MAHA MBT-, MBT 2100 Original Operating Instructions

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MBT 2100

Roller Brake Tester

Original Operating Instructions

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Contents

1 Safety ...................................................................................................................... 5

1.1 Introduction ......................................................................................................................................... 5

1.2 Symbols .............................................................................................................................................. 5

1.3 Intended Use ....................................................................................................................................... 5

1.4 Safety Instructions for Installation and Initial Operation ........................................................................ 5

1.5 Safety Instructions for Operation ......................................................................................................... 6

1.6 Danger Zone ....................................................................................................................................... 7

1.7 Safety Instructions for Servicing ........................................................................................................... 7

1.8 Safety Features ................................................................................................................................... 7

1.9 Accessories ......................................................................................................................................... 8

1.10 What to Do in the Event of an Accident ............................................................................................... 8

2 Description ............................................................................................................. 10

2.1 General Information ........................................................................................................................... 10

2.2 Specifications .................................................................................................................................... 15

3 Operation ............................................................................................................... 16

3.1 Display .............................................................................................................................................. 16

3.2 Remote Control ................................................................................................................................. 18

3.3 Test Procedure .................................................................................................................................. 20

3.3.1 Standard Mode without Remote Control ........................................................................................... 21

3.3.2 Standard Mode Automatic 4-Wheel Drive Recognition ...................................................................... 22

3.3.3 Standard Mode Blink Mode ............................................................................................................... 23

3.3.4 Standard Mode Reco 1-Procedure ................................................................................................... 25

3.3.5 Standard Mode Reco 1-4-Wheel Drive .............................................................................................. 27

3.3.6 Standard Mode Motorcycle Procedure .............................................................................................. 29

3.3.7 Standard IFB Mode Motorcycle ......................................................................................................... 31

3.3.8 Standard IFB Mode with 4-Wheel Drive ............................................................................................. 33

3.3.9 Standard IFB Mode Procedure .......................................................................................................... 35

3.3.10 NL Mode with IFB.............................................................................................................................. 37

3.3.11 NL Mode with Reco 1 ....................................................................................................................... 39

3.3.12 NL Mode without Remote Control ..................................................................................................... 41

3.3.13 NL Mode Wheel Circumference ......................................................................................................... 42

3.4 Deceleration Chart ............................................................................................................................. 43

4 Maintenance .......................................................................................................... 44

4.1 Annual Inspection .............................................................................................................................. 44

4.2 Maintenance by the Operator ............................................................................................................ 44

4.2.1 Checking the Chain Tension .............................................................................................................. 44

4.2.2 Greasing the Sensor Roller Hinges .................................................................................................... 46

4.3 Error Codes ....................................................................................................................................... 47

4.4 Care Instructions ............................................................................................................................... 47

4.5 Spare Parts ....................................................................................................................................... 47

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5 Dismantling ............................................................................................................ 48

6 Contents of the Declaration of Conformity .............................................................. 48

7 Company Information ............................................................................................. 49

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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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Any use other than described is inappropriate.

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1.4

Safety Instructions for Installation and Initial Operation

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• The system shall only be commissioned by MAHA service technicians or

authorized service partners.

• All parts of the electrical equipment must be protected from moisture and

wetness.

• 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).

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• When folding the display, grasp it on the edges. Danger of pinching!

• Ensure that a lockable emergency-stop main switch is installed based on

installation 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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1.5

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

restart 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.

• 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

damage.

• 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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1.6

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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1.7

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.

• 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

service department.

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1.8

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

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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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1.9

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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1.10

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.

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• 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.

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General Information about Brake Testing To avoid skidding it is important that the brake forces of the individual wheels of

one axle are the same. Just as important is the minimum brake torque for each individual wheel, so that when braking no vehicle brake is overburdened. Consequently, each wheel is tested individually on the brake tester.

For measuring the brake force, a static and a dynamic method are available. Using the static method the force necessary to rotate a wheel which is positioned on a plate, with applied brakes is determined. The dynamic method is more practice orientated - whereby the wheel is brought up to a predetermined RPM by the motor driven roller set and then the brakes are applied. A sensor roller measures the wheel revolutions. A comparison of the drive roller RPM to the sensor roller RPM determines how large the slippage is. For safety reasons, all MAHA brake testers automatically interrupt the brake test at a slippage of approximately 30%.

