MAHA CONNECT Series User manual

CONNECT SERIES
Roller Brake Tester for Passenger Cars and Vans
Original Operating Instructions
BA023001-en
C_MBT C 3.5 W220
C_MBT S 3.5 W220
C_MBT C 3.5 W250
C_MBT S 3.5 W250
C_MBT C 4.0 W220
C_MBT S 4.0 W220
C_MBT C 4.0 W250
C_MBT S 4.0 W250
C_MBT C 5.0 W280
C_MBT S 5.0 W280

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BA023001-en
BA023001-en
2021-03-15
© MAHA Maschinenbau Haldenwang GmbH & Co. KG
The reproduction, distribution and utilization of this document as well as the communication of its con-
tents 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 design.
The contents of this edition have been checked with great care. However, errors cannot be fully excluded.
Subject to technical change without notice.
Manufacturer
MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany
Phone: [phone]
Fax: [phone]
Mail: [email protected]
Web: www.maha.de
Service
MAHA SERVICE CENTER
Maybachstraße 8
87437 Kempten
Germany
Phone: [phone]
Fax: [phone]
Mail: [e-mail]
Web: www.mahaservicecenter.de

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Contents
1General safety instructions .............................................................................................7
1.1 Introduction ........................................................................................................................ 7
1.2 Symbols and signal words ................................................................................................... 7
1.2.1 Personal injury .................................................................................................................... 7
1.2.2 Damages to products, machinery and equipment .............................................................. 7
1.2.3 Information......................................................................................................................... 8
1.3 Procedure in the event of a malfunction............................................................................. 8
1.4 Procedure in the event of an accident ................................................................................ 8
1.5 Requirements for operators and service personnel............................................................ 8
2Description .....................................................................................................................9
2.1 Service life........................................................................................................................... 9
2.2 General machine description .............................................................................................. 9
2.2.1 Structure and legend........................................................................................................... 9
2.2.2 Description of the test bench............................................................................................ 10
2.2.3 Intended use ..................................................................................................................... 11
2.2.4 Brake test of vehicles with one driven axle ....................................................................... 11
2.2.5 Brake test of four-wheel drive vehicles............................................................................. 12
2.2.6 Overview with components .............................................................................................. 14
2.3 Technical data ................................................................................................................... 15
2.3.1 Safety area ........................................................................................................................ 18
2.3.2 Set-up diagram.................................................................................................................. 19
2.4 Control unit description .................................................................................................... 21
2.4.1 Wiring diagram.................................................................................................................. 22
2.4.2 Control cabinet structure Basic variant............................................................................. 23
2.4.3 Control cabinet structure Full equipment......................................................................... 24
2.4.4 Connection and termination of the central module (ZM) ................................................. 26
2.4.5 Coding ZM-OM.................................................................................................................. 27
2.4.6 Coding ZM-IFM.................................................................................................................. 29
2.4.7 Control buttons................................................................................................................. 34
2.4.8 Indicator light on the control cabinet in the event of a fault ............................................ 34
3Transport, handling and storage ...................................................................................35
3.1 Safety instructions............................................................................................................. 35
3.2 Scope of delivery............................................................................................................... 36
3.3 Packaging information ...................................................................................................... 37
3.3.1 Centre of gravity of the packed roller set.......................................................................... 37

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3.4 Transport and handling..................................................................................................... 37
3.5 Storage.............................................................................................................................. 37
4Installation....................................................................................................................38
4.1 Safety instructions............................................................................................................. 38
4.2 Installation diagrams......................................................................................................... 39
4.3 Mounting the control cabinet ........................................................................................... 40
4.3.1 Mechanical installation ..................................................................................................... 40
4.3.2 Electrical installation......................................................................................................... 41
4.4 Mounting the roller set..................................................................................................... 43
4.4.1 Mechanical installation ..................................................................................................... 43
4.4.2 Electrical installation......................................................................................................... 47
4.5 Functional test .................................................................................................................. 54
5Calibration / Adjustment ..............................................................................................55
5.1 Adjusting the brake force.................................................................................................. 55
5.1.1 Adjusting the zero point.................................................................................................... 55
5.1.2 Adjusting brake forces with adjusting device.................................................................... 55
5.1.3 Adjusting brake forces with MJV II.................................................................................... 56
6Operation .....................................................................................................................57
6.1 Safety instructions............................................................................................................. 57
6.2 Safety devices ................................................................................................................... 58
6.3 Preparations...................................................................................................................... 60
6.3.1 Switching on the test bench.............................................................................................. 60
6.3.2 Variant 1: Establish LAN connection to PC/notebook ....................................................... 60
6.3.3 Establish a browser connection......................................................................................... 60
6.3.4 Variant 2: Establishing a WiFi connection ......................................................................... 61
6.3.5 Variant 3: Integration of the test bench into own network............................................... 62
6.4 Test procedure.................................................................................................................. 62
6.4.1 Drive on test bench........................................................................................................... 62
6.4.2 Carry out brake test with automatic sequence ................................................................. 63
6.4.3 Carry out brake test with semi-automatic sequence ........................................................ 64
6.4.4 Carry out four-wheel brake test with SmartDevice/PC in automatic mode ...................... 65
6.4.5 Carry out manual four-wheel brake test with SmartDevice/PC in counter-rotation mode66
6.4.6 Carry out four-wheel brake test in counter-rotation by means of pushbutton switch on
control cabinet................................................................................................................................ 68
6.4.7 Carry out manual single wheel brake test with SmartDevice/PC ...................................... 69
6.4.8 Carry out single wheel brake test by means of pushbutton switch on control cabinet..... 70
6.4.9 Exit the test bench ............................................................................................................ 72

