MLS MMLS3 Operator's Manual

Scaled down heavy vehicle simulator

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MMLS3 OPERATOR'S MANUAL

The aim of the MMLS3 Operators

Manual

give

information

regarding safe and efficient techniques

in operating the MMLS3.

The machine is a scaled down heavy

vehicle simulator used for accelerated

trafficking of model- or full scale

pavements.

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Summary of Contents for MLS MMLS3

Page 1 MMLS3 OPERATOR’S MANUAL The aim of the MMLS3 Operators Manual give information regarding safe and efficient techniques in operating the MMLS3. The machine is a scaled down heavy vehicle simulator used for accelerated trafficking of model- or full scale pavements.
Page 2: Table Of Contents
MLS Test Systems Pty Ltd MMLS3 operator’s manual Contents SECTION 1: UNPACKING AND INSPECTION ........1 Packing list ................1 Unpacking ................2 Inspect the machine for damage during transport ....3 SECTION 2: FEATURES AND DESCRIPTION ........4 SECTION 3: USING THE MACHINE ............8 Operation ..................8...
Page 3: Section 1: Unpacking And Inspection
SECTION 1: UNPACKING AND INSPECTION Packing list You should have received the following items The MMLS3 machine frame plus the following accessories: One steerable “jockey wheel” and two fixed transport castors wheels. (See Fig.1(h). Two “skate boards” with base plates (See Fig.1(g)) Two link arms, about 350mm long, to link the machine to the base plates (See fig.
Page 4: Unpacking
MLS Test Systems Pty Ltd Unpacking The machine comes strapped to a wooden pallet inside a wooden crate and can be handled by either a forklift or a crane. Once removed from the pallet the machine should not be handled by a forklift, which will damage its underside. Off the pallet the machine can be moved around on its own transport wheels, or handled by crane.
Page 5: Inspect The Machine For Damage During Transport
MLS Test Systems Pty Ltd Inspect the machine for damage during transport Visually check for bent or broken parts. If anything looks suspicious, please contact the supplier. Revised: April 2013...
Page 6: Section 2: Features And Description
MLS Test Systems Pty Ltd SECTION 2: FEATURES AND DESCRIPTION The MMLS is a scaled down heavy vehicle simulator used for accelerated trafficking of model- or full scale pavements. The four 300mm diameter single wheels can typically apply 7200 real wheel loads per hour.
Page 7 MLS Test Systems Pty Ltd Revised: April 2013...
Page 8 Power supply to the machine is 220 Volt 50/60 Hz AC at about 1.5 kW (7 Amp). Using the machine on wet pavements The MMLS3 may be used on wet pavements. Most parts of the machine (including the ball bearings in all the wheels) are made of stainless steel or other corrosion resistant material.
Page 9 MLS Test Systems Pty Ltd however, that under wet and dirty conditions faster than normal wear and tear will occur which may shorten the life of the machine or some of its components. Revised: April 2013...
Page 10: Section 3: Using The Machine
MLS Test Systems Pty Ltd SECTION 3: USING THE MACHINE Operation To operate the machine, follow the following steps:  Set the wheel load and tyre pressure as described under 3.1.  Move the machine into position by its transport wheels or by crane as described under 3.2.1...
Page 11: Setting The Wheel Load
MLS Test Systems Pty Ltd  Press the red STOP button to stop the machine when necessary.  Before using the machine on wet pavements, read section 2 in Supplementary Manual.  Every 500 000 wheel loads, apply grease to the side walls of the guide wheels as described under 4.1...
Page 12 MLS Test Systems Pty Ltd Revised: April 2013...
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Page 14: Adjusting The Wheel Load
MLS Test Systems Pty Ltd removing its hinge pins.) Mount and hand tighten the flange. Plug the unit into a 220 Volt AC supply. 3.1.1.2 Handling the chain of bogies by the round wheel shafts on the link sections only, move one of the 300mm wheels to be exactly underneath the flange of the calibration unit.
Page 15: Setting Up The Machine On The Pavement
MLS Test Systems Pty Ltd the flange and record the number of turns. To increase the load, screw the flange away from the u-bracket (i.e. compressing the spring). It should be possible to rotate the spring by hand if nut A is, at the same time, rotated in the same direction by a 24mm ring wrench.
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Page 17: Adjusting The Height
MLS Test Systems Pty Ltd The jockey wheel with the beam is mounted by pushing the two 25mm holes horizontally over the two studs at the end of the machine, then moving it slightly upwards and engaging the pin. The two fixed wheels are mounted, one on each side of the...
Page 18 MLS Test Systems Pty Ltd Refer to fig. 5 below. It shows a side view of the bogie suspension system. In the machine the system can only be seen from the top. The large spring at the bottom pushes the rubber wheel downwards to create the load of the wheel onto the pavement.
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Page 20 MLS Test Systems Pty Ltd 3.2.2.1 Look through the large inspection opening in the side of the machine and move any one bogie until the forward four of its six yellow guide wheels are just out of the curve coming down on the opposite side of the drive drum, and onto the start of the bottom straight rail section.
Page 21: Running The Machine
MLS Test Systems Pty Ltd Running the machine 3.3.1 Set the machine up as described under 3.2 above. 3.3.2 Connect the control unit to a 220 VAC supply and connect the three cables to the machine. The red plug feeds 3-phase power...
Page 22 MLS Test Systems Pty Ltd 3.3.7 After a few millimetres of rutting has developed, it may be necessary to stop the machine and readjust the suspension gaps as described under 3.2.2 above. 3.3.8 To use the RUN and STOP buttons on the keypad, (instead of...