The measurement principle is the same for both methods of testing. The drive motor is supported in a rotary fashion (motor housing not supported); without any additional support, the drive shaft and the housing would counter rotate when under load, depending on the force distribution. The additional support consists of a flexible beam, on which the housing rests. The steel beam bends corresponding to the torque produced by the motor, which the beam resists. The torque is zero at the beginning of the static test. With the dynamic test method, the torque is just high enough to set the drive rollers with the vehicle wheel in motion with the brakes not applied.

A strain gauge is mounted on the transverse beam which converts the brake force into a usable electrical value.

For this brake tester the dynamic test method is used. This method ensures the most accurate measurement. In addition, there is simply no alternative for 4 wheel drive brake testing.

Vehicles with

One

Driven Axle

Drive the wheel axle to be tested onto the roller set. This will push both sensors rollers down which measure the RPM of the wheels. Now both drive motors of the roller set will slowly accelerated to nominal speed turning both vehicle wheels

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forward. When the drive motors have reached nominal speed a comparison is made between the nominal drive roller speed and the sensor roller speed in order to be able, at any time, to switch off the drive motors when a slippage of 30% is exceeded. (This is to protect the drive motors against overload and the tires against excessive wear.)

The READY indicator will light up, signaling that the test rig is ready to start the brake test. During brake tests the vehicle is decelerated to a point, that at least one sensor roller exceeds 30% slippage and the drive motors are switched off.

4-Wheel Drive Vehicles

On non-permanent 4-wheel drive vehicles the brakes are tested with the 4-wheel drive switched off, just like vehicles with only one drive axle.

Principle of 4 Wheel Drive On 4-wheel drive vehicles the torque applied to the drive shaft is evenly distributed

to all four wheels, i.e. a quarter of the total torque will be applied to each wheel. The same applies for the brake torques that arise when braking. When testing 4 wheel drive vehicles it must therefore be ensured that no brake torque will be transferred from one vehicle wheel to the other. This is accomplished if no torque is applied to the drive shaft of the differential during the brake test.

The following example will explain this in detail: In order to simulate a defective brake, one brake is disabled. Now only one brake

of the axle to be tested is enabled. If the brake test is done on a standard test stand where the torque is not eliminated from the drive shaft, the same force applies to the strain gauges of both drive motors, i.e. the same brake torque will be indicated. This would lead to the false assumption that the brakes are fully intact. If the test was conducted correctly, no brake torque would be indicated for the wheel with the disabled brake and the actual brake torque applied to the other wheel would appear.

If both wheels of the axle to be tested are rotating forward during the brake test, the vehicle will be lifted out of the test rig, as torque is transferred by the drive shaft to the wheels of the other vehicle axle. To prevent this, the wheels counter rotate with the same RPM, one vehicle wheel is driven in forward direction and the other wheel in reverse direction. This eliminates the torque built-up in the differential against the drive shaft and transmission of torque to the other vehicle axle.

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As the brake characteristics depend on the rotating direction of the wheels (the brake linings and brake drums are ground in forward direction), only the brake torque of the wheel rotating in forward direction is measured. For this reason, the brake test has to be done separately for each wheel.

In order to obtain a reliable comparision between the brake forces of both wheels of the same axle, the same pedal force will have to be applied at the brake test of the left and right wheel. To accomplish this, a pedal force meter can be connected to the vehicle's brake pedal.

It is also possible to measure the current pressure Pm of the hydraulic brake by means of a pressure sensor.

Testing of various 4-wheel drive types There are three different types of 4-wheel drives:

a) Disengageable drive shaft leading to the differential b) Viscous clutch (VC) in the drive shaft leading to the differential c) Rigid drive shaft between the differentials

a) Disengageable drive shaft leading to the differential

On vehicles equipped with non-permanent 4-wheel drive, the brakes are tested with the 4-wheel drive switched off, just like vehicles with only one drive axle.

b) Viscous clutch (VC) in the drive shaft leading to the differential

There are two different viscous clutch types. The soft viscous clutch has a higher torsibility (viscosity) than the hard viscous clutch, therefore no torque is transferred to the other wheels when the drive shaft rotation is low.