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6.5 Results display................................................................................................................... 73
6.6 Measured value display .................................................................................................... 74
6.7 Settings ............................................................................................................................. 76
6.7.1 Support ............................................................................................................................. 77
6.7.2 Language........................................................................................................................... 77
6.7.3 Network ............................................................................................................................ 78
6.7.4 Event logging..................................................................................................................... 78
6.7.5 Test report ........................................................................................................................ 79
6.7.6 Machine data .................................................................................................................... 80
6.7.7 Calibrating brake force...................................................................................................... 80
6.7.8 Diagnostics Brake tester.................................................................................................... 81
6.7.9 External devices ................................................................................................................ 82
6.7.10 Service technician menu login........................................................................................... 82
6.8 Service technician menu ................................................................................................... 83
6.8.1 Account management....................................................................................................... 84
6.8.2 Network ............................................................................................................................ 84
6.8.3 Adjusting the brake force.................................................................................................. 87
6.8.4 Test bench settings ........................................................................................................... 87
6.8.5 Options overview.............................................................................................................. 88
6.8.6 Software update ............................................................................................................... 88
6.8.7 Input/output test .............................................................................................................. 89
6.9 Deceleration table............................................................................................................. 90
7Inspection and maintenance.........................................................................................91
7.1 Safety instructions............................................................................................................. 91
7.2 Care instructions ............................................................................................................... 92
7.3 Inspection and maintenance schedule.............................................................................. 92
7.4 Maintenance of the chains................................................................................................ 92
7.4.1 Cleaning the chains ........................................................................................................... 93
7.4.2 Checking for chain wear.................................................................................................... 93
7.4.3 Retensioning the chains / Replacing the test rollers ......................................................... 94
7.4.4 Lubricating the chains ....................................................................................................... 96
7.4.5 Lubricating the sensing roller hinges................................................................................. 97
8Trouble shooting and error resolution ..........................................................................98
8.1 Safety instructions............................................................................................................. 98
8.2 Error codes........................................................................................................................ 99
9Repair .........................................................................................................................105

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9.1 Safety instructions........................................................................................................... 105
9.2 Configuring the control unit............................................................................................ 105
9.3 Check sensor function..................................................................................................... 107
9.4 Adjusting the switching distance of the sensors ............................................................. 107
9.5 Releasing motors with mechanical brake........................................................................ 108
9.6 Enabling the test rollers via the Service technician button ............................................. 111
10 Decommissioning, dismantling and disposal...............................................................112
11 Accessories .................................................................................................................112
11.1 Roller cover W220, W250, W280 .................................................................................... 112
11.2 Crossing and lowering threshold..................................................................................... 112
11.3 C_MSA (MAHA universal analogue display) .................................................................... 113
11.3.1 Description...................................................................................................................... 113
11.3.2 Scope of delivery............................................................................................................. 114
11.3.3 Technical data ................................................................................................................. 114
11.3.4 Installation ...................................................................................................................... 114
11.3.5 Status LEDs...................................................................................................................... 117
11.3.6 Setup............................................................................................................................... 118
11.3.7 Function test ................................................................................................................... 122
11.3.8 Update ............................................................................................................................ 123
11.3.9 Other............................................................................................................................... 123
11.4 C_BOX ............................................................................................................................. 124
11.4.1 Description...................................................................................................................... 124
11.4.2 Scope of delivery............................................................................................................. 125
11.4.3 Display requirements ...................................................................................................... 125
11.4.4 Installation ...................................................................................................................... 125
11.4.5 Connecting the C_BOX with the brake tester.................................................................. 126
11.4.6 Coupling with the brake tester........................................................................................ 127
11.4.7 Error handling ................................................................................................................. 128
11.4.8 Software update ............................................................................................................. 128
11.5 Radio remote control RECO S.......................................................................................... 132
11.5.1 Description...................................................................................................................... 132
11.5.2 Coupling with the receiver (pairing)................................................................................ 132
11.5.3 Operation........................................................................................................................ 133
12 Content of the declaration of conformity....................................................................137
13 Annex .........................................................................................................................138
13.1 Naming convention......................................................................................................... 138

