MAHA Maschinenbau Haldenwang MPP 2140 User manual

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MPP 2140 / 2240
Plate Brake Tester
Original Operating Instructions
BA260401-en

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Contents
1Safety.......................................................................................................................3
1.1 Introduction ........................................................................................................................................... 3
1.2 Symbols ................................................................................................................................................ 3
1.3 Intended Use ........................................................................................................................................ 3
1.4 Safety Instructions for Commissioning ................................................................................................. 3
1.5 Safety Instructions for Operation .......................................................................................................... 4
1.6 Safety Instructions for Servicing ........................................................................................................... 4
2Description ..............................................................................................................5
2.1 Range of Application ............................................................................................................................ 5
2.2 Specifications........................................................................................................................................ 5
2.3 Equipment Overview ............................................................................................................................ 6
2.4 Remote Control..................................................................................................................................... 7
2.4.1 Infrared Remote Control IFB 3 ............................................................................................................. 7
2.4.2 Radio Remote Control RECO 1............................................................................................................ 7
2.5 PCB IW 2 BA V1.0................................................................................................................................ 9
2.5.1 PCB Overview ...................................................................................................................................... 9
2.5.2 Connector Assignment ....................................................................................................................... 10
3Operation...............................................................................................................12
3.1 Switching On the Tester ..................................................................................................................... 12
3.2 Conducting a Standard Test............................................................................................................... 13
3.3 Conducting a Test with PC and Remote Control................................................................................ 14
3.4 Error Message .................................................................................................................................... 15
4Maintenance ..........................................................................................................15
5Installation.............................................................................................................16
5.1 Requirements for the Place of Installation.......................................................................................... 16
5.2 Installing the Brake Plates .................................................................................................................. 17
5.3 Installing the Display........................................................................................................................... 20
5.3.1 Wall Mounting ..................................................................................................................................... 21
5.3.2 Side Wall Mounting............................................................................................................................. 21
5.3.3 Pedestal Mounting.............................................................................................................................. 21
5.4 Electrical Connection .......................................................................................................................... 22
6Calibration .............................................................................................................23
6.1 Tools ................................................................................................................................................... 23
6.2 Procedure ........................................................................................................................................... 23
7Company Information...........................................................................................25

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1 Safety
1.1 Introduction
Thoroughly read this manual before operating the equipment and comply with the instructions.
Always display the manual in a conspicuous location.
Personal injury and property damage incurred due to non-compliance with these safety
instructions are not covered by the product liability regulations.
1.2 Symbols
Important safety instructions. Failure to comply with instructions could result in personal injury or
property damage.
Important information.
1.3 Intended Use
•This equipment is to be used exclusively for the brake testing of motor vehicles. Observe the
rated axle load.
•The equipment may not be modified without the express written consent of the manufacturer.
In case of non-compliance the declaration of conformity becomes void.
Any use other than described is inappropriate.
1.4 Safety Instructions for Commissioning
•The standard version of the tester may not be installed and commissioned in explosion or
fire endangered operating areas or in humid rooms (e.g. wash halls).
•Position the control cabinet so that the main switch is always easily accessible.
•For safety reasons the installation of a CO warning device is recommended.
•Safety devices should be inspected by a skilled technician before initial commissioning and
then at a regular two year interval.

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1.5 Safety Instructions for Operation
•Pay attention to the detailed operating instructions.
•The tester may only be operated by trained personnel who are over the age of 18.
•Adhere to the statutory guidelines for accident prevention.
•The permissible load capacity shown on the type nameplate may not be exceeded.
•Keep the tester and the working area clean.
•Operating personnel are responsible that no persons are in the tester area during testing.
•The main switch is also the emergency switch. Turn to position "0" in emergency situations.
•All parts of the electrical system must be protected from moisture.
•The tester may not be operated if there is damage to the electrical system.
•Lock the main switch to prevent unauthorized usage of the tester.
•Danger of carbon monoxide poisoning when running vehicle engines in enclosed rooms. The
operator is responsible for supplying sufficient air exchange in the tester and pit area and
adhering to statutory limit values for harmful substances.
•Warning and information labels attached to the tester may not be changed or removed.
Missing or illegible labels must be replaced.
1.6 Safety Instructions for Servicing
•Service work may only be done by authorized service technicians.
•Disconnect main plug before doing any repair, maintenance and setup work.
•Only qualified electricians may do work on the tester’s electrical components.
•Do not operate the tester when electrical components have been damaged. Damaged parts
should be exchanged immediately.
•Environmentally hazardous materials must be disposed of properly.
•The tester may not be cleaned using high-pressure or steam-jet cleaners.
•Do not replace or override the safety equipment.

