MAHA CONNECT Series Original Operating Instructions
  1. Manuals
  2. Brands
  3. MAHA Manuals
  4. Test Equipment
  5. CONNECT Series
  6. Original operating instructions
MAHA CONNECT Series Original Operating Instructions

MAHA CONNECT Series Original Operating Instructions

Roller brake tester for passenger cars and vans
Hide thumbs Also See for CONNECT Series:
Table of Contents

Advertisement

Quick Links

CONNECT SERIES
Roller Brake Tester for Passenger Cars and Vans
Original Operating Instructions
BA023001-en
C_MBT C 3.5 W220
C_MBT S 3.5 W220
C_MBT C 3.5 W250
C_MBT S 3.5 W250
C_MBT C 4.0 W220
C_MBT S 4.0 W220
C_MBT C 4.0 W250
C_MBT S 4.0 W250
C_MBT C 5.0 W280
C_MBT S 5.0 W280

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CONNECT Series and is the answer not in the manual?

Questions and answers

Related Manuals for MAHA CONNECT Series

Summary of Contents for MAHA CONNECT Series

  • Page 1 CONNECT SERIES Roller Brake Tester for Passenger Cars and Vans Original Operating Instructions BA023001-en C_MBT C 3.5 W220 C_MBT C 4.0 W220 C_MBT C 5.0 W280 C_MBT S 3.5 W220 C_MBT S 4.0 W220 C_MBT S 5.0 W280 C_MBT C 3.5 W250 C_MBT C 4.0 W250...
  • Page 2 BA023001-en 2021-03-15 © MAHA Maschinenbau Haldenwang GmbH & Co. KG The reproduction, distribution and utilization of this document as well as the communication of its con- tents to others without explicit authorization is prohibited. Offenders will be held liable for the payment of damages.

  • Page 3: Table Of Contents

    Contents General safety instructions ..................... 7 Introduction ........................7 Symbols and signal words ....................7 1.2.1 Personal injury ........................7 1.2.2 Damages to products, machinery and equipment .............. 7 1.2.3 Information ......................... 8 Procedure in the event of a malfunction ................8 Procedure in the event of an accident ................
  • Page 4 Transport and handling ..................... 37 Storage ..........................37 Installation ........................38 Safety instructions......................38 Installation diagrams ......................39 Mounting the control cabinet ................... 40 4.3.1 Mechanical installation ..................... 40 4.3.2 Electrical installation ......................41 Mounting the roller set ..................... 43 4.4.1 Mechanical installation .....................
  • Page 5 Results display ........................73 Measured value display ....................74 Settings ..........................76 6.7.1 Support ..........................77 6.7.2 Language ........................... 77 6.7.3 Network ..........................78 6.7.4 Event logging ........................78 6.7.5 Test report ........................79 6.7.6 Machine data ........................80 6.7.7 Calibrating brake force ......................
  • Page 6 Roller cover W220, W250, W280 ..................112 11.2 Crossing and lowering threshold ..................112 11.3 C_MSA (MAHA universal analogue display) ..............113 11.3.1 Description ........................113 11.3.2 Scope of delivery ......................114 11.3.3 Technical data ......................... 114 11.3.4 Installation ........................114 11.3.5 Status LEDs ........................

  • Page 7: General Safety Instructions

    General safety instructions Introduction • These operating instructions must be read carefully and understood before work commences. • Please observe the specific safety information provided for the respective sections of the operating manual. • Adhering to the procedures, sequences and corresponding safety instructions is essential.

  • Page 8: Information

    1.2.3 Information indicates important information. Procedure in the event of a malfunction If the fault cannot be rectified using the procedures described in chapter "Troubleshooting", proceed as follows: • Switch off the main switch and secure it against being switched on again (unau- thorised use).

  • Page 9: Description

    Description Service life The test bench is designed for a service life of approx. 10 years. This depends, among other things, on the existing operating conditions. After this period, the test bench must be replaced with a new product or undergo a general overhaul. A general overhaul should only be carried out by the manufacturer or persons authorized by them.

  • Page 10: Description Of The Test Bench

    LAN cable or wirelessly via WiFi. Furthermore, a commercially available TV monitor (together with a MAHA C_BOX) or the MAHA universal analogue display can be used as a simultaneous display.

  • Page 11: Intended Use

    The sensing roller directly measures the wheel speed. The magnitude of the slip can be determined by comparing the drive speed with the sensing roller speed – both values determined via sensors. To avoid unnecessary tyre wear, MAHA test benches switch off automatically when the (legally) specified maximum slip is reached.

