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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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

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Once the brake test has been completed, return the switch on
the dynamometer to position 1.
The rollers of the brake testers are now switched off.
To remove the straps, release the pull-down mechanism:
Switch: Turn the switch to position
↑
(release).
The hydraulic pistons move upwards. Once the tightening
straps hang completely loose, return the switch on the dyna-
mometer to position 0.
The hydraulic pump are now switched off and the straps can
be removed.
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3.2
Control via EUROSYSTEM
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3.2.1
Weight Simulator
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When the Brake Test screen ap-
pears:
1 Open the Load Simulation screen
using <F6>.
2 Install the chains to the vehicle.
3 Enter the target weight.
The program will not accept any in-
puts greater than the maximum final
load which has been preset with the
key switch on the hydraulic power
unit.
When simulating loads of 12 / 14 / 20 t make sure to keep a minimum distance of
1 m between cylinders!
Load currently ap-
plied by the MLS
Current weight of
left-side wheel
Current weight of
right-side wheel
Current total axle weight
Target weight entered by user
LED indicating
preset maximum
final load

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4 Start the load simulation using <F6>.
5 When the target weight is reached, use <Esc> to return to the Brake Test
screen.
6 When prompted, confirm with <Enter>.
7 Conduct the brake test.
8 At completion of the brake test, open
the Load Simulation screen again us-
ing <F6>.
9 Release the chains using <F7>.
The release time is indicated in the
bottom right-hand corner. The value
is adjustable in the variables list.
10Remove the chains from the vehicle.
If the chains are still tensioned and
cannot be removed, repeat the re-
lease procedure using <F7>.
11Use <Esc> to return to the Brake
Test screen.
12When prompted, confirm with <En-
ter>.
The motors switch on automatically.
13Change axles or exit the brake tester.
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3.2.2
Roller Set Lift
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•Drive onto the barke tester, the scale
screen is displayed.
•Motors start automatically, the meas-
urement screen is displayed.
•Start the load simulation with the
<F6> button, the load simulation
screen is displayed.
•Motors stop automatically.
•Attach shackles to the vehicle.
•Enter target weight via the keyboard,
confirm with <return>. Maximum
weight: 5.00 t.
If a higher weight is entered, this is
automatically reduced to the maxi-
mum value.
•Activate control with <F6>.

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•Vehicle is lifted up to the target
weight. A blue dot indicates that the
target weight has been reached.
•Exit screen with <ESC>.
•Start motors with <Return> or
button, the measurement
screen is displayed.
•Perform brake test.
WARNING: Do NOT activate parking brake while roller set is lifted!
The vehicle can be lifted out of the roller set.

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•If the weight control responds during
the braking operation, this is indicat-
ed through the following symbols:
Arrow up, green: Weight too low
Arrow down, yellow: Weight too high
Blue dot: Weight OK
•Apply brakes if the vehicle slips.
•Save measurement values: Enter axle number, then <Return> or .
•If the minimum brake pressure is not
reached, this message appears. Sel-
ect option.
•After completion of the brake test,
switch to load simulation screen with
the <F6> button.
•Motors stop automatically.
•Press <F5> button. Roller set is low-
ered, and control is deactivated.
•Once the pre-set time has expired,
this query is displayed. Select an-
swer.

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•Release shackles on the vehicle.
•Leave load simulation screen with
<ESC>.
•Start motors with <Return> or
button, the measurement
screen is displayed.
•Change axle, repeat test steps as
required.
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3.3
Cable Remote (Roller Set Lift only)
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A
Roller set Up
B
Roller set Down
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3.4
Remote Control FFB3
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3.4.1
Weight Simulator
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1 Drive onto the brake tester.
2 Pull vehicle down to the desired tar-
get weight by pressing the <Shift>
button, followed by the <Pull down>
button.
Shift Release Pull down
3 Perform brake test.
4 Quit weight simulation by pressing the <Shift> button, followed by the
<Release> button.
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3.4.2
Roller Set Lift
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1 Drive onto the brake tester.
2 Raise vehicle to the desired target
weight by pressing the <Shift> but-
ton, followed by the <Raise> button.
Shift Raise Lower
3 Perform brake test.
4 Lower vehicle to the desired final position by pressing the <Shift> button,
followed by the <Lower> button.
The height adjustment of the roller set is terminated by releasing the buttons. The-
re is no automatic limit stop.
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A
B

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3.5
Operation of the stand-alone variant (roller set lift only)
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Operation via Remote Control (Model: MRC 1000)
A Control LED
B UP
C DOWN
Operation via Control Box
D Manual UP
E Switchover Remote control / Manual
F Manual DOWN
G Main switch with EMERGENCY STOP function
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A
B
C
D
E
F
G

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Programming the Remote Control
In the event of loss a new remote control can be "taught" to the receiver:
1 Remove cover lid of receiver.
2 Press the <ON> button on the remote control.
3 Press and hold the TA1 button at the receiver for roughly 3 sec until the LED
starts flashing.
4 Briefly press the <UP> button on the remote control within the next 10 sec.
►After the receiver has saved the transmitter code, the LED flashes quickly for
roughly 2 sec.
5 Repeat steps 2 through 4 for the DOWN function. To do this, press the
<DOWN> button on the remote control and the TA2 button on the receiver.
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