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As described above, brake tests on 4-wheel drive vehicles are feasible if both wheels on the same axle counter-rotate at the same speed. As, in practice, the circumference of the left and right wheel is not exactly the same due to different tire tread depths and uneven tire pressure, the RPM of the two drive motors is normally different. Therefore the drive motors must control their speed in order to obtain the same RPM for both wheels.

Approximately the same speed of the roller set drive motors will be sufficient for a 4-wheel drive vehicle having a soft viscous clutch in the drive shaft as no brake torque is transferred by the viscous clutch when the drive shaft rotation is low. Therefore the speed control of the drive motors alone will be sufficient in this case.

Contrary to the above, when testing the brakes of 4-wheel drive vehicle having a hard viscous clutch in the drive shaft, both wheels on the same axle must rotate synchronously during the brake test, as the clutch viscosity is so low that even the slowest rotation of the drive shaft will transfer brake torque to the other wheels.

c) Rigid drive shaft between the differentials

To perform a brake test on a 4-wheel drive vehicle having a rigid drive shaft, the wheel rotations must be exactly controlled in such a way that no brake torque

can be transferred by the drive shaft. Controlling the synchroneous rotation of the wheels In order to control synchronous rotation of the wheels, reflector strips are fastened

to the sides of the wheels which trigger a signal via two photo-electric cells, mounted on the side of the roller set.

Reflector strips

Light barrier

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On vehicles equipped with a rigid drive shaft or with a hard viscous clutch the wheels cannot be individually turned. If one vehicle wheel is turned forward in the roller set, the other wheel (on the same axle) will be turning backwards in a synchronous manner. If one wheel is turned slowly in forward or backward direction, one will note that the other wheel starts turning with a little delay. This slight delay in following the other wheel to turn is caused by the gear play (backslash of teeth) inside of the differential.

Tooth play

To perform a brake test on a 4-wheel drive vehicle having a rigid drive shaft, the wheel rotation must be controlled in such a way that no brake torque can be transferred by the drive shaft. This is achieved by staying within the gear play of the differential during the brake test. The differential will be in a "balance" state.

To be able to effectively use this, the exact backlash of teeth is assessed in a learning mode: Initially the left drive motor will be switched on to accelerate the left vehicle wheel to nominal speed. As the right drive motor is switched off and thus running free, the left wheel is dragging the right wheel along. The flanks of a tooth in the differential touch each other on one side. Now the first limit position of gear play is measured by the reflector strips and the photo electric cells. The procedure is now reversed, the left drive motor of the roller set is switched off and the right vehicle wheel is accelerated to nominal speed. This time the left wheel is dragged along and in the differential the flanks of teeth touch each other on the opposite side. The second limit position of the gear play will now be measured. Out of the two measured limit positions the center of gear play is calculated. This "center of gear play" is used to control the rotation of wheels during the brake test.

During the brake test, both drive motors are accelerated to a speed where the "center of gear play" is reached. One vehicle wheel will rotate forward, the other in opposite direction. As soon as the nominal speed is reached by both wheels, and no brake torque is being transferred to the drive shaft, brake testing may be started.

As with standard vehicles, the drive motors will be switched off if excessive slip occurs.

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2.2

Specifications

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Standard

Option

Axle load (drive-over) max. [kg] 3000 4000 / 5000

Drive power [kW] 2 x 3 2 x 4

Test speed [km/h] 3 5

Measurement range [kN] 2 x 0…6 2 x 0…8

Display accuracy

2 % of the measurement range end value 2 % Difference left – right

Track width min….max. [mm] 780…2200 780…2800

Roller diameter [mm] 202

Test stand dimensions [mm]

Height 280

Width 680

Length 2320 2925

Voltage supply [V] 3~ 400 3~ 230

Frequency [Hz] 50/60 50/60

Fuse (slow) [A] 16…25

Roller friction

Dry Steel / synthetic ca. 0.9 / ca. 0.9

wet Steel / synthetic ca. 0.7 / ca. 0.8

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Operation

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3.1

Display

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A Differential display

Read the difference between the right and left-hand brake value in % on the differential display. The differential display is only triggered after a fixed total brake force is exceeded.

B Power on lamp

The test stand is active when the lamp above this symbol is lit.

C Brake Front Axle / Parking Brake / Rear Axle

D Print

E Ready lamp

When the lamp above this symbol lights up, the brake pedal/parking brake can be operated.