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2 Description
2.1 Range of Application
The MPP 2140 / 2240 Plate Brake Tester is a diagnostic device for vehicle brakes of cars and
vans up to 4 t axle load. The condition of the brakes can be tested quickly and easily. Defects
on the vehicle brakes are identified via the digital display and the measurement values printed
out (as long as the optional remote control and PC connection exist).
The measurement simulates real road conditions thanks to galvanized test plates with high-
quality expanded metal surface.
The test plates are displaced when decelerating on them. The forces that are then created
which act proportionally to the brake forces, are recorded via strain gauge and converted
electronically in utilizable measurement quantities. The brake forces determined are displayed
on the digital display for the right and left-hand sides. Brake force difference is visualized by a
display bar. Optionally the brake force difference can also be displayed in percentage.
Vehicles with disengageable four-wheel drive can be tested on the MPP just like conventional
vehicles. The MPP is not suitable for 4WD vehicles with permanent 4WD, as erroneous
measurement results would be given. We offer, among other devices, the IW 2 PROFI LON
4WD for this purpose.
In both versions, the MPP can be surface or inground mounted.
2.2 Specifications
•Quick and easy brake testing
•Digital display with brake force difference indication
•Galvanized test plates with high-quality expanded metal surface
•Stable plate positioning with 3 ball tracks per plate
•Overload protected strain gauge
•RS 232 interface for PC connection
•Low mounting height of only 44 mm or inground mounting
•Electronic strain gauge measurement system
Supply voltage.............................................................................................. 100…240 V; 50/60 Hz
Main switch fuse..................................................................................................... 16 A time-delay
Axle load..............................................................................................................................4000 kg
Brake plate dimensions MPP 2140...................................................................44 x 600 x 915 mm
Brake plate dimensions MPP 2240.................................................................44 x 600 x 1850 mm
Display board dimensions ................................................................................. 800 x 350 x 80 mm
Display range .......................................................................0…12 kN / 0…1224 kgf / 0…120 daN
Specifications are subject to change without notice.

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2.3 Equipment Overview
A Brake force display left
B Brake force display right
C Bar display for brake force difference and user guidance
D Optional brake force difference display in % with integrated user guidance
E Optional RS 232 interface for PC connection
F Main switch and connection for power supply
G Ramps
H Plate brake tester
I Cable channel

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2.4 Remote Control
2.4.1 Infrared Remote Control IFB 3
Separate operating instructions
for the IFB 3 are available.
2.4.2 Radio Remote Control RECO 1
Not used
Menu item upwards
Menu item downwards
Confirm
Transmitter Radio Module HLE Receiver
Battery G1:
Typel: "CR 2032" 3 V Lithium
DIP Switch S1:
See next page for channel setting.
Rotary coding
switch for
channel selection

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Transmission
Channel
Frequency
in MHz
DIP Switch
Setting
Transmission
Channel
Frequency
in MHz
DIP Switch
Setting
0 868.000
4 868.800
1 868.200
5 869.000
2 868.400
6 869.200
3 868.600
7 869.800
8 870.000
11 869.525
9 868.300
12 869.850
10 868.950
Do not use transmis-
sion channels 8…12!

