Maha Mfp 3000 User manual

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MFP 3000

Driving Test Bench

Original Operating Instructions

BA690101-en

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Contents

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

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

1.2 Symbols .............................................................................................................................................. 5

1.3 Intended Use....................................................................................................................................... 5

1.4 Requirements on Operating and Service Personnel............................................................................. 5

1.5 Safety Instructions for Commissioning................................................................................................. 6

1.6 Safety Instructions for Operation ......................................................................................................... 6

1.7 Safety Instructions for Servicing........................................................................................................... 8

1.8 Safety Instructions for Handling Hydraulic Fluid ................................................................................... 8

1.9 What to Do in the Event of an Accident............................................................................................... 8

2Specifications...........................................................................................................9

3Software Operation ................................................................................................12

3.1 Home Screen .................................................................................................................................... 12

3.2 User Login......................................................................................................................................... 13

3.3 Manual Emergency Operation ........................................................................................................... 14

3.4 Settings / Operating Data.................................................................................................................. 15

3.4.1 Settings: Language ........................................................................................................................... 15

3.4.2 Settings: Time Management.............................................................................................................. 15

3.4.3 Settings: Torque Smoothing.............................................................................................................. 16

3.4.4 Settings: Test Duration...................................................................................................................... 17

3.4.5 Settings: Roller Diameter ................................................................................................................... 17

3.4.6 Settings: Speed Difference at 60 kph ................................................................................................ 17

3.4.7 Switching to the User Management................................................................................................... 17

3.5 User Management............................................................................................................................. 18

3.6 Showing Warning and Error Messages.............................................................................................. 20

3.7 Showing Charts................................................................................................................................. 23

3.8 Showing Equipment Data.................................................................................................................. 24

3.9Quitting the Program ......................................................................................................................... 25

4Test Procedure ......................................................................................................26

4.1 Switching on ..................................................................................................................................... 26

4.2 Setting the Wheelbase ...................................................................................................................... 26

4.3Driving onto the Test Bench .............................................................................................................. 26

4.4 Preparing the Test............................................................................................................................. 27

4.5 Performing the Test........................................................................................................................... 27

4.6 Using the Tyre Pressure Control........................................................................................................ 28

4.7 Terminating the Test.......................................................................................................................... 29

4.8 Switching out .................................................................................................................................... 29

5Maintenance ..........................................................................................................30

5.1 Annual Inspection.............................................................................................................................. 30

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5.2 Maintenance Interval ......................................................................................................................... 30

5.3 Care Instructions ............................................................................................................................... 30

5.4 Spare Parts ....................................................................................................................................... 30

6Service Lifetime......................................................................................................31

7Dismantling ............................................................................................................31

8Disposal.................................................................................................................31

9Company Information.............................................................................................32

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Safety

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1.1

Introduction

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Thoroughly read this manual before operating the equipment and comply with the

instructions. Always display the manual in a conspicuous location.

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

safety instructions are not covered by the product liability regulations.

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These operating instructions are intended only for the appropriate use of the

driving test bench MFP 3000. For other technical equipment or machines, which

are no direct components of the driving test bench (such as the scissors lift),

please refer to the operating instructions provided with the product.

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1.2

Symbols

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Important safety instructions. Failure to comply with instructions could result in

personal injury or property damage.

Important information.

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1.3

Intended Use

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The MAHA driving test bench MFP 3000 shall be used exclusively for the direct

functional testing of electronic systems which require a steady and even drive of

the vehicle wheels within the framework of regular vehicle inspections.

The MFP 3000 simulates regular driving conditions and therefore allows system

checks on ABS, ESP, cornering/turning lights, AFS-Emergency stop signal, safety

belt warning, ASR and tyre pressure monitoring (partial check).

The driving test bench shall not be modified without the express written consent of

the manufacturer. In case of non-compliance the declaration of conformity

becomes void.

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1.4

Requirements on Operating and Service Personnel

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All persons employed in the operation, maintenance, installation, removal and

disposal of the device must

•be at least 18 years old,

•be trained and instructed in writing,

•have read and understood this manual

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•be on record as having been instructed in safety guidelines.

