MAHA MBT, MBT 1000 Eurosystem Operating Instructions Manual

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MBT 1000 EUROSYSTEM

Roller Brake Tester for Motorcycles and Lightweight Vehicles

Original Operating Instructions

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Contents

1 Safety ...................................................................................................................... 3

1.1 Introduction ......................................................................................................................................... 3

1.2 Symbols .............................................................................................................................................. 3

1.3 Intended Use ....................................................................................................................................... 3

1.4 Inappropriate Use ................................................................................................................................ 3

1.5 Requirements on Operating and Service Personnel ............................................................................. 3

1.6 Safety Instructions for Installation and Initial Operation ........................................................................ 4

1.7 Safety Instructions for Operation ......................................................................................................... 4

1.8 Danger Zone ....................................................................................................................................... 5

1.9 Safety Instructions for Servicing ........................................................................................................... 5

1.10 Safety Features ................................................................................................................................... 6

1.11 Accessories ......................................................................................................................................... 7

1.12 What to Do in the Event of an Accident ............................................................................................... 7

2 Description ............................................................................................................... 8

2.1 General Information ............................................................................................................................. 8

2.2 Overview ............................................................................................................................................. 9

2.3 Specifications .................................................................................................................................... 10

2.4 Noise Emission .................................................................................................................................. 10

3 Transport and Storage ........................................................................................... 11

4 Installation and Initial Operation .............................................................................. 11

5 Operation ............................................................................................................... 11

5.1 Main Switch....................................................................................................................................... 11

5.2 Control Unit ....................................................................................................................................... 12

5.3 Test Procedure .................................................................................................................................. 13

6 Maintenance .......................................................................................................... 14

6.1 Annual Inspection .............................................................................................................................. 14

6.2 Care Instructions ............................................................................................................................... 14

6.3 Spare Parts ....................................................................................................................................... 14

6.4 Chain Drive Maintenance: Cleaning, Retensioning, Lubricating .......................................................... 15

6.5 Greasing the Sensor Roller Hinges .................................................................................................... 17

7 Dismantling ............................................................................................................ 19

8 Disposal ................................................................................................................. 19

9 Contents of the Declaration of Conformity .............................................................. 20

10 Company Information ............................................................................................. 21

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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 the testing of motorcycles and
lightweight 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 dis­posal 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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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 emergency­stop 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 ser­vice 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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2

Description

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2.1

General Information

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The safety test lane EUROSYSTEM uses modular design. It is easily expandable
and has the following function groups as standard equipment: side-slip tester,
shock tester, brake tester. In addition, all kinds of MAHA test equipment can be
connected. Test equipment from other manufacturers can be integrated in some
instances.

PC and screen display as well as EUROSYSTEM software are standard
equipment. This test lane-specific software developed by MAHA is based on the
Windows operating system and is network-compatible. The measurement values
can be processed on your own computer network.

Measurement data can be stored with or without remote control and organized in
databases. An additional analog display (pointer) can be used.

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2.2

Overview

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Examples:

A

Flush-floor version

B

Surface-mounted version

Illustrations show highest expansion stage with roller sets 1 + 2 and clamping de­vice.

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A

B

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2.3

Specifications

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RS1 RS2

Fuse 25 A time-delay

Drive power 3 kW

Roller set dimensions
(H x W x L)

280/315* x700 x 1150 mm 280/315* x1400 x 1150 mm

Display range 0 – 3 kN

Testable wheel bases 800 – 1500 mm

Testable wheel diameters 380 – 700 mm

Test speed 5 km/h

Wheel load (drive-over load) 1000 kg

Roller centre distance 380 mm

Roller diameter 202 mm

Roller length 350 mm 1100 mm

Power supply 3 x 400 V/NPE 50 Hz

*315 mm height only in conjunction with dynamometer

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2.4

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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3

Transport and Storage

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Check package to ensure it is complete, in accordance with the order
confirmation. Report any transport damage to the carrier immediately.

During loading, unloading and transport always use suitable lifting equipment,
material handling equipment (e.g. cranes, forklifts, etc.) and the right load handling
attachments and slings. Always ensure that the parts to be transported are
suspended or loaded properly so that they cannot fall, taking into account size,
weight and the centre of gravity.

Store the packages in a covered area, protected from direct sunlight, at a low
humidity and with temperatures between 0...+40 °C (32…104 °F). Do not stack
packages.

When unpacking, take care to avoid any possibility of injury or damage. Keep at a
safe distance when opening the package strapping, do not allow any parts to fall
out.

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4

Installation and Initial Operation

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Installation and initial operation of the equipment may be done only by authorized
and trained service technicians provided by the manufacturer, licensed dealers or
service partners.

