MAHA MBT 2200 LON User manual

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MBT LON
Roller Brake Tester
Original Operating Instructions
BA022301-en
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MBT 2200 LON
MBT 2400 LON 4WD
MBT 3200 LON
MBT 3400 LON 4WD
MBT 4200 LON COMPETENCE/CLASSIC
MBT 4400 LON 4WD
MBT 5200 LON W COMPETENCE/CLASSIC
MBT 6200 LON W CLASSIC
MBT 7200 LON W COMPETENCE/CLASSIC
MBT 7400 LON 4WD
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Contents
1Safety ......................................................................................................................5
1.1 Introduction......................................................................................................................................... 5
1.2 Symbols .............................................................................................................................................. 5
1.3 Intended Use....................................................................................................................................... 5
1.4 Inappropriate Use................................................................................................................................ 5
1.5 Requirements on Operating and Service Personnel............................................................................. 5
1.6 Safety Instructions for Installation and Initial Operation ........................................................................ 6
1.7 Safety Instructions for Operation ......................................................................................................... 6
1.8 Danger Zone ....................................................................................................................................... 7
1.9 Safety Instructions for Servicing........................................................................................................... 7
1.10 Safety Features ................................................................................................................................... 8
1.11 Accessories......................................................................................................................................... 9
1.12 What to Do in the Event of an Accident............................................................................................... 9
2Description.............................................................................................................10
2.1 General Information ........................................................................................................................... 10
2.2 Noise Emission.................................................................................................................................. 10
2.3 Specifications .................................................................................................................................... 11
3Transport and Storage ...........................................................................................18
4Installation and Initial Operation ..............................................................................18
5Operation...............................................................................................................18
5.1 Main Switch....................................................................................................................................... 18
5.2 Analog Displays................................................................................................................................. 19
5.3 Remote Control................................................................................................................................. 24
5.4 Menu Structure ................................................................................................................................. 27
5.5 Car Brake Tester with MAH-DOT and IFB ......................................................................................... 30
5.6 Car Brake Tester with MAH-DOT and RECO 1.................................................................................. 31
5.7 Truck Brake Tester with MAH-DOT and FFB..................................................................................... 33
5.8 Truck Brake Tester with MAH-DOT and RECO 1 .............................................................................. 35
5.9 Option Drive Control.......................................................................................................................... 36
5.10 Noise Detection with IFB / FFB / RECO 1.......................................................................................... 38
5.11 MSD 3000......................................................................................................................................... 40
5.12 Clock Changing between Daylight Saving Time/Standard Time......................................................... 42
5.13 Test Procedure with Software ........................................................................................................... 43
6Maintenance ..........................................................................................................46
6.1 Annual Inspection.............................................................................................................................. 46
6.2 Care Instructions ............................................................................................................................... 46
6.3 Spare Parts ....................................................................................................................................... 46
6.4 Chain Drive Maintenance: Cleaning, Retensioning, Lubricating.......................................................... 47
6.5 Greasing the Sensor Roller Hinges .................................................................................................... 51

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6.6 Troubleshooting ................................................................................................................................ 52
7Dismantling ............................................................................................................55
8Disposal.................................................................................................................55
9Contents of the Declaration of Conformity ..............................................................56
10 Company Information.............................................................................................57
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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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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 the brake testing of motor vehicles.
Observe the rated axle load.
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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1.4
Inappropriate Use
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Any use other than described is inappropriate.
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1.5
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 at least 18 years old,
•be trained and instructed in writing,
•have read and understood this manual
•be on record as having been instructed in safety guidelines.
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BA022301-en
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1.6
Safety Instructions for Installation and Initial Operation
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•The system shall only be commissioned by MAHA service technicians or au-
thorized service partners.
•All parts of the electrical equipment must be protected from moisture and wet-
ness.
•The system shall not be installed and operated in hazardous locations or wash
halls.
•The operator must provide for optional safeguards (e.g. warn lamps, barriers,
etc.) depending on local conditions.
•Wear safety shoes and gloves.
•Safeguard roller set with suitable means (e.g. cordon chains or strap).
•The display must be installed in a secure area and folded into the wall when not
in use (wall hinges optionally available).
•When folding the display, grasp it on the edges. Danger of pinching!
•Ensure that a lockable emergency-stop main switch is installed based on instal-
lation instructions before connecting the feed line. Use motor protection switch
and cable cross sections as per specification. Reference in circuit diagram
(standard delivery), nameplate. Fuse max. X.X A (see nameplate).
•The main switch must be provided by the customer and installed on-site. It
must be positioned in direct vicinity to the tester and takes over the emergency-
stop function.
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1.7
Safety Instructions for Operation
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•The system shall only be operated within its performance limits.
•The system shall only be operated by trained personnel.
•The system and surrounding area must be kept clean.
•Switch off the system when not in use and secure the main switch against re-
start with a padlock.
•In emergency situations switch off system with main switch or emergency-stop
switch.
•No persons shall be in the danger zone of the system. Rotating or moving parts
(e.g. test stand rollers) are dangerous.
•Danger of carbon monoxide poisoning with running vehicle engine in closed
rooms. The operator is responsible for providing sufficient air exchange.
•Avoid unnecessary strain on vehicle and tester.
•Drive the vehicle slowly on to the tester.
•Check the danger zone before driving the vehicle onto the tester.