Automatic 4WD recognition

G Motorcycle

H Delete

Remote control (optional)

In course of the brake test with remote control the lamp shows the following signals: 1st-Interval  front axle; 2nd-Interval  parking brake; 3rd-Interval  rear axle; permanent light  Measurement value available, print possible; permanent blinking  New vehicle.

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3.2

Remote Control

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 RECO 1

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Pos: 47 /Technische Dokumentation/Prüf- und Sicherheitstechnik/Archiv/Z2 Fernbedienungen/2601 RECO 1/TI/Inhalt: E126 Fernbedienung RECO 1 (Text)_12pt @ 27\mod_1327394842267_75.docx @ 1513653 @ @ 1

Motors Off

Start Motor left

Start Motor right / Start Ovality test

Menu item upwards

Confirm

Menu item downwards

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A B D C E

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 IFB / FFB

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S T D G H L Q J I K M N P

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Key

Function

F4 Start Ovality test

F8 Pointer stop

F9 Store Front axle

F10

Store Parking brake Re-display MSD measurement value

F11 Store Rear axle

F12 Auto OFF

F7 Start Print menu

* Confirm

Select Sensor Quit Noise detection

Program 1 key

Shift key

Motor Off left

Motor On right

Motor On left

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3.3

Test Procedure

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Following test procedures are available:

• Standard mode without remote control

• Standard mode automatic 4 wheel-drive recognition

• Standard mode blink mode

• Standard mode Reco 1-procedure

• Standard mode Reco 1-4 wheel drive procedure

• Standard mode motorcycle procedure

• Standard IFB mode with motorcycle

• Standard IFB mode with 4 wheel drive

• Standard IFB mode procedure

• NL mode with IFB

• NL mode with Reco 1

• NL mode without remote control

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• NL mode wheel circumference

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3.3.1

Standard Mode without Remote Control

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Without remote control

MBT – test flow without remote control

Drive on to RS

Automatic roller set

Ready for braking, Light signal on

Brake up to slip or release before.

Stop rollers!

The pointers go to the max. brake value

The rollers start after 2 seconds again, pointers

do to zero and/or roller resistance.

Axle change and new measurement can start.

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3.3.2

Standard Mode Automatic 4-Wheel Drive Recognition

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Without remote control

Automatic 4 wheel-drive recognition

(Drive Control Pro)

Display is optional

Drive on to RS

Automatic roller start

INFO

After 1X o 2X (DC PRO) start up monitoring the

test stand switches into 4 wheel drive mode.

(4x4 LED lights up)

Left-hand wheel rotates in test

direction, the right-hand wheel

in the opposite direction.

Ready for braking when light signal on.

Brake until slip limit or release before. Pay attention:

If the brake value of 500N is not

exceeded within 10 seconds after roller

start, the wheel measurement is stopped

and the right-hand side automatically

started. If the 500N is not exceeded here

either, the rollers stop and an axle change

must be done.

Rollers stop!

Max. brake force is displayed on the respective

test side.

INFO

After 2 seconds the rollers start again automatically to test the second side.

Right-

hand wheel rotates in test direction,

the left-hand wheel in the opposite

direction.

After testing the left and right-hand side the

pointers remain on the max. value. The rollers

do not start up again.

Do axle change.

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3.3.3

Standard Mode Blink Mode

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MBT-test procedure with Reco 1 and Drucker

Drive on to roller set

Status lamp optical procedure

FA: 1 blink -»- Pause

Automatic roller start PB: 2 blinks -»- Pause

RA: 3 blinks -»- Pause

Lights up permanently: print possible.

Activate pointer stop

Permanent quick blinking: delete measurement

Manual Auto OFF:

Measurement completion if necessary.

Light blinks for axle measurement

Type of axle

change possible

using arrow up or

downt. (FA, PB,

RA)

Ready for braking when LED lit

Brake up to slip or release before

Rollers stop !

Pointers go to max. brake value!

Repeat

measurement possible with arrow up once and then down

Rollers start again. Storage possible.

Store measurement

Axle change, new measurement can start

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Automatic print out after FA,

PB, RA (only if function

activated)

Manual print out

(only possible outside of the

roller set)

Lights up p

ermanently

Start print out

After printing the status lamp blinks very quickly. If this is confirmed

with the blue enter key , all measurement values are deleted.