  • Page 12: Brake Test Of Four-Wheel Drive Vehicles

    from excessive tread wear. On light vehicles, even a small amount of slip can cause tyre damage. 2.2.5 Brake test of four-wheel drive vehicles NOTICE In order to avoid stresses in the drive train and resulting damage, care must be taken with four-wheel drive vehicles to ensure that –...
  • Page 13 Mode 3: Automatic four-wheel drive detection In this mode the starting resistance of the vehicle axle is monitored and evaluated. This detects a vehicle axle that is not freewheeling, and an automatic switchover to reverse operation takes place. During the braking efficiency test, two measuring processes take place, between which the direction of rotation is automatically reversed.

  • Page 14: Overview With Components

    2.2.6 Overview with components Test bench rollers Electric motor Sensing roller with slip and drive sensor (Namur) Middle cover (shown transparently) Bearing cover (shown transparent) IFM (Interface module) Overview with components BA023001-en...

  • Page 15: Technical Data

    Technical data C_MBT C 3.5 C_MBT C 3.5 C_MBT S 3.5 C_MBT S 3.5 W220 W250 W250 W220 Track 2.20 RS 2 Track 2.50 RS 4 Track 2.50 RS 4 Track 2.20 RS 2 unsplit unsplit split split Axle load [kg] 3500 3500 3500...
  • Page 16 C_MBT C 4.0 C_MBT C 4.0 C_MBT S 4.0 C_MBT S 4.0 W220 W250 W250 W220 Track 2.20 RS 2 Track 2.50 RS 4 Track 2.50 RS 4 Track 2.20 RS 2 unsplit unsplit split split Axle load [kg] 4000 4000 4000 4000...
  • Page 17 C_MBT C 5.0 C_MBT C 5.0 W280 W280 Track 2.80 RS 5 Track 2.80 RS 5 unsplit split Axle load [kg] 5000 5000 Track width min. [mm] Track width max. [mm] 2800 2800 Drive power 4 kW 4 kW Test speed 5 km/h 5 km/h Roller length [mm]...

  • Page 18: Safety Area

    2.3.1 Safety area When operating the test bench, there must be no persons or obstacles (danger of crushing) in the safety area. This shall be indicated by a yellow and black marking around the test bench. Safety area BA023001-en...

  • Page 19: Set-Up Diagram

    2.3.2 Set-up diagram Set-up diagram I BA023001-en...
  • Page 20 Set-up diagram II BA023001-en...

  • Page 21: Control Unit Description

    Control unit description The control unit consists of a control cabinet with electronic components in connection with the corresponding operating, control and monitoring software and the operating elements necessary for safe operation. The electronic components consist of: • a ZM (central module) with a CPU module and 2 microprocessors •...

  • Page 22: Wiring Diagram

    2.4.1 Wiring diagram BA023001-en...

  • Page 23: Control Cabinet Structure Basic Variant

    2.4.2 Control cabinet structure Basic variant BA023001-en...

  • Page 24: Control Cabinet Structure Full Equipment

    2.4.3 Control cabinet structure Full equipment BA023001-en...
  • Page 25 BA023001-en...

  • Page 26: Connection And Termination Of The Central Module (Zm)

    2.4.4 Connection and termination of the central module (ZM) Connection of the central module BA023001-en...

  • Page 27: Coding Zm-Om

    2.4.5 Coding ZM-OM Connection of the option modules ZM-OM • Possibility 1 (ZM only) Central module ZM: S2 (+S-A1.0-S2) - Term ON BA023001-en...
  • Page 28 • Possibility 2 (ZM and OM) Central module ZM: S2 (+S-A1.0-S2) - Open (Term OFF) Option module OM: +S option -S3 (Open/Term OFF) -A2.0 Direction of rota- 0-15 tion/measurement via pushbutton Term ON only at the last mod- -A2.1 Lowering bar 0-15 -A2.2 Roller set lift 0-15...

  • Page 29: Coding Zm-Ifm

    2.4.6 Coding ZM-IFM Connection of the interface module ZM-IFM S1 - Termination OFF S1 - Termination ON CAN address IFM-CT Terminating resistor OFF Terminating resistor ON „0“ 8 (IFM-BA*) „1“ „2“ „3“ „4“ BA023001-en...
  • Page 30 S1 - Termination OFF S1 - Termination ON CAN address IFM-CT Terminating resistor OFF Terminating resistor ON „5“ „6“ „7“ *IFM-BA always preset with address “0” and term ON. • Possibility 1 (Closed roller set) Central module ZM: -S3 (+S-A1.0-S3) - Term ON Interface module Basic IFM-BA: (no rotary switch S1 available) BA023001-en...
  • Page 31 • Possibility 2 (Closed roller set) Central module ZM: -S3 (+S-A1.0-S3) - Term ON Interface module Comfort IFM-CT: -S3 (+A-A3-S1) – Term ON: Address "0" (-> rotary switch S1 to 8) BA023001-en...
  • Page 32 • Possibility 3 (Split roller set) Central module ZM: -S3 (+S-A1.0-S3) – Open (Term OFF) Left interface module Comfort IFM-CT: S1 (+A-A3-S1) – Term ON: Address ”1” (-> rotary switch S1 to 9) Right interface module Comfort IFM-CT: -S1 (+B-A3-S1) – Term ON: Address ”2” (->...
  • Page 33 • Possibility 4 (Split roller set, in series ZM-IFM-IFM) Central module ZM: -S3 (+S-A1.0-S3) – Term ON Left interface module Comfort IFM-CT: -S1 (+A-A3-S1) – Term OFF: Address ”1” (-> rotary switch S1 to 1) Right interface module Comfort IFM-CT: -S1 (+B-A3-S1) – Term ON: Address ”2” (->...

