MAHA MLS Series User manual

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MLS
Weight Simulators
Original Operating Instructions
BA042501-en
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MLS 1100
MLS 2100
MLS 2150
MLS 2200
MLS 2300
Roller Set Lift MBT 2000 RS5
Roller Set Lift MBT 4000/7000 RS2/W
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© MAHA Maschinenbau Haldenwang GmbH & Co. KG
Legal notice based on ISO 16016:
The reproduction, distribution and utilization of this document as well as the communication of its
contents to others without explicit authorization is prohibited. Offenders will be held liable for the
payment of damages. All rights reserved in the event of the grant of a patent, utility model or de-
sign.
The contents of this edition have been checked with great care. However, errors cannot be fully
excluded. Subject to technical change without notice.
Document
Document No.: BA042501-en
Approval Date: 2019-01-14
Manufacturer
MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany
Phone: [phone]
Fax: [phone]
Mail: [email protected]
Web: http://www.maha.de
Service
MAHA SERVICE CENTER
AutomoTec GmbH
Maybachstraße 8
87437 Kempten
Germany
Phone: [phone]
Fax: [phone]
Mail: [e-mail]
Web: www.automo-tec.com

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Contents
1
Safety ....................................................................................................................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....................................................................................................6
2
Description ............................................................................................................6
2.1 General Information..................................................................................................6
2.2 Design .....................................................................................................................7
2.2.1 Weight Simulator......................................................................................................7
2.2.2 Roller Set Lift............................................................................................................7
2.3 Specifications...........................................................................................................8
2.3.1 Weight Simulator......................................................................................................8
2.3.2 Roller Set Lift............................................................................................................8
3
Operation...............................................................................................................9
3.1 Control via Desk/Power Unit (Weight Simulator only).................................................9
3.2 Control via EUROSYSTEM .....................................................................................12
3.2.1 Weight Simulator....................................................................................................12
3.2.2 Roller Set Lift..........................................................................................................14
3.3 Cable Remote (Roller Set Lift only)..........................................................................18
3.4 Remote Control FFB3 ............................................................................................18
3.4.1 Weight Simulator....................................................................................................18
3.4.2 Roller Set Lift..........................................................................................................18
3.5 Operation of the stand-alone variant (roller set lift only)............................................19
3.6 Emergency Lowering..............................................................................................21
3.6.1 Weight Simulator....................................................................................................21
3.6.2 Roller Set Lift..........................................................................................................21
3.7 Pneumatic Emergency Lowering for MBT 4000/7000 with Integrated Roller Set Lift24
3.7.1 Function.................................................................................................................24
3.7.2 Operation...............................................................................................................25
4
Maintenance ........................................................................................................26
4.1 Annual Inspection...................................................................................................26
4.2 Maintenance by the Operator .................................................................................26
4.3 Refilling with Hydraulic Fluid ...................................................................................27
4.4 Spare Parts............................................................................................................27

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4.5 Checking and Refilling the Bladder Accumulator.....................................................28
5
Dismantling..........................................................................................................30
6
Disposal...............................................................................................................30
7
Contents of the Declaration of Conformity.............................................................30
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1
Safety
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1.1
Introduction
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Thoroughly read this manual before operating the equipment and comply with the
instructions. Always display the manual in a conspicuous location.
Personal injury and property damage incurred due to non-compliance with these
safety instructions are not covered by the product liability regulations.
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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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This equipment is to be used exclusively for load simulation during brake testing on motor vehicles.
The equipment 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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Any use other than described is inappropriate.
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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 dis-
posal of the device must
•be mentally and physically suited for these activities,
•be at least 18 years old,
•be trained and instructed in writing,
•have read and understood the operating instructions, especially the instructions
what to do in the event of defects or malfunctions,
•be on record as having been instructed in safety guidelines,
•have practical experience in working with vehicle lifts and the hazards inherent
in such equipment.
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1.5
Safety Instructions
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•All safety features must be checked before commissioning of the unit and then
periodically, at least once every two years.
•The edge of the pit should be painted with a warning strip.
•The straps and clamps may be installed by trained personnel only. Inexpert in-
stallation may result in damage to the axle or other vehicle components.
•Ensure that the straps are not cut by sharp edges.
•Before moving the load simulator, verify that the chains are not under tension.
•The parking brake must not be tested when the roller set is in a raised position.
•Protect the load simulator from any kind of water or moisture. Never use high
pressure or steam jet cleaners.
•Avoid contact with hydraulic oil.
•Ensure that no hydraulic oil seeps into the ground.
•Work on the electrical equipment may be done by qualified electricians only.
•Do not perform any adjustment or maintenance work while the rollers are run-
ning.
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2
Description
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2.1
General Information
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Truck brake tests are mostly performed when empty. Since truck brakes are
largely load-dependent, braking behaviour differs between empty and partially or
fully loaded vehicles.
The load simulator serves to simulate the effect of a load, so that the braking
behaviour of an empty vehicle can also be tested under load.
The roller set lift is also available for passenger car brake testers.
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2.2
Design
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2.2.1
Weight Simulator
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A
Hydraulic cylinder
(foldable for MLS 1100 and 2100)
C
Lock
B
Eyelet for chain slings
D
Hydraulic power unit
(Example)
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2.2.2
Roller Set Lift
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•Hydraulic power unit and gear flow divider
The power unit is attached in a foundation recess, and connected to the hydraulic
cylinder via eight tubes.
•Built-in tub and cylinder
The eight cylinders of the two roller sets are synchronised with each other, i.e. the
roller sets move up and down at the same level, and are secured with stop valves.
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B
A
D
C

