axle transmission will be tested. Initially the
left-hand motor will be driven, which forcibly reverses the right wheel via the differential. The
transmission now hangs on the left teeth surfaces. The positions of the reflector strips will be verified
and saved. This procedure will be confirmed by the left-hand brake force indicator showing a higher
torque than the right-hand one. As soon as the left-hand stop was found, the left-hand drive will switch off
and the right-hand drive will switch on. The transmission is now hangs at the right teeth surfaces.(visible
by the torque display of the right pointer).

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Chapter 4 Operations

Again the positions of the reflector strips will be verified. The difference between the left and right teeth
surfaces will be the play of the drive. Now the computer will center the wheels into a middle position of
the play. The test stand pointers will display approximately the same value ->. The gears of the
differential will now be running and completely disengaged (this is the only way to transfer the brake
torque). Centering of the transmission play may take several minutes, depending on the wheel size and
the magnitude of the play. After completion of balancing the "ready" indicator will switch on again. Test
the right wheel (rotating in forward direction) in the same way as described in Para 4 "Four-wheel Drive
Brake Test". Repeat this procedure for the left-hand side and store test data as usual.

4.3.6.4. Switch Position 3

Switch postion 3 is used for the testing of four-wheel drives with a Visco clutch (such as a VW-Syncro).
Contrary to a permanent four-wheel drive, no transmission play can be tested. The computer will
therefore control rotation of the wheels synchronised to the angle. If a soft Visco clutch is available,
speed-synchronised control will be sufficient (no reflector strips required). If a hard Visco clutch is
installed, reflector strips must be attached (if in doubt always attach reflector strips) Testing: drive axle
onto roller set. Switch on right-hand side. The test rig will balance according to its operation mode (with
or without reflector strips). The "ready" indicator will switch on. Now the test may be carried out as
described in Point 4 "Four-Wheel Drive Brake Test".

4.3.7. Reviewing of the Test Values

The screen displays will differ depending on how the test stand and/or test lane is equipped. The test
results can only be viewed if the test stand is equipped with a remote control or keyboard. Further
information about the status menu is provided in the operating instructions for the "SCREEN/EUROTEST
2000 Communication Desk".

It is possible to re-display the test values of a completed brake test via the status menu. In order to do
this select the menu point "Test values" on the right side of the screen using the arrow keys and press
the "confirmation" key. A green selection frame will appear on the left side of the screen. Move the frame
to the "BT" line. If an entire brake test has been completed the "FA", "PB", ""EB", and "FE" boxes will be
highlighted red and the green frame will be on "FA".
All highlighted boxes can be selected with the arrow keys and the test data called up with the
"Confirmation" key.
The operator guidance always appears in the lower blue instruction line on the screen.

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Operating Instructions IW2 SCREEN/EUROTEST

If the "confirmation" key is pressed now the bar diagram containing the appropriate test data will appear.
Use the F1 to F4 keys to display the various data in diagram form. The red curves show the left side
values and the blues curves the right side values.
The diagrams are described in the function key description in paragraph "Keyboard description " at the
beginning of this chapter.

A complete final evaluation of the brake test can be viewed via point "FE".

4.3.8. Print out of Test Results

The test results of a brake test can be printed out using the "Print" menu point in the status menu.
Further information about the status menu is provided in the operating instructions for the
"SCREEN/EUROTEST 2000 Communication Desk".
All diagrams which can be displayed in the menu point "Test Values" using the function keys F1 to F4
can also be printed out in menu point "Print" by selecting the "Select the graphic" box. This of course
assumes that test data is available.

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Chapter 5 Maintenance, Malfunction Diagnosis

Chapter 5

Maintenance, Malfunction Diagnosis

5.1. Maintenance of the Roller Set

The main switch should always be turned off and locked when the test stand is not in use,
during repair work, or when malfunctions occur! This prevents unauthorized use of the test
stand as well as unintentional switch on during repair work.

The test stand should be disconnected from all power supply before it is opened for any
kind of service or repair work. (Switch off main switch and lock)

Only trained, authorized personell shall be allowed to carry out electrical service work on
the brake tester. Unskilled work on the brake tester can be life threatening!

The roller set must be inspected and serviced every 200 operating hours or once a year.
Inspection should include a thorough check of the anchoring of the roller set and its fasteners.
The chain tension must be checked for the first time 14 days after initial commissioning and afterwards
inspected on a monthly basis.

A Chain D Fastening screw

B Sensor roller hinge E Tension screw
C Outer support

Fig. 5-1: Maintenance points on the brake roller set

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Operating Instructions IW2 SCREEN/EUROTEST

5.1.1. Chain Lubrication

Remove the cover plate in the middle of the roller set. Now grease the chain (A in Fig. 5-1) well with a
universal type lubricant along the entire length of the chain. It will be necessary to turn the rollers
manually.

5.1.2. Chain Tension

The chain should have a play of about 5 mm in either direction. If the chain does not have enough
tension loosen the fastening screw (D in Fig. 5-1). Turn the tightening screw (E in Fig. 5-1) until the chain
has the proper tension. Retighten fastening screw (D in Fig. 5-1) and check the chain slack again.

5.1.3. Greasing or Oiling Sensor Roller Hinge

The sensor roller hinge must be greased or oiled every 200 operating hours or at least once a year.