Page 23: Section 4: Maintenance
MLS Test Systems Pty Ltd SECTION 4: MAINTENANCE Also read the maintenance recommendations in Appendix C The yellow (polyurethane) guide wheels The two wheels in the centre of each bogie (in line with the shaft of the rubber wheel) carries nearly all the load.
Page 24 MLS Test Systems Pty Ltd Revised: April 2013...
Page 25: The Drive Belts
MLS Test Systems Pty Ltd The drive belts The drive drum is driven by two V-belts. From time to time (say every 500 000 axle loads) Remove the safety cover (two M6 bolts on top and two at the bottom) and inspect the belts for wear and damage.
Page 26 MLS Test Systems Pty Ltd Revised: April 2013...
Page 27: Aligning The Drive Drum
MLS Test Systems Pty Ltd Should the gaps need adjustment, proceed as follows: Note: The following procedure assumes that the upper guide rail ends have not been disturbed and can serve as reference for the position of the drum. If this is not true, the drum has to be re-aligned as described under 4.3 below.
Page 28 MLS Test Systems Pty Ltd The drum, curved outer rail and upper rail ends have been aligned for proper working in the factory. As long as the upper rail ends are not moved from the factory setting, they can be used as reference for the position of the drum by setting the gap between them as described in 4.2...
Page 29: Changing A Tire
MLS Test Systems Pty Ltd be pinched between the drum and outer rails so that it is impossible to rotate them by hand. Move the wheels further on and they should both simultaneously be released somewhere between positions M and N. If this is not true, adjust the left and/or right hand bearing plates as described in 4.2.2 above, but...
Page 30 MLS Test Systems Pty Ltd end of the guide wheel axle. Slide the trailing arm outwards so that the wheel shaft can be disengaged and the 300mm wheel removed. Revised: April 2013...
Page 31 MLS Test Systems Pty Ltd 4.5.4 Remove the old tyre and tube from the rim: If the tyre is not already flat, deflate to about 50 kPa and undo the five M8 capscrews that hold the two rim halves together.
Page 32 MLS Test Systems Pty Ltd from the top and push it down as far as it will go. Apply some lubricant to the treads of the five cap screws and insert them with their flat washers (picture bottom right). Tighten them in sequence, half a turn at a time, so that the two rim halves are pulled together evenly.
Page 33: Removing And Replacing The Springs
MLS Test Systems Pty Ltd 4.5.8 Replace the wheel in the bogie and tighten nuts A & B. Move the circlip back in place. Replace plate G and tighten capscrews, F, to 20 Nm. Tighten nuts A & B as hard as you can (100 Nm).
Page 34: Appendix A: Using The Varispeed Motor Controller
MLS Test Systems Pty Ltd APPENDIX A: Using the Varispeed motor controller (YASKAWA - J1000) The motor controller is used to give the machine a soft start, control the speed, protect the motor against overload and to indicate certain faulty conditions on the machine.
Page 35 The “A” behind the value is the unit “Ampere” Changing factory defaults The following parameter have been changed from their factory default values. Do not change any of these values before first consulting MLS Test Systems. Please see section 1, Programming, which explains how to change a parameter.
Page 36: Appendix B: The Lateral Displacement System
MLS Test Systems Pty Ltd APPENDIX B: The lateral displacement system The purpose of the system is to spread the wheel loads on the pavement in the lateral direction from the centreline of the track by moving the entire machine. It consists of the following parts: Two base plates that can be anchored to the pavement Two “skate boards”.
Page 37: Appendix C: Maintenance Checklist
MLS Test Systems Pty Ltd APPENDIX C: Maintenance checklist The following checks are recommended for proper maintenance of the MMLS3. If anything looks suspicious, or is not fully understood, please contact the manufacturers following e-mail address: info@mlstestsystems.com Reference: For easy reference, devise a numbering system for the bogies, link sections and guide wheels.
Page 38 MLS Test Systems Pty Ltd able to lift the wheels 40 to 50mm off the rails. If necessary, adjust one or both of the two adjustable links between the bogies and link sections. If the chain of bogies is too short, it pulls the drum towards the centre of...
Page 39 MLS Test Systems Pty Ltd Visually check that the bolts and nuts linking the bogies and link sections together are not loose Inspect the rubber stoppers on the bogie (see fig.2 or fig.3 in manual) for cracks. Replace both stoppers if necessary Every 1 000 000 axles Measure and write down the diameters of all 48 guide wheels.
Page 40 MLS Test Systems Pty Ltd Refer to section 4 and measure the gap between the upper guide rail ends and the drive drum. If a feeler gauge is not available, use two layers of office paper. If the gap is not correct, adjust the drum as described.
Page 41 MLS Test Systems Pty Ltd make contact with the washer. The wheel will then be damaged by the washer, creating sharp edges on the wheel which will cut away more Vesconite. Make sure that there is at least 2mm between the washers and the edge of the Vesconite where the wheels run, over the entire length of the strips.
Page 42: Appendix D: Circuit Diagrams
MLS Test Systems Pty Ltd APPENDIX D: Circuit diagrams Revised: April 2013...
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Page 47: Appendix E: Technical Specifications
MLS Test Systems Pty Ltd APPENDIX E: Technical Specifications No. of bogies No. of wheels Wheel diameter 300mm Tyre width 80mm 0 -  75mm Lateral spread of track Total track width 80 - 230mm Nominal load per wheel 1900 - 2700 Newton...
Page 48 MLS Test Systems Pty Ltd Revised: April 2013...