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2.5 PCB IW 2 BA V1.0
2.5.1 PCB Overview
X1 IR Eye Remote control RT1 Zero point left
X2 RS 485 RT2 Amplification left
X3 RS 232 RT3 Amplification right
X4 Analog IN RT4 Zero point right
X5 Not used HD1 Calibration
X6 Not used HD2 Not used
X7 Not used HD3 Not used
X8 Not used HD4 Not used
X9 Not used B1 Lithium battery, Date/Time,
3 V, Type CR 2032
X10 Supply voltage F1 Fuse of input voltage T 3, 15 A
X11 Not used

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2.5.2 Connector Assignment
Connector X1: IR Eye Remote Control
1 +24 V
2 Lamp via MOS FET on GND
3 GND
4 Data from Eye
5 +5 V
Connector X2: RS 485
1 +5 V
2 Data A
3 Data B
4 GND
Connector X3: RS 232
2 RxD
3 TxD
5 GND

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Connector X4: Analog IN, Proximity Switch IN
DMS left OUT+ 2 1 DMS left +12 V
DMS left GND 4 3 DMS left OUT-
DMS right OUT+ 6 5 DMS right +12 V
DMS right GND 8 7 DMS right OUT-
Not used 10 9 Not used
Not used 12 11 Not used
Not used 14 13 Not used
Not used 16 15 Not used
Not used 18 17 Not used
Not used 20 19 Not used
top
Connector X10: Supply Voltage
1 +24 V OUT
2 18 VAC IN
3 18 VAC IN
4 18 VAC OUT

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3 Operation
Danger! Risk of personal injury or death in the area of the tester!
¾Operating personnel are responsible for keeping all persons out of the tester area
during testing.
Danger of carbon monoxide poisoning when operating vehicle engines in enclosed
rooms!
¾The operator is responsible for ensuring there is sufficient air exchange in the
tester and pit area.
Danger of slipping when tester surface is icy or oily!
¾Keep tester and working area clean.
3.1 Switching On the Tester
•Switch on the tester using the main switch (F; see paragraph "Equipment Overview") .
⇒The tester conducts a self-test. The following messages appear:
No. Display left Display center Display right
1 LED-Test
2 Software status Display
3 Data bus address Data bus address
4 MPP2 Software status PCB
5 --,--
Front axle ready for braking
or --% --,--
⇒The tester is ready for operation as soon as the messages No. 5 appear.

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3.2 Conducting a Standard Test
In the standard version the brake test is always done following the same procedure regardless
of the axle being tested:
1 Drive onto the tester with 5…15 km/h.
2 As soon as the desired axle is on the test plate, brake sharply.
3 Stay on the brakes until the measurement values are displayed.
A minimum brake force of 0.4 kN is needed to trigger a measurement.
⇒Brake force and brake force difference can now be read for 20 s.
⇒The tester can be occupied again immediately. The measurement values which still may be
displayed will be overwritten.
If the plates are exitted in reverse by the driven axle, an undesired measurement may be
triggered. Therefore, the plates should always be exitted in a forward direction. Roll onto the
plates with a forceful movement for the next axle of the vehicle.

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3.3 Conducting a Test with PC and Remote Control
If the tester is used in connection with a PC, pay attention to the user guidance (C or D; see
paragraph "Equipment Overview"). This shows the user which axle is to be tested and/or has
already been tested. The following symbols are used:
Front axle
Parking brake
Rear axle
Delete measurement values in the PC
Flashing LED at signal input of the remote control
An already tested axle can be identified in that at re-display the values of the brake force
difference appear.
As long as the measurement values have not been stored in the PC, the existing values of the
tested axle are overwritten after each measurement.
The use of the remote control offers the following additional functions:
•Pre-selection possibilities for the axle to be tested
•Deletion of the measurement values in the PC
•Re-display of the already measured values

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3.4 Error Message
The electronic system continuously checks the
signal transmitted by the strain gauges. This
error message is issued when invalid signals
are sent due to line interruption or strain gauge
defect:
The error message always appears on the side on which the error has occurred.
4 Maintenance
•Check all movable cables monthly for damage.
•The test plates are suspended on ball tracks which must be cleaned and greased with high-
pressure adhesive lubricant (e.g. arecal LONG LUB):
1 Disassemble the track surfaces of the test plates. Remove the screws designated with (A)
and remove the surfaces.
2 Remove the balls and spacers from the guide rails and completely remove the old lubricant.
3 Fill the guide rails and the longitudinal guides generously with high-pressure adhesive
lubricant.
4 Place the balls and spacers at equal distances and re-assemble the track surfaces. Also
lubricate the screws (A).