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1General safety instructions
1.1 Introduction
•These operating instructions must be read carefully and understood before work
commences.
•Please observe the specific safety information provided for the respective sections
of the operating manual.
•Adhering to the procedures, sequences and corresponding safety instructions is
essential.
•A printed copy of the operating instructions shall be kept permanently available at
the test bench.
•The relevant regulations regarding accident prevention and health and safety must
be observed.
1.2 Symbols and signal words
1.2.1 Personal injury
DANGER
indicates an imminent danger. Death or severe injuries will follow if this danger is not
avoided.
WARNING
indicates a potentially imminent danger. Death or severe injuries may follow if this
danger is not avoided.
CAUTION
indicates a potentially imminent danger. Slight or minor injuries may follow if this dan-
ger is not avoided.
1.2.2 Damages to products, machinery and equipment
NOTICE
indicates a potentially harmful situation. The product or something in its vicinity may
suffer damage if this is not avoided.

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1.2.3 Information
indicates important information.
1.3 Procedure in the event of a malfunction
If the fault cannot be rectified using the procedures described in chapter
"Troubleshooting", proceed as follows:
•Switch off the main switch and secure it against being switched on again (unau-
thorised use).
•Contact service team.
1.4 Procedure in the event of an accident
•Notify first aiders, the ambulance service and/or immediate care doctor:
oWhere did the accident happen (address, workshop ...)?
oWhat happened?
oHow many are injured?
oWhat injuries have occurred?
oWho is reporting the accident?
•Keep calm and answer questions.
1.5 Requirements for operators and service personnel
Only persons qualified for testing in accordance with TRBS 1203 may be used as service
personnel.
All persons involved in the operation, maintenance, assembly, dismantling and
disposal of the equipment must
•be 18 years of age or older,
•have the mental and physical capacity for their role,
•be demonstrably trained and instructed,
•have read and understood the operating instructions, in particular the instructions
on how to behave in the event of a malfunction and on proper use,
•the locally applicable regulations on occupational health and safety must be ob-
served,
•show knowledge and experience in handling the equipment and the dangers
posed.

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2Description
2.1 Service life
The test bench is designed for a service life of approx. 10 years. This depends, among
other things, on the existing operating conditions. After this period, the test bench
must be replaced with a new product or undergo a general overhaul.
A general overhaul should only be carried out by the manufacturer or persons
authorized by them. Among other things, the safety structures are to be inspected
and, if necessary, other parts are to be replaced in accordance with the manufacturer's
specifications.
2.2 General machine description
2.2.1 Structure and legend
Structure of the test bench
1
Immediate danger zone around the test bench (within the inner yel-
low/black markings)
2
Area of the vehicle parking area before and after the test bench
3
Side area to the left and right of the test bench
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7
3
3
6
5
4
2
2
1

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Brake tester
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Control cabinet
6
Universal console
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Simultaneous display, analogue / TV screen
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Mobile devices (browser capable) with touch screen / WiFi router
2.2.2 Description of the test bench
In order to prevent dangerous situations in road traffic caused by a defective braking
system of a vehicle, motor vehicles should be subjected to a brake performance test at
regular intervals and e.g. after repairs. This is generally done on a brake tester.
The present roller brake tester allows wheel- and axle-wise dynamic braking and
essentially consists of a base assembly, a control unit and a display unit.
Components for driving the rollers and for absorbing the braking forces are installed in
the floor assembly: Test roller(s), sensing roller(s), drive motors, strain gauge bending
beam for measuring the braking force and various sensors. These sensors are plugged
into an interface module in the floor assembly, which is connected to the control unit
via cable.
The control unit consists of a control box with electronic components and a central
control board (central module) with firmware and the operating elements required for
safe operation.
In the simplest case, the display unit is a monitor of an existing PC or a notebook in the
immediate vicinity of the test bench and is connected to the control unit via LAN cable
or wirelessly via WiFi.
Furthermore, a commercially available TV monitor (together with a MAHA C_BOX) or
the MAHA universal analogue display can be used as a simultaneous display.
If WiFi is available, a browser-capable smart device (mobile phone, tablet PC, etc.) can
also be used as a display and operating unit.
On the one hand, the display is used for status indication of the system, user guidance
and visualization of the measured values; on the other hand, operating options can be
selected or data can be stored with the corresponding input device.
Function of a roller brake tester
To measure the braking forces of a motor vehicle, the test bench is driven over with a
vehicle axle. The wheel(s) of the motor vehicle is/are brought to a preset speed by
motor-driven rollers.
As soon as the set engine speed is reached, the operator is prompted to apply the
service or parking brake, slowly increasing the braking force.
The rotatably mounted drive motor would rotate freely during operation. This is
prevented by the bending beam (range spring). This connects the housing of the drive
motor to the test bench frame and thus forms a torque support.