Permanent quick blinking

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3.3.4

Standard Mode Reco 1-Procedure

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MBT-test procedure with Reco 1 and printer

Drive onto roller set

Automatic roller start

Axle type change

possible with arrow

up or down /FA, PB,

RA)

Ready for brakikng, when LED lights up

Brake until slip limit or release before

Rollers stop!

The pointers go to the max. brake value!

Repeat measurement possible with arrow once up and down

Rollers start again. Storage possible.

Store measurement

Axle change, new measurement can start

Final evaluation after

“Auto Off“

After measurement of the rear axle (RA) the final evaluation follows and the printer symbol is automa-

tically active. After printing of the blue enter key

the print out is done.

Printing is only possible outside of the roller set.!

Display x2 = Brake force total

Display x10 = deceleration in %

if a scale is present.

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If only one axle should be printed out, do a “Auto Off“

The final evaluation is done. Printing is now possible.

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3.3.5

Standard Mode Reco 1-4-Wheel Drive

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MBT 4 WD Test Procedure with

Reco 1 and Printer

Select 4WD: (only possible outside of RS) Scroll to 4x4 with the Motor On key. . Confirm the mode with the enter key.

Press again to activate the measurement (FA blinks)

Note: If the RS is not occupied within 30 sec, there is a reset to the standard mode!

Autom. 4 WD recognition if 4x4 not pre-selected. (DC = Drive Control) (Wait once for start up monitoring DC Single) (Wait twice for start up monitoring DC PRO)

Drive onto roller set

Automatic roller start

INFO

Left-hand wheel rotates in testing direction, the righthand in the other direction.

Use arrow up or

down for axle

change. (FA, PB, RA)

Ready for braking when LED lights up.

Brake until slip or release beforehand

Note: If after roller start the brake value of 500 N is

not exceeded within 10 sec, the wheel measurement is stopped and the right side automatically started. If the 500 N is also not exceeded here, the rollers stop and an axle change must be done.

Rollers stop.

Max. brake force is displayed on the respective

test side.

To repeat measurement use arrow up once and down again. After change the rollers start again. (only DC PRO!!)

After 2 sec the rollers start again to test the 2nd

side.

Rollers stop, measurement can be saved.

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Save measurement

Axle change, new measurement can start, or print.

Final evaluation after

"Auto Off"

After measuring the rear axle (RA) the final evaluation is done and the printer symbol is automatically active.

The printout appears after pressing the blue Enter key . Printing is only possible outside of the roller set!

Display x 2 = Brake force total.

Display x 10 = Deceleration in %

if weighing machine is available.

If only one axle is to be printed an "Auto Off" must

be done. Then the final evaluation is done. Printing is now possible.

After confirming the waste basket with Enter the measurement is deleted.

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3.3.6

Standard Mode Motorcycle Procedure

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MBT-Motorcycle test procedure with Reco 1

(test only possible on left-hand roller set)

Left motorcycle: Scroll to motorcycle mode with the Motor-On-

key . Confirm the mode using the enter key.

Pay attention: If the RS is not occupied within 30 sec. there is a reset to the standard mode!

FA blinks for axle measurement

Left-side RS occupied

Start Left-side with RC

Timer runs out (left-hand pointer

display)

Automatic roller start after timer run out. (Left

pointer goes to zero in seconds intervals. Now

the motor starts.)

Ready for braking when LED lights up

Brake until slip or release beforehand

Rollers stop

Pointer moves to the max. brake value!

Measurement is automatically stored.

Axle change , new measurement can start or print.

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Final evaluation

After measuring the rear axle (RA) the final evaluation is done and the printer symbol is automatically active. The print out appears after pressing the blue Enter key . Printing is only possible outside of the roller set!

Display x 2 = Brake force total

Display x 10 = decleration in %

If scale is available.

After confirming the waste basket with Enter the measurement is deleted.

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3.3.7

Standard IFB Mode Motorcycle

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MBT-Motorcycle test procedure with IFB

(test only possible in left-hand roller set)

Select motorcycle:

Scroll to motorcycle mode with the motor-on-

key. Use star key to confirm the mode.

Pay attention: if the roller set is not occupied

within 30 sec. There is a reset back to Standard

mode!