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•When the vehicle with the driven axle is on the roller set, exit only with running
roller drive. Exiting with roller drive at standstill can destroy the motors due to
extreme roller acceleration.
•The system shall not be operated without functioning slip monitoring. This can
cause tire damage.
•Never jump start a vehicle with the system. This can lead to equipment dam-
age.
•No 4 wheel-drive vehicles shall be tested on the standard roller set. Damage to
vehicle and system are possible. When in doubt contact your responsible ser-
vice representative.
•The vehicle must be closed during testing. If persons outside of the vehicle are
endangered, use noise protection.
•The operator shall not leave the vehicle during testing.
•No vehicle shall be parked in/on the roller set or on the optional ramps.
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1.8
Danger Zone
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During brake tester operation no persons are allowed in the danger zone:
5 (five) meters
around the roller set in all directions.
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1.9
Safety Instructions for Servicing
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•Service work shall only be done by MAHA service technicians or authorized
service partners.
•Work on electric parts of the system shall only be done by trained electricians.
•The main switch must be switched off and secured against restart before doing
repair, maintenance and set-up work.
•Fire danger due to rubber abrasion on the roller set. Clean regularly. Remove
abrasion before maintenance work.

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•The main switch must be secured and if necessary the motor protection switch
turned off when doing work in the roller set.
•When working on the control cabinet or on the roller sets pay attention to the
heating (optional) or hot parts.
•Immediately turn off the tester when it starts up unintentionally. Contact the ser-
vice department.
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1.10
Safety Features
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The safety features (partly optional) are to be inspected regularly by an authorized
service technician. Official guidelines must be followed at all times. The equipment
shall not be operated when the safety features are defective!
•
Lockable Main Switch
Serves as normal On and Off switch for the equipment and as emergency switch.
The switch can be padlocked to protect it against unauthorized usage.
•
Emergency Switch
Is used for quick switch-off during operation. Interrupts the power supply to the
equipment.
•
Startup Monitoring
Prevents the rollers from starting up in case the wheels are blocked (seized
bearings, jammed brake pads). This feature helps prevent the vehicle tyres from
being damaged.
•
Sensor Rollers
The RPM difference between equipment rollers and sensor rollers determines the
slip. Both sensor rollers must be pushed down in order to start the roller brake
tester.
•
Visual and Audible Warning Devices
These must be positioned at a suitable location and must be easily seen or heard
at all times. In the event that the warning devices are defective, the brake tester
must be shut down until they are fully functional again.
•
Pit Safety
Light barrier or infrared movement sensor. If any person enters the safety area, the
brake tester is switched off.
•
Yellow-Black Marking Tape
The yellow-black marking tape around roller set and pit serves to mark out the
brake tester and nust be replaced if defective. Part # 19 6014 (Ø 38 mm) /
19 6015 (Ø 50 mm).
•
Warning and Information Labels
Warning and information labels are attached to the equipment. These must not be
changed or removed and must be replaced if unreadable (see below for part
numbers).
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54 2132 54 2683
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1.11
Accessories
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The equipment shall be operated only with accessories which have been
approved or permitted by MAHA.
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1.12
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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Description
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2.1
General Information
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This brake tester belongs to the group of roller brake testers. This class includes
two different measuring methods to record brake forces:
•the testing of drive torque or
•the testing of drive power.
The former is applied in this brake tester. It consists of a proven roller set and an
open-ended electronic system based on a processor board with an integral
operating system.
The standard brake tester can be expanded to a complete test lane.
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2.2
Noise Emission
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The noise emission during a vehicle test results mainly from the vehicle’s engine.
The noise emission varies from vehicle to vehicle and cannot be attributed to the
testing equipment.
Roller Brake Tester
The noise emission value created by the brake tester (roller drive) is less than
70 dB(A) in the work area of the operator.
Shock Tester
The noise emission value created by the shock tester (oscillating test plates) is
between 75 and 80 dB(A) in the work area of the operator.
Side-Slip Tester
The noise emission value created by the side-slip tester is less than 70 dB(A) in
the work area of the operator.
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