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5

Operation

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5.1

Main Switch

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• Main switch in position 0: Power supply OFF

• Main switch in position 1: Power supply ON

• When in position 0, the main switch can be protected against

tampering by means of a padlock.

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5.2

Control Unit

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A

Emergency stop button

D

Lifting bar Speedometer tester (opt.)

B

Motors On/Off

E

Clamping device, front (option)

C

Lifting bar Brake tester (left: option)

F

Clamping device, rear (option)

The control unit is continuously movable along the handrail and can be swivelled
sideways after pulling it in a forward direction.

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A

B C D

E F

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5.3

Test Procedure

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IMPORTANT NOTICE

The statutory requirements for the verification of braking efficiency do not demand
that the brake test be completed until slippage cutoff occurs.

Automatic slippage cutoff should be generally regarded as a safety feature,

not

as

the cutoff point for brake testing.*
It is adequate to terminate the test at approx. 90% of the maximum braking force.

This method is strongly recommended to help prevent tyre damage!

* Please note the implementing provisions for braking efficiency determination.

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1 Enter the roller set with the front wheel/axle (A).
2 Secure the rear wheel/axle with the clamping device (B).
3 Perform the brake test.
4 Open the clamping device at the rear wheel/axle.
5 Enter the roller set with the rear wheel/axle.
6 Secure the front wheel/axle with the clamping device.
7 Perform the brake test.
8 Open the clamping device at the front wheel/axle.
9 Exit the brake tester.

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For a detailed description of the test lane software please see the operating in­structions MBT EUROSYSTEM (document No. BAE10101-en, included).

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A B

14

BAE12901-en

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6

Maintenance

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Danger! Electric shock hazard!
Before doing any maintenance work, turn off the main switch and protect it

against tampering.

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6.1

Annual Inspection

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• The maintenance interval prescribed by the manufacturer is

12 (twelve) months

.
This maintenance interval refers to normal workshop usage. If the equipment is
used more frequently or under severe operating conditions (e.g. outdoors), the
interval must be reduced accordingly.

• Maintenance work shall be done only by authorized and trained service techni-

cians provided by the manufacturer, licensed dealers or service partners.

• In case of non-compliance the manufacturer's warranty becomes void.

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6.2

Care Instructions

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• Periodically clean the equipment and treat it with a care product.

• Repair damage to the paintwork immediately to prevent corrosion.

• Usage of caustic cleaning agents or high pressure and steam jet cleaners may

lead to equipment damage.

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Regular care and maintenance is the key condition for functionality and long life
expectancy of the equipment!

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6.3

Spare Parts

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To ensure safe and reliable operation, only use original spare parts supplied by the
equipment manufacturer.

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15

BAE12901-en

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6.4

Chain Drive Maintenance: Cleaning, Retensioning, Lubricating

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

Maintenance interval: Monthly

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Before doing any maintenance work, turn off the main switch and protect it
against tampering.
Remove the roller set covers from above the chains, reinstall before restarting the
brake tester.

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Cleaning the Chains
The chains can normally be cleaned using a cloth or brush, stubborn dirt can be

removed with petroleum solvent or benzine. Do not use pickles or acids! Reapply
a new anticorrosive film immediately after using degreasing agents (see section
"Greasing the Chains").

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Retensioning the Chains
Check the chain slack: the chain should be movable by hand approx. 5 mm up

and down. If the chain needs retensioning, proceed as follows:

• Open the fastening screws.

• Adjust the chain tension using the tensioning screw.

• Tighten the fastening screws (see table for torque figures).

• Recheck the chain slack.

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Brake tester

model

Thread

Strength

Tightening

torque

Position

Required for chain

tensioning?

MBT

1xxx/2xxx/3xxx

M10 8.8 50 Nm Running roller yes

M16 8.8 120 Nm Motor mount yes

MBT 4xxx

M18 8.8 350 Nm Running roller yes

M20 8.8 350 Nm Motor mount only for RS1

MBT 5xxx

M16 8.8 220 Nm Running roller no

M18 8.8 350 Nm Motor mount yes

MBT 6xxx/7xxx

M18 8.8 350 Nm Running roller yes

M20 8.8 350 Nm Motor mount only for RS1 + RS3

MBT 7xxx

M18 8.8 500 Nm

Raised running

roller

yes

M27 8.8 500 Nm Motor mount 3:4 no

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16

BAE12901-en

Lubricating the Chains

The service lifetime of the chains directly depends on correct lubrication. Provided
that the lubricating film is continuously maintained, chain wear can be reduced to
a minimum

Recommended lubricant: LongLub adhesive lubricant (MAHA part # 35 1020)

• Lubricate the chain over its entire length while turning over the rollers by hand.