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5 Installation
Danger! Risk of personal of injury during installation and maintenance work!
¾Pay attention to pinch points when assembling plate upper part and floor frame.
¾Pay attention to edges and corners on the control cabinet and test plates.
¾Skin can be scraped on the tester surface when the tool slips while opening the fastening
screws.
5.1 Requirements for the Place of Installation
•The test equipment may not be operated in wash halls, humid rooms or in explosion
endangered rooms. Humidity and dirt can affect the proper functioning of the tester. The
operator is responsible for selecting a suitable location.
•The required space depends on the tester equipment. Contact our service center to receive
the technical data sheets with the current dimension specifications.
•The test equipment can be installed inground or surface mounted. The brake plates must lie
full surface on the ground. The level positioning surface for the tester may not deviate more
than 2 mm and give the anchors sufficient hold. The foundation dimensions can be found in
the foundation plans for the MPP 2140 / MPP 2240.
Risk of damage!
The foundation work must be done exactly according to plan. Otherwise there is danger of
framework warping which leads to inaccurate measurements and mechanical defects during
tester operation.
•The tester must be positioned in such a way that
•driving over is no problem,
•sufficient front and lateral run-out is available,
•it is accessible at all times.
•The operator is responsible for providing a power supply with 100…240 V, 50/60 Hz. The
service center will provide you with the remaining requirements for the customer.
The illustrations in the installation instructions show the MPP 2240 version, but are analogous
with the MPP 2140 version.

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5.2 Installing the Brake Plates
Fig 1: Fastening screws for the track surface
1 Disassemble the surface tracks of the plates. Remove the screws designated in Fig. 1 as (A)
and lift the track surface.
The cable outlet (B) is located on the side face of the brake plate.
At mounting distinguish between left and right, as the plate tester is delivered already pre-
calibrated. Pay attention to the side designation on the connection cable. (see Fig. 2).
Fig. 2: Designation of the plate side
Align the left- and right-hand floor assembly of the tester on the foundation according to Fig. 3
using a positioning slat and spirit level. See the foundation plans for the mounting dimensions
(available under http://www.maha.de).

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Fig. 3: Arrangement of the components of the floor assembly
Fig. 4: Laying the strain gauge cable

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3 Fasten each brake plate (B) with 4 heavy-duty anchors M10x90 (C) on the foundation.
4a With surface mounting, use the foundation plans to install the drive-on ramps (E) and the
cable cover (F). Lay the measurement strain gauge cable through drill hole (D) under the
ramps and the cable cover.
4b With inground mounting, route the strain gauge cable through the opening (G) and follow the
foundation plan.
5 Re-place the track surfaces and attach with the screws (A) from Fig. 1.
Make sure that the guide rails, balls, spacers and the inside of the track surfaces are free of dirt
before closing!

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5.3 Installing the Display
No matter how the display is being attached, the instrument dial must be removed first and all
pre-lasered drill holes needed for the respective attachment option opened:
1 Following Fig. 5 use the openings (A) to push the panel and instrument dial up and forward
out of the display box.
2 Open the drill holes with hammer and drift punch.
Fig. 5: Opening the display
The following options are available for the attachment of the display (see Fig. 6):
•Wall mounting (pictures 2 and 4)
•Ceiling mounting (picture 2)
•Side wall mounting left and right (pictures 1 and 3)
•Pedestal mounting (picture 5; VZ 955260 "Pedestal for LED digital display" required)
Fig. 6: Attachment and positioning options for the display