MAHA MBT 2400 LON 4WD, MBT 3400 LON 4WD, MBT 4200 LON COMPETENCE, MBT 4200 LON CLASSIC, MBT 5200 LON W COMPETENCE Original Operating Instructions
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MBT LON
Roller Brake Tester
Original Operating Instructions
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MBT 2200 LON
MBT 2400 LON 4WD
MBT 3200 LON
MBT 3400 LON 4WD
MBT 4200 LON COMPETENCE/CLASSIC
MBT 4400 LON 4WD
MBT 5200 LON W COMPETENCE/CLASSIC
MBT 6200 LON W CLASSIC
MBT 7200 LON W COMPETENCE/CLASSIC
MBT 7400 LON 4WD
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Contents
1 Safety ...................................................................................................................... 5
1.1 Introduction ......................................................................................................................................... 5
1.2 Symbols .............................................................................................................................................. 5
1.3 Intended Use ....................................................................................................................................... 5
1.4 Inappropriate Use ................................................................................................................................ 5
1.5 Requirements on Operating and Service Personnel ............................................................................. 5
1.6 Safety Instructions for Installation and Initial Operation ........................................................................ 6
1.7 Safety Instructions for Operation ......................................................................................................... 6
1.8 Danger Zone ....................................................................................................................................... 7
1.9 Safety Instructions for Servicing ........................................................................................................... 7
1.10 Safety Features ................................................................................................................................... 8
1.11 Accessories ......................................................................................................................................... 9
1.12 What to Do in the Event of an Accident ............................................................................................... 9
2 Description ............................................................................................................. 10
2.1 General Information ........................................................................................................................... 10
2.2 Noise Emission .................................................................................................................................. 10
2.3 Specifications .................................................................................................................................... 11
3 Transport and Storage ........................................................................................... 18
4 Installation and Initial Operation .............................................................................. 18
5 Operation ............................................................................................................... 18
5.1 Main Switch....................................................................................................................................... 18
5.2 Analog Displays ................................................................................................................................. 19
5.3 Remote Control ................................................................................................................................. 24
5.4 Menu Structure ................................................................................................................................. 27
5.5 Car Brake Tester with MAH-DOT and IFB ......................................................................................... 30
5.6 Car Brake Tester with MAH-DOT and RECO 1 .................................................................................. 31
5.7 Truck Brake Tester with MAH-DOT and FFB ..................................................................................... 33
5.8 Truck Brake Tester with MAH-DOT and RECO 1 .............................................................................. 35
5.9 Option Drive Control .......................................................................................................................... 36
5.10 Noise Detection with IFB / FFB / RECO 1 .......................................................................................... 38
5.11 MSD 3000 ......................................................................................................................................... 40
5.12 Clock Changing between Daylight Saving Time/Standard Time ......................................................... 42
5.13 Test Procedure with Software ........................................................................................................... 43
6 Maintenance .......................................................................................................... 46
6.1 Annual Inspection .............................................................................................................................. 46
6.2 Care Instructions ............................................................................................................................... 46
6.3 Spare Parts ....................................................................................................................................... 46
6.4 Chain Drive Maintenance: Cleaning, Retensioning, Lubricating .......................................................... 47
6.5 Greasing the Sensor Roller Hinges .................................................................................................... 51
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6.6 Troubleshooting ................................................................................................................................ 52
7 Dismantling ............................................................................................................ 55
8 Disposal ................................................................................................................. 55
9 Contents of the Declaration of Conformity .............................................................. 56
10 Company Information ............................................................................................. 57
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1
Safety
1.1
Introduction
1.2
Symbols
1.3
Intended Use
1.4
Inappropriate Use
1.5
Requirements on Operating and Service Personnel
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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
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safety instructions are not covered by the product liability regulations.
Important safety instructions. Failure to comply with instructions could result in
personal injury or property damage.
Important information.
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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
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void.
Any use other than described is inappropriate.
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
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• be on record as having been instructed in safety guidelines.
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1.6
Safety Instructions for Installation and Initial Operation
1.7
Safety Instructions for Operation
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• The system shall only be commissioned by MAHA service technicians or au-
thorized service partners.
• All parts of the electrical equipment must be protected from moisture and wet-
ness.
• The system shall not be installed and operated in hazardous locations or wash
halls.
• The operator must provide for optional safeguards (e.g. warn lamps, barriers,
etc.) depending on local conditions.
• Wear safety shoes and gloves.
• Safeguard roller set with suitable means (e.g. cordon chains or strap).
• The display must be installed in a secure area and folded into the wall when not
in use (wall hinges optionally available).
• When folding the display, grasp it on the edges. Danger of pinching!
• Ensure that a lockable emergency-stop main switch is installed based on instal-
lation instructions before connecting the feed line. Use motor protection switch
and cable cross sections as per specification. Reference in circuit diagram
(standard delivery), nameplate. Fuse max. X.X A (see nameplate).
• The main switch must be provided by the customer and installed on-site. It
must be positioned in direct vicinity to the tester and takes over the emergency-
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stop function.
• 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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1.8
Danger Zone
5 (five) meters
1.9
Safety Instructions for Servicing
• 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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During brake tester operation no persons are allowed in the danger zone:
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around the roller set in all directions.
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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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1.10
Safety Features
Lockable Main Switch
Emergency Switch
Startup Monitoring
Sensor Rollers
Visual and Audible Warning Devices
Pit Safety
Yellow-Black Marking Tape
Warning and Information Labels
• 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-
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vice department.
The safety features (partly optional) are to be inspected regularly by an authorized
service technician. Official guidelines must be followed at all times.
shall not be operated when the safety features are defective!
•
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.
•
The equipment
Is used for quick switch-off during operation. Interrupts the power supply to the
equipment.
•
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.
•
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.
•
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.
•
Light barrier or infrared movement sensor. If any person enters the safety area, the
brake tester is switched off.
•
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 are attached to the equipment. These must not be
changed or removed and must be replaced if unreadable (see below for part
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9
1.11
Accessories
1.12
What to Do in the Event of an Accident
54 2132 54 2683
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The equipment shall be operated only with accessories which have been
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approved or permitted by MAHA.
• 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.
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• Remain calm and answer any questions that may arise.
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2
Description
2.1
General Information
2.2
Noise Emission
Roller Brake Tester
Shock Tester
Side-Slip Tester
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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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The standard brake tester can be expanded to a complete test lane.
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.
The noise emission value created by the brake tester (roller drive) is less than
70 dB(A) in the work area of the operator.
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.
The noise emission value created by the side-slip tester is less than 70 dB(A) in
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the work area of the operator.
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2.3
Specifications
MBT 1000 EUROSYSTEM
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Version MCD 1000 MCD 2000 MCD 2000 PC
Absicherung (träge) 25 A
Antriebsleistung 3 kW
Messwertanzeige max. 2500 N
Messwertanzeige min. 0 N
Netzfrequenz 50 Hz
Netzspannung 400 V
Ovalität in kN
Phasen 3
Prüfgeschwindigkeit 5 km/h
Radlast (überfahrbar) 2000 kg
Rollenachsabstand 400 mm
Rollendurchmesser 202 mm
Rollenlänge 730 mm
Rollensatz Breite 680 mm
Rollensatz Höhe 280 mm
Rollensatz Länge 1420 mm
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MBT 2000
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Version
MBT 2100
MBT 2200 LON
MCD 1000
MCD 2000
MCD 2000, PC
ALLRAD MCD 2000
MBT 2250 EUROSYSTEM
MBT 2250 EUROSYSTEM
MBT 2250 EUROSYSTEM
MBT 2450 EUROSYSTEM
MBT 2450 EUROSYSTEM
Absicherung (träge) 25 A
Analoganzeige Durchmesser
Antriebsleistung der Motoren
350 mm - - - - - -
3,0 kW
Anzeigekasten Breite 840 mm - - - - - -
Anzeigekasten Höhe 470 mm - - - - - -
Anzeigekasten Tiefe 100 mm - - - - - -
Laufrollendurchmesser 202 mm
Messwertanzeige 0 – 6 kN 0 – 8 kN
Netzfrequenz max. 60 Hz 50 Hz
ALLRAD MCD 2000, PC
Netzfrequenz min. 50 Hz - - - - - -
Netzspannung 400 V
Phasen 3
Prüfgeschwindigkeit 5 km/h
Rollenachsabstand 400 mm
Rollensatz Breite 680 mm - - - - - -
Rollensatz Höhe 280 mm - - - - - -
Rollensatz Länge 2320 mm - - - - - -
Spur max. 2200 mm
Spur min. 780 mm
Zul. Achslast (überfahrbar) 3000 kg 3500 kg
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MBT 3000
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Version
MBT 3200 LON
MBT 3250 EUROSYSTEM
MCD 1000
MBT 3250 EUROSYSTEM
MCD 2000
MBT 3250 EUROSYSTEM
MCD 2000, PC
Absicherung (träge) 35 A
MBT 3400 LON ALLRAD
MBT 3450 EUROSYSTEM
ALLRAD MCD 1000
MBT 3450 EUROSYSTEM
ALLRAD MCD 2000
MBT 3450 EUROSYSTEM
ALLRAD MCD 2000, PC
Antriebsleistung der Motoren
5,5 kW
Messwertanzeige 0-8 kN / 0-16 kN
Netzfrequenz - 50 Hz - 50 Hz -
Netzfrequenz max. 60 Hz - 60 Hz
Netzfrequenz min. 50 Hz - 50 Hz
Netzspannung 400 V
Phasen 3
Prüfgeschwindigkeit 5 km/h
Rollenachsabstand 400 mm
Rollendurchmesser 202 mm
Rollensatz Breite 680 mm
Rollensatz Höhe 280 mm
Rollensatz Länge 2925 mm
Spur max. 2800 mm - 2800 mm
Spur min. 870 mm - 870 mm
Zulässige Achslast (überfahrbar)
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8000 kg
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MBT 4000
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Version
MBT 4200 LON CLASSIC
MBT 4200 LON W CLASSIC
MBT 4200 LON W COMPE-
TENCE
Absicherung (träge) 50 A
Antriebsleistung der Motoren
9 kW
Netzfrequenz 50 Hz
Netzspannung 400 V
Phasen 3
Prüfgeschwindigkeit 2,3 km/h
Rollenachsabstand 430 mm
Rollendurchmesser 202 mm
Rollensatz Länge 1000 mm
Zulässige Achslast (überfahrbar)
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13000 kg
MBT 4250 EUROSYSTEM
MCD 2000
MBT 4250 EUROSYSTEM
MCD 2000 PC
MBT 4450 EUROSYSTEM
ALLRAD, MCD 2000
BA022301-en
15
MBT 5000
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Version
MBT 5200 LON CLASSIC
MBT 5200 LON W COMPE-
TENCE
Absicherung (träge) 63 A
Antriebsleistung der Motoren
11 kW
Gewicht pro Rollensatz 800 kg
Netzfrequenz 50 Hz
Netzspannung 400 V
Phasen 3
Prüfgeschwindigkeit 2 km/h
Rollenachsabstand 450 mm
Rollendurchmesser 130 mm
Rollenlänge 1220 mm
Rollensatz Breite 1171 mm
Rollensatz Höhe 460 mm
MBT 5250 EUROSYSTEM
MCD 2000
MBT 5250 EUROSYSTEM
MCD 2000 PC
Rollensatz Länge 2042 mm
Zulässige Achslast (überfahrbar)
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18000 kg
BA022301-en
16
MBT 6000
Pos: 52 /Techn ische Dok ument atio n/Brem spr üftec hnik /- Arc hiv -/- Brems prüf technik A lle -/I nhalte/I nhalt : Technisc he Daten MB T 60 00 ( Tab ell e) @ 41\mod_1419244506240_75.docx @ 2177682 @ @ 1
Version
MBT 6200 LON W CLASSIC
MBT 6250 EUROSYSTEM
MCD 2000
Absicherung (träge) 63 A
Antriebsleistung der Motoren
11 kW
Netzfrequenz 50 Hz
Netzspannung 400 V
Phasen 3
Prüfbarer Raddurchmesser max.
Prüfbarer Raddurchmesser min.
2200 mm
800 mm
Prüfgeschwindigkeit 3 km/h
Rollenachsabstand 685 mm
Rollendurchmesser 265 mm
MBT 6250 EUROSYSTEM
MCD 2000 PC
Rollenlänge 1600 mm
Spurbreite max. 3600 mm
Spurbreite min. 400 mm
Zulässige Achslast (überfahrbar)
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BA022301-en
18000 kg
17
MBT 7000
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Version
MBT 7200 LON CLASSIC
MBT 7200 LON W CLASSIC
MBT 7200 LON W COMPE-
TENCE
Absicherung (träge) 63 A
Antriebsleistung der
Motoren
11 kW
Netzfrequenz 50 Hz
Netzspannung 400 V
Phasen 3
Prüfgeschwindigkeit 3 km/h
Rollenachsabstand 475 mm
Rollendurchmesser 265 mm
Rollenlänge 1150 mm
Zulässige Achslast
(überfahrbar)
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18000 kg
MBT 7250 EUROSYSTEM
MCD 2000
MBT 7250 EUROSYSTEM
MCD 2000, PC
MBT 7450 EUROSYSTEM
ALLRAD, MCD 2000
BA022301-en
18
3
Transport and Storage
4
Installation and Initial Operation
5
Operation
5.1
Main Switch
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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
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out.
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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
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service partners.
• 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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BA022301-en
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