Important: The lubricant must contact the chain links!

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17

BAE12901-en

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A

Chain

B

Fastening screws

C

Tensioning screw

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6.5

Greasing the Sensor Roller Hinges

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

Maintenance interval: 200 hours / 12 months

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B B

C

A

18

BAE12901-en

Grease the sensor roller hinges every 200 (two hundred) operating hours or once
annually.

1 Remove the cover plates from the roller set.
2 Treat the greasing points (D) using a spray lubricant. Move the sensor roller up

and down.

3 Reinstall the cover plates to the roller set.

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D D

19

BAE12901-en

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7

Dismantling

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Decommissioning and dismantling of the equipment may be done only by
specially authorized and trained personnel provided by the manufacturer, licensed
dealers or service partners.

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8

Disposal

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Pay attention to the product and safety data sheets of the lubricant used. Avoid
damage to the environment. Should a disposal of the device be necessary it must
be done in adherence with locally applicable legal regulations regarding
environmental protection. Remove all materials properly sorted out and bring them
to a suitable waste disposal service. Collect operating materials such as grease,
oils, coolant, solvent-based cleaning fluids etc. in suitable containers and dispose
of in an environmentally protective manner.

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Alternatively, you may take the equipment to a specialised waste management
plant to ensure that all components and operating liquids are properly disposed
of.

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20

BAE12901-en

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9

Contents of the Declaration of Conformity

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MAHA Maschinenbau Haldenwang GmbH & Co. KG
herewith declares as a manufacturer its sole responsibility to ensure that the

product named hereafter meets the safety and health regulations both in design
and construction required by the EC directives stated below.
This declaration becomes void if any change is made to the product that was not
discussed and approved by named company beforehand.

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Model: MBT 1000 EUROSYSTEM / MBT 2250 EUROSYSTEM

MBT 2450 EUROSYSTEM 4WD / MBT 3250 EUROSYSTEM
MBT 3450 EUROSYSTEM 4WD / MBT 4250 EUROSYSTEM
MBT 4450 EUROSYSTEM 4WD / MBT 5250 EUROSYSTEM
MBT 6250 EUROSYSTEM / MBT 7250 EUROSYSTEM
MBT 7450 EUROSYSTEM 4WD

Designation:

Safety Test Lane, consisting of:
Roller Brake Tester:

MBT 1000 EUROSYSTEM:
(optional) Motorcycle Holding Device
Rated Axle Load 2000 kg
Motor Power 2x3 kW

MBT 2250 EUROSYSTEM / MBT 2450 EUROSYSTEM 4WD
MBT 3250 EUROSYSTEM / MBT 3450 EUROSYSTEM 4WD:
Rated Axle Load 3500 kg (optional 4000, 5000 or 8000 kg)
Motor Power 2x3 kW (4 or 5,5 kW optional)

MBT 4250 EUROSYSTEM / MBT 4450 EUROSYSTEM 4WD
MBT 5250 EUROSYSTEM / MBT 6250 EUROSYSTEM:
Rated Axle Load 13 000 kg (optional 15 000 or 18 000 kg)
Motor Power 2x7,5 kW, 2x9 kW, 2x11 kW, 2x15 kW

MBT 7250 EUROSYSTEM / MBT 7450 EUROSYSTEM 4WD:
Rated Axle Load 18 000 kg (optional 20 000 kg)
Motor Power 2x9 kW, 2x11 kW, 2x16 kW

Side-Slip Tester MINC EURO / MINC II EURO:
Rated Axle Load 3000 / 5000 kg

Shock Tester SA2 EURO oder MSD 3000:
Rated Axle Load 1100 kg (optional 2000 kg) or 2200 kg

Speedometer Tester TPS I / II / III; TPS 25

Directives: 2006/42/EC; 2014/30/EU

Standards: DIN EN ISO 12100:2010; DIN EN ISO 13850,

DIN EN ISO 13857,
DIN EN 349; DIN EN 60204-1; DIN EN 61000-6-3,
DIN EN 61000-6-2

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21

BAE12901-en

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10

Company Information

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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 de­sign.

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.: BAE12901-en
Approval Date: 2016-06-01

Manufacturer

MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany

Phone: [phone]
Fax: [phone]
Fax Parts: [phone]
Internet: http://www.maha.de
E-Mail: [e-mail]
Hotline: [phone] for Brake Testers and Test Lanes
[phone] for Automotive Lifts
[phone] for Dynamometers and Emission Testers

Service

AutomoTec GmbH
Maybachstraße 8
87437 Kempten
Germany

Phone: [phone]
Fax: [phone]
Internet: http://www.automo-tec.com
E-Mail: [e-mail]

=== Ende der Liste für Textm arke In halt ===