FA blinks for axle measurement

Drive on to left roller set side

Start left side with the remote control

Timer runs out (left-han

d pointer

display)

Automatic roller start after timer expires. (Left-

hand pointer moves in seconds to zero. Now

the motor starts)

Ready for braking when LED lights up

Brake up to slip limit or release before

Rollers stop

The pointer goes to the max. brake value!

Measurement is automatically stored after 5 seconds.

Axle change, new measurement can start or print

Manual Auto OFF! e.g. printing of only one axle test.

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Final evaluation

After measurement of the RA the final evaluation follows. After pressing the key the print out follows.

Printing is only possible outside of the roller set!

Display 2 times= Brake force total.

Display x10 = deceleration in %

if a scale is present.

Delete measurement with

or drive onto anew.

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3.3.8

Standard IFB Mode with 4-Wheel Drive

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MBT-4 wheel drive test procedure with Reco 1

and printer

Select 4 wheel drive: Use the motor-on-key scroll to 4x4. Confirm the mode with the star key. Pay attention: if the roller set is not occupied within 30 sec. then it returns to standard mode !

Autom. 4 wheel drive if 4x4 not pre-selected. (Drive-Control Pro) (wait 2x start-up monitoring)

Drive on to roller set

Automatic roller start

INFO

Left-hand wheel rotates in test direction, the righthand one in the opposite direction.

Ready for braking when LED lights up

Brake until slip limit or release before

Pay attention: If the brake value of 500N is not

exceeded within 10 seconds after roller start, the wheel measurement is stopped and the right-hand side automatically started. If the 500N is not exceeded here either, the rollers stop and an axle change must be done.

Rollers stop!

The pointer goes to the max. brake value!

Repeat

measurement possible. Delete axle measurement. Repeat measurement!

After 2 seconds, the rollers start again to test

the second side.

Roller stops, measurement ready for storage

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Store: Front axle Parking brake Rear axle

Axle change! New measurement can start or

print.

Manual Auto OFF! e.g. printing of only one axle measurement.

Start printing.

Final evaluation

Print out is only possible outside of the roller set.

Display x2 = Brake force total

Display x10 = decleration in %

if a scale is present.

Delete measurement with

or drive on again.

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3.3.9

Standard IFB Mode Procedure

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MBT-test procedure with remote control IFB (without LED)

Drive on to roller set

LED display is only needed when

option 4x4, motorcycle or 2nd driving

direction is present.

Automatic roller start

Ready for braking when light signal on

Activate pointer Stopp

slowly brake until slip limit or release before

Stop rollers!

the pointer goes to the max. brake value.

Roller starts again.

Storage possible!

Delete axle measurement

. Repeat measurement

Store: Front axle Parking brake Rear axle

Axle change! New measurement can start.

Manual Auto OFF! e.g. print of only one axle measurement.

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Start print

Final evaluation

Print out is only possible outside of the roller set

Display x2 = Brake force Ges.

display x10 = deceleration in %

as long as a scale is present.

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3.3.10

NL Mode with IFB

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APK-test procedure with IFB remote control (optional pedal force meter)

Drive on to roller set

Automatic roller set

Activate pointer stop

Measurement front and rear axle Measurement parking brake

Slowly brake

Lamp blinks permanently

Ready lamp blinks once

Measurement point P1 is measured.

One wheel rotation (1WR)

Brake until slip and release brake (no

APK-procedure necessary)

Brake until slip limit

Pedal steady

Ready lamp blinks twice

Measurement point P2 is measured.

Valid APK measurement after two

wheel rotations (2WR)

Release brake or brake until slip.

Stop rollers.

The pointer goes to the last valid APK value and not

to the max. value!

The rollers start again, storing possible.

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Store: Front axle Parking brake Rear axle

Axle change! New measurement can start or

print.

Manual Auto OFF! e.g. print of only one axle measurement.

Start print

Print out is only possible outside of the roller set.

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3.3.11

NL Mode with Reco 1

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APK-test procedure with Reco 1 and printer

Drive on to roller set

Optical Procedure

FA: blink once -»- Pause

Automatic roller start

PB: blink twice -»- Pause (no APK procedure necessary)

RA: blink three times -»- Pause

Lights up permanently: print possible.

Activate pointer Stopp

Permanent rapid blinking: delete measurement

Manual Auto OFF:

e.g. printing of only one axle measurement

Pointer stop active. Light blinks

Slowly brake

Ready lamp blinks once

Measurement point P1 is measured.