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2.3
Specifications
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2.3.1
Weight Simulator
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MLS 1100 MLS 2100 MLS 2150 MLS 2200 MLS 2300
Qty. HD cylinders 1 2 2 2 2
Working stroke per HD cyl-
inder
400 mm 400 mm 144 mm 400 mm 400 mm
Hydraulic oil fill volume (initial
filling) 10 l 12 l 12 l 12 l 42 l
Max. weight simulation 5000 kg 10.000 kg (2 x 5000 kg)
Fuse (time-lag) 16 A
Power supply 3 x 400 V + N + P; 50/60 Hz
Working temperature range 5 to 40 °C
Noise emission < 70 dB(A)
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2.3.2
Roller Set Lift
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MBT 2000
RS5
MBT 4000/7000
RS2/W
MBT 4000/7000
RS2 integrated
Maximum capacity (axle load) 2500 kg 10 000 kg 5000 kg
Lifting height 100 mm 250 mm 180 mm
Hydraulic oil fill volume 8 l 60 l 2 x 8 l
Working pressure 65 bar 200 bar ca. 130/140 bar
Supply voltage 3 x 400 V + N + PE; 50 Hz
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3
Operation
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3.1
Control via Desk/Power Unit (Weight Simulator only)
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1 After switching on the brake tester, drive into the roller set with the selected
axle.
2 Set the switch with the “pull down” symbol on the brake
testers to position 1.
This sets the roller of the brake testers to ‘inactive’, and they can no longer start-
up or, if they have already started up, they will switch off.
3 Now switch on the pull-down mechanism at the main
switch (if available). When doing so, the switch for the di-
rection of travel (if available) should be set to position 0.
4 Bring the hydraulic cylinders into the upper 1/3.
Switch:
Turn the switch into the
position
↑
(release) or
↓
(tighten).
Then bring the
switch back into
position 0.
5 Hooking in the straps
There is an eyelet at the hydraulic cylinder that the tightening straps are pulled
through. Then place the straps around the vehicle axle and lash them moderately
tight by moving the handles up and down.
Improper hooking in of the straps may lead to damage of the axle or other parts
hooked in at the same time. This is why the straps must only be hooked in by
trained personnel! Avoid contact with sharp edges!
Once the straps have been hooked in properly and checked for correct fit, the
pull-down process can be started.
6 Tightening the pull-down mechanism.
Switch: Turn the switch into position
↓
(tighten)

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Set the maximum permissible axle weight at
the manometer with the trick-screw on the
hydraulic pump.
Please note:
1 bar = 100 kg weight. A maximum of 120
bar is possible, i.e. 12.000 kg.
The increase in weight is simultaneously displayed on the brake tester display (if
available).
7 Once the desired weight has been reached, perform the following steps:
Switch: Return the switch to position 0.
8 Activate the dynamometer again by returning the “pull
down” switch to position 0. The brake test can now be car-
ried out in accordance with the description in the operating
instructions.
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0
1
2
3
4
5
6
7
8
9
10
11
12
0
10 20 30 40 50 60 70 80 90
100 110 120
simuliertes Gewicht in t
Druck in bar