5.1.4. Grease Motor Outer Support

Every 200 operating hours or once a year the drill holes of the motor outer support must be oiled by
injecting a thick oil into the holes.(C in Fig. 5-1)

5.2. Safety Inspection

All safety features must be inspected carefully before the test stand is put into operation for the
first time. After this an inspection must be carried regularly by trained, authorized service
technicians at least once every 2 years.

The owner of the machinery is responsible for ensuring that all safety inspection regulations are carefully
followed.

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Chapter 5 Maintenance, Malfunction Diagnosis

5.3. Malfunction Check-List

Malfunction possible cause Remedy

"Ready"-Lamp does not blink À no electricity À Reconnect the power supply
although the test stand has been Á Control power fuse F1 is to the test stand.
turned on. defective. Á Replace fuse.
 Fuse F2 defective.  Replace fuse.
à Lamp defective à Replace lamp.
"Deceleration limiter!!!" Deceleration limiter is activated À Apply brakes more slowly
"Please brake slowly!!!" À Brake pedal was pressed too Á Interrupt brake test. Turn off
quickly the test stand at the main
Á Brakes are blocked switch and get rid of the
blocking. Turn the test stand
on again and let the rollers
run.
After the roller set has been
switch off and on again drive
the test vehicle onto the
rollers again and the repeat
the brake test.
"Max. imbal has been The max. brake force imbal. is Repeat test
exceeded!!" too large
"Repeat axle test!"
"Reflex strips on the left/right À The reflex strips were not À Attach reflex strips.
wheel are not OK" attached. Á Clean light barrier.
"Check the Reflex strips Á Light barrier is dirty. Â Contact MAHA-Service Dept.
left/right!" Â Light barrier is defective.
"No Reflex strips on the wheels" À Reflex strips are missing on À Attach reflex strips.
"Attach reflex strips on both both wheels. Á Clean both light barriers.
wheels!" Á Both light barriers are dirty
"Sensor roller left/right is not The sensor rollers left/right are Drive straight onto the rollers,
pressed down" not occupied. centrally positioned.
"Sensor roller left/right is
occupied"
"The brake tester is occupied!!!" A vehicle is on the roller set at Cofirm message with the
"Please drive off the rollers" the moment when the main confirmation key. Once the
switch on the test stand is turned rollers start running the vehicle
on. can exit the roller set.
The main switch must be
switched on and off again so that
the test stand can initialize itself
again.
"The printer is not ready" The printer inquiry has Timeout Turn on the printer
"Turn on printer."
Roller set does not run. Both motor protection switches Contact the MAHA-Service Dept.
are "OFF", or defective

Continuation⇒

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Operating Instructions IW2 SCREEN/EUROTEST

Malfunction possible cause Remedy

One roller set side runs and One of the protection switches is Contact the MAHA-Service Dept.
switches off again immediately "OFF" or defective
The brake force imbalance is too Zero point is no longer OK Contact the MAHA-Service Dept.
large on all vehicles The test stand must be calibrated
anew.
No picture. Monitor is not turned on Turn on the Monitor .
The monitor picture is blue. À GRAPH-LO mother board is Contact the MAHA-Service Dept.
defective.
Á F1 fuse on the SH8-board is
defective.
 F2 fuse is defective.

5.4. Disassembly and Repair of the Test Stand

The test stand may only be installed and commissioned by the manufacturer's trained authorized
personell or other qualified technicians of MAHA dealers or representatives.
Authorized service technicians have technical handbooks and other documents at their disposal when in-
stalling or dismantling the test stand.

• Operational malfunctions of the test stand due to improper installation or alterations are not
covered by the warranty. This regulation also applies when the regular warranty period has not yet
expired.
The manufacturers CE Declaration of Conformity becomes invalid when improper installation ord
alterations have been undertaken on the equipment.

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Chapter 6 Warranty, Service

Chapter 6

Warranty, Service

6.1. Warranty
Based on the General Conditions of Sale, Maschinenbau Haldenwang (MAHA) grants a warranty and
agrees to repair or replace faulty components free of charge during the warranty period provided that the
product is returned to MAHA - directly or via an approved MAHA dealer - or is repaired and/or installed
by an authorised engineer. This warranty shall only apply if the product was installed by an authorised
engineer.

Damage due to inappropriate changes or gross negligence shall not be covered by the warranty.

The warranty for MAHA products will only apply if a completed guarantee card and a warranty application
are in hand in connection with a signed original proof of the purchase stating the date of purchase and
the serial number of the product. Proof of a regular maintenance schedule must also exist.

6.2. Warranty Exclusion Clause

Warranty coverage provisions stipulate that all MAHA products are to be used properly, that is, in strict
accordance with manufacturer's installation and operating instructions, including subsequent operational
and service information.

Excluded from warranty coverage is all normal wear and tear on vehicle parts of test vehicles due to op-
erational requirements. In addition, warranty coverage does not include damage to vehicles or MAHA
equipment or other products which occurs based on subsequent changes, modifications or other devia-
tions from the original vehicle model undertaken on individual vehicles.

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Operating Instructions IW2 SCREEN/EUROTEST

6.3. Service
MAHA maintains service centres in numerous countries. These centres will be available at any time to
answer product queries. Contact your MAHA dealer or MAHA direct for product repairs. All repairs
carried out after termination of the warranty period will be invoiced.

Address of service department:

MAHA Maschinenbau Haldenwang GmbH & Co. KG.

D-87490 Haldenwang/Allgäu
Telephone : 08374 / 585-0
Telefax : 08374 / 585-499

34 GV Hoà Höõu Chaán