One wheel rotation (1RU)

Brake up to slip

Pedal steady

Ready lamp blinks twice

Measurement point P2 is measured.

Valid APK measurement after two wheel

rotations (2WR)

Release brake or brake up to slip.

Stop rollers!

The pointers go to the last, valid APK value and

not to the max. value!

Rollers start again. Storage possible.

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orage measurement

Axle change, new measurement can start

Automatic print out after

measurement of FA, PB, RA

(only when function activated)

Manual print out

(only possible outside of roller

set)

Lights

permanently

Start print out

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3.3.12

NL Mode without Remote Control

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APK-test procedure without remote control

Drive on to roller set

Automatic roller start

Slowly brake

Measurement point P1 is measured.

One wheel rotation (1WR)

Ready lamp blinks once

Brake up to slip limit, keep pedal steady.!

Measurement point P2 is measured. Valid APK

measurement after two wheel rotations. (2WR)

Ready lamp blinks twice

Release brake or brake up to slip.

Rollers stop

The pointers go back to the last, valid APK value

and not to the max. value!

The rollers start again, pointers go back to zero.

Axle change or new measurement can start.

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3.3.13

NL Mode Wheel Circumference

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Version control with strain gauge detuning

Switch on test stand

Pointer initialization (~10 sec)

Display of the version number e.g. 300R100

Display 5

Strain gauge detuning.

visible at pointer.

Press power on key

Test stand is ready for testing

Enter wheel circumference

Press power on key 5 sec. Zero point check

After 5 sec.

• Pointers go to 60 cm.

• Each key press increases it by 1 cm.

• Permanent pressing reduces by 2 cm.

• After 5 sec. without value change automatic

storage As confirmation the left-hand pointer

goes to the same value.

Blinks in this mode

Value is stored until new vehicle is executed!

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3.4

Deceleration Chart

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Permiss Axle Load in kg

Axle Brake Force in kN

200

100

300

100

400

100

500

100

600

100

700

100

800

100

900

100

1000

100

1100

100

1200

100

1300

100

1400

100

1500

100

1600

100

Deceleration in %

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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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4.1

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

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

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

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4.2

Maintenance by the Operator

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4.2.1

Checking the Chain Tension

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

Maintenance interval: Monthly

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Check the chain tension for the first time 14 working days after initial operation, then monthly:

1 Remove cover plates from roller set. 2 Grease the chain (A) well with multi-purpose grease along its entire length.

While greasing, turn the rollers by hand.

3 Check that the chain has a slack of approx. 5 mm in either direction.

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If the chain does not have enough tension, proceed as follows: 4 Open the fastening screws (B). 5 Tighten the tensioning screw (C) until the chain has the proper tension. 6 Retighten the fastening screws.

Brake testers with elevated roller sets: Tightening torque

500 Nm

7 Recheck the chain tension. 8 Reinstall the cover plates to the roller set.

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4.2.2

Greasing the Sensor Roller Hinges

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

Maintenance interval: 200 hours / 12 months

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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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4.3

Error Codes

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Error code

Description Remedy

Connection to multi-function display missing

Contact service

Left sensor roller impulse sensor defective

Check motor protection switch. If o.k. contact service.

Both sensor roller impulse sensors defective

Check motor protection switch. If o.k. contact service..

Right sensor roller impulse sensor defective

Check motor protection switch. If o.k. contact service.

Zero point of the brake force strain gauge outside of range

Contact service

Only left-hand sensor roller pressed

Drive onto both sides of test stand.

Only right-hand sensor roller pressed

Drive onto both sides of test stand.

50 Scale zero point outside of range

Roller set may not be occupied when switching on.

Test stand is already occupied when switching on.

Exit test stand with vehicle and switch main switch off/on.

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4.4

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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4.5

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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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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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 2100 / 2110 / 2120 / 2130

Designation:

Roller Brake Tester

Rated Axle Load 3000 kg (4000 / 5000 kg optional) Motor Power 2 x 2.25 kW (2 x 4 kW optional)

EC Directives:

2006/42/EC; 2014/30/EU

EN Standards:

EN 12100-1/-2; EN 13850; EN 13857; EN 349; EN 60204-1; EN 61000-6-3, EN 61000-6-2

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MAHA MBT-, MBT 2100 Original Operating Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual