MAHA MBT-Series, 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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