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1.5

Safety Instructions for Commissioning

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•The driving test bench shall be installed and commissioned by authorized

service personnel only.

•The driving test bench shall not be installed and commissioned in hazardous

locations, outdoors, in moist rooms (e.g. car wash) or outside a temperature

range of 5…40 °C (41…104 °F).

•The control desk must be positioned so that the operating personnel cannot be

hit by flying particles ejected from the rotating wheels. Otherwise put up a

sufficiently dimensioned protective wall between the operating panel and the

MFP 3000. (Note steering angle of front wheels!)

•Use a 40 amps time-delay fuse for the mains power supply. This is adequate

for the current development stage of the test bench (and lift). To be prepared

for future stages and options, we recommend to use a power supply line

suitable for a fuse protection of up to 63 amps.

•Usage of an RCD should be avoided if possible (risk of undefined triggering!). If

installation of an RCD is mandatory, use a short-time delayed type which is

suitable for frequency converters and requires a minimum trigger current of

300 mA. Other standards and regulations may apply.

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1.6

Safety Instructions for Operation

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•The test bench shall be used and operated exclusively for its intended purpose

and only within its performance limits.

•Observe the detailed operating instructions supplied with the DUO CM lift.

•Pay close attention to accident prevention regulations.

•The test bench shall be operated by trained personnel only.

•The test bench shall only be operated by persons who are physically and

mentally fit. These persons must be well rested and not under the influence of

alcohol, drugs or medication.

•When not in use, the system must be switched off and the main switch

protected against re-start.

•No persons shall be in the danger zone while a vehicle is entering, crossing or

exiting the test bench.

•In addition to the danger zone, the operator is responsible for confining the area

of the test room in which no persons are allowed during testing with a safety

catch device or a cell wall. Mark the danger zone (roller width + 1100 mm) on

both sides behind the vehicle up to cell wall/safety catch device.

•Keep the test bench surface clean and dry. Danger of slipping when surface is

wet, oily or icy! Do not place any objects (tools, material etc.) on the test bench.

Wear protective shoes with anti-slip soles and steel toe caps to avoid slipping

BA690101-en

and mechanical injuries. Parts which protrude more than 20 mm out of the floor

are to be marked with black-yellow tape.

•Do not exceed the rated load capacity of the lift.

•Drive onto the test bench only when it is in a fully lowered position.

•The test bench can be driven over in its retracted position with a maximum

wheel load of 1000 kg. This load corresponds to a vehicle gross weight of

approx. 3500 kg.

•Use a non-slip ladder for entering and leaving the vehicle.

•After switching over the operating mode from "DUO" to "MFP 3000" remove

the key and keep it in a safe place.

•Center the vehicle in the prism of the axle play tester and secure it against

rolling off by pulling on the parking brake.

•During test preparation the inspector must keep a safe distance.

•The vehicle tests must be performed by two persons. One person is at the

control desk, the other in the passenger compartment.

•During the vehicle tests no additional persons are allowed in the test room.

•The emergency stop device must be easily accessible at all times.

•While the rollers are being driven, the inspector must remain in the passenger

compartment and have the emergency device readily at hand.

•Do not step on the roller sets, not even when they are in a locked position.

•Avoid unnecessary strain on vehicle and test bench. Drive the vehicle slowly

onto the test bench.

•Damage to low lying vehicles is not covered by the warranty.

•Regularly check the tightness of the cover plate attachment screws.

•Wear personal protective clothing. If necessary wear protective goggles.

Particles ejected from rotating vehicle wheels can cause severe injuries. Wear

tightly fitting working clothes and bind long hair together. Clothing or hair can

get caught and pulled into machinery.

•Danger of hearing damage due to high noise level! Use hearing protection

approved up to 120 dB(A). Noise levels over 110 dB(A) can be reached during

vehicle testing. The operator is responsible for determining the noise level in

vehicle and test room. When necessary, wear suitable hearing protection. The

operator must attach warning stickers.

•Danger of carbon monoxide poisoning by poisonous vehicle exhaust. The test

stand may only be operated if the room in which the test stand is installed has

sufficient exhaust suction and ventilation including the appropriate warning

system.

•Wait until vehicle and rollers have stopped moving before exiting the vehicle.

Danger of body parts and clothing being pulled into rotating rollers and vehicle

wheels.

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•Pull on the parking brake before lowering the vehicle from the wheel-free jack

onto the runways to prevent the vehicle from rolling away.

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1.7

Safety Instructions for Servicing

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•Service work must be done by authorized service technicians.

•Turn off the main switch and secure it against being turned on again before

doing any repair, maintenance or setup work.

•DANGER! Electric shock hazard. After switching off all voltages dangerous

voltage can still be present for at least 5 minutes!

•During maintenance work the system must be depressurized.

•Ensure that ecologically harmful substances are disposed of in accordance with

the appropriate regulations.

•Use caution when cleaning the equipment: system is under pressure!

•Do not use high pressure or steam jet cleaners. Do not use caustic cleaning

agents.

•The safety devices must be set by authorized service technicians.

•Do not replace or override the safety devices.

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1.8

Safety Instructions for Handling Hydraulic Fluid

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•Neutralize hydraulic fluid spills with binder.

•Remove contaminated clothing immediately.

•Inhalation: If symptoms persist, seek medical treatment.

•Skin contact: Wash skin immediately with soap and water. If skin irritation

persists, seek immediate medical advice.

•Eye contact: Rinse thoroughly with water and seek medical advice.

•Ingestion: Do not induce vomiting. Seek immediate medical attention.

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1.9

What to Do in the Event of an Accident

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•The injured person is to be removed from the danger area. Find out where

dressing and bandages are kept. Seek first-aid.

•Provide first-aid (stop bleeding, immobilise injured limbs), report the accident

and seal off the accident site.

•Immediately report any accident to your supervisor. Make sure a record is kept

of every occasion first-aid is provided, e.g. in an accident book.

•Remain calm and answer any questions that may arise.

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Specifications

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MFP 3000

(Front axle)

MFP 3000

(Rear axle)

Test bench

Working pressure 100 bar

Width (FA / RA) 633 mm 628 mm

Height (FA / RA) 111 mm 111 mm

Length (FA / RA) 391 mm 461 mm

Axle distance (min. / max.) 2375 mm / 3490 mm

Track width with 850 mm installation width 1200 mm / 1600 mm

Steering angle ± 15°

Contact pressure 30 kg

Weight 2 x 65 kg 2 x 55 kg

Weight of hydraulic unit (runway) 2 x 40 kg

Load capacity 3500 kg

Full travel 130 mm 80 mm

Lifting time typical

Drive-over height with compensation plates 58 mm 61 mm

Friction coefficient of test roller/tyre (depending

on tyre model) approx. 0.9

Noise emission (without vehicle) <80 dB

Possible wheel diameters R10…R24

(min. axle distances limited by wheel diameter)

Possible function tests (depending on vehicle

status)

ABS; ESP; Cornering light; ASR;

RDK (Tyre pressure monitoring; indirectly)

Motor

Diameter / Width 100 mm / 470 mm

Rated power 2.5 kW

Rated torque (Maximum torque) 7.5 Nm (15 Nm)

Maximum speed (Master-Slave) 70 kph (80 kph)

RPM (at 80 km/h) 4244 1/min

Electronics

Fuse (time-delay) 40 A

Control cabinet (height / width / depth) 1300 mm / 1200 mm / 400 mm

Control cabinet weight 170 kg

Temperature range (operation / storage) 5…30 °C / -15…30 °C

Cable length (lift  control cabinet) 10 m

Mains frequency 50 Hz

Mains voltage 400 V

Phases 3

Rated power 27.0 kW

Overall

Hydraulic power unit (lift) 5.5 kW

Working temperature range 5…40 °C

Shipping weight preinstalled on lift

Shipping dimensions (height / width / length) preinstalled on lift

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Software Operation

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3.1

Home Screen

Manual emergency operation

Reset control

Settings/Operating data

Increase speed by 10 kph

Go to "Login" screen

(for service technicians only)

Reduce speed by 10 kph,

master-slave operation

Quit program

Extend MFP 3000

Show warning/error messages

Retract MFP 3000

Show diagrams

Stop drives

Back to home screen

Acknowledge warning/error

message

Display of target speed

Start drives

Display of master-slave

operation

Logout/Login

Enable tyre pressure control,

rear left

Enable tyre pressure control, rear

right

Enable tyre pressure control,

front left

Enable tyre pressure control,

front right

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3.2

User Login

1 Touch any button except for and .

The login dialog appears.

2 Enter the user password and confirm with "OK".

The user logged in is displayed in the top left-hand corner of the screen. The

driving test bench is ready for operation.

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3.3

Manual Emergency Operation

Rear axle

In the event of control or hydraulic system failure the driving test bench is

depressurised at the rear axle and is lowered by its own weight.

Front axle

In the event of a system failure the front axle can be manually lowered into bottom

position.

1 When a pressure value is displayed, push Button / . When "0 bar"

is displayed, hold down the button and retract the driving test bench with

muscle power.

2 After retraction push button / and lower the driving test bench

using a mechanical tool, e.g. a rod.

Back to previous screen

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Crushing hazard!

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3.4

Settings / Operating Data

Go to user management screen (admin password required)

Back to previous screen

Connect desktop PC to control unit

Disconnect desktop PC from control unit

3.4.1

Settings: Language

1 Choose the desired language from the selection menu.

3.4.2

Settings: Time Management

Disabling summer/winter time:

1 Touch button <Disable summer/winter time>.

Summer/winter time change is disabled.

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Enabling summer/winter time:

1 Touch button <Enable summer/winter time>.

2 Make your settings in the dialog

menu.

3 Confirm with <OK>.

Setting the Time Zone:

1 Choose the desired time zone from

the selection menu.

Setting the Time:

1 Touch the white field.

2 Enter date and time.

3 Confirm with ENTER.

4 Push button .

Data transfer to control unit.

3.4.3

Settings: Torque Smoothing

1 Touch the white field.

2 Enter the desired value.

3 Confirm with ENTER.

The graph in the diagram will be smoothed.

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3.4.4

Settings: Test Duration

1 Touch the white field.

2 Set the test duration (10…60 min).

3 Conform with ENTER.

Data transfer to control unit.

3.4.5

Settings: Roller Diameter

1 Touch the white field.

2 Set the roller diameter (0.098…0.102 m).

3 Conform with ENTER.

Data transfer to control unit.

3.4.6

Settings: Speed Difference at 60 kph

1 Touch the white field.

2 Set the speed difference (0…10 kph).

3 Conform with ENTER.

Data transfer to control unit.

3.4.7

Switching to the User Management

1 Push button .

The login dialog appears:

2 Enter the administrator password. (Password is chosen by service technician at

initial operation.)

3 Confirm with OK.

Button is displayed in green.

4 Touch button .

The User Management appears.

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3.5

User Management

Creating a User Account

1 Touch the empty line in column <Users>.

2 Enter the user name (10 characters max.), confirm with ENTER.

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3 Touch the line containing the new user in column <Password>. Enter and

repeat password and confirm with <OK>.

4 Touch the line containing the new user in column <Group>. Choose a group (=

access level) and confirm with ENTER.

The group members have the following rights:

<Administrator group>: user management

<User group>: operation of the driving test bench

<Unauthorised>: no rights

5 Touch the line containing the new user in column <Logout time>. Enter a time

period (60 min max.) and confirm with ENTER.

The logout time should be chosen depending on the test cycle used. It should be

defined as short as possible to prevent unauthorised access during absence of

the user.

6 Push button .

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3.6

Showing Warning and Error Messages

As long as the list of all pending warning and error messages is displayed, the

buttons are disabled.

Choose a message text from the list by clicking it with the left mouse button.

Touch button . The help text appears.

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List of Warning and Error Messages

No.

Message

1 EMERGENCY STOP triggered!

2 Error! Pressure transducer RL: Wire breakage!

3 Error! Pressure transducer RR: Wire breakage!

4 Error! Pressure transducer FL: Wire breakage!

5 Error! Pressure transducer FR: Wire breakage!