  • Page 34: Control Buttons

    2.4.7 Control buttons 2.4.8 Indicator light on the control cabinet in the event of a fault The “Control On” indicator light (-P1) in the front cover of the control cabinet lights up as soon as the main switch is switched on and the control is initialised and there is no fault.

  • Page 35: Transport, Handling And Storage

    Transport, handling and storage Safety instructions WARNING • For loading, unloading and transport, always use suitable lifting equipment, load handling devices (e.g. crane, forklift truck) and correct load attachment devices and lifting accessories. See also section "Transport and handling". • Always ensure that the parts to be transported are suspended or loaded properly and in a fall-proof manner, taking into account their size, weight and centre of gravity.

  • Page 36: Scope Of Delivery

    Scope of delivery Each test bench is shipped from the factory with packaging as standard. The delivery contains: • Roller set (basic equipment) • Control cabinet (basic equipment) • Options according to price list The number of delivered packages and contents must be checked for damage and completeness according to the order confirmation.

  • Page 37: Packaging Information

    Packaging information • Roller set on separate Euro pallet: Dimensions (L x W x H, depending on equipment) ..... approx. 230-300 x 70 x 50 cm Weight (depending on equipment) ............ approx. 500-800 kg • Control cabinet on separate Euro pallet: Dimensions (L x W x H, depending on equipment) .....

  • Page 38: Installation

    Installation Safety instructions WARNING • Installation and initial commissioning of the device may only be carried out by specially trained personnel who are provided with a detailed technical manual. Such specialist staff include authorised, trained specialists employed by the manu- facturer, the authorised dealers and the relevant service partners.

  • Page 39: Installation Diagrams

    Installation diagrams C_MBT C 3.5/4.0 C_MBT S 3.5/4.0 C_MBT C 3.5/4.0 C_MBT S 3.5/4.0 W220 W220 W250 W250 Foundation plan 10022761 10022761 Electrical circuit 202.01.005800 diagram C_MBT C 5.0 W280 C_MBT S 5.0 W280 Foundation plan 10022761 Electrical circuit 202.01.005800 diagram BA023001-en...

  • Page 40: Mounting The Control Cabinet

    3 pcs 6 mm washers, MAHA # 22 0125 06 3. • 3 pcs 8 mm anchors, MAHA # 23 5008. These anchors are suitable for normal con- crete, masonry walls, light weight concrete with a high degree of porosity and aer- ated concrete.

  • Page 41: Electrical Installation

    4.3.2 Electrical installation NOTICE • The cable cross-section of the on-site supply cable depends on the local conditions (e.g. ambient temperature, type of installation, cable length, mains impedance) and the local regulations. • During installation and regular maintenance work, authorised and trained person- nel must check that all electrical terminals are firmly seated and retighten all elec- trical screw terminals.
  • Page 42 Image: PHOENIX CONTACT Image: PHOENIX CONTACT Image: PHOENIX CONTACT NOTICE Ensure that the yellow warning covers are then reattached to the terminals. The supply line L1 – L2 – L3 must have a clockwise rotating field. BA023001-en...

  • Page 43: Mounting The Roller Set

    Mounting the roller set 4.4.1 Mechanical installation Installation accessories • 4 pcs. bolt anchors B, M10x90 galvanised, MAHA # 23 5090. These bolt anchors are suitable for non-cracked concrete. Anchor dimensions Hole diameter [mm] Anchoring depth [mm] Tightening torque Tinst...
  • Page 44 Remove the middle cover and set aside. Hand over the mounting material to the operator for reuse (disassembly, repair). Remove the bearing covers on the left and right so that the test bench can be fixed in the foundation. To do this, remove the 4 M8 screws (marked red) with WAF 13 and remove the bearing covers.
  • Page 45 If a drill with sufficient length is not available, remove the sensing roller spiral spring (marked red) if necessary. Dismantling of the spiral spring must be carried out identically on the left and right. Center the test bench all around in the foundation, then drill a minimum depth of 90 mm at the fixing points (marked red) using a suitable 10 mm masonry drill bit.
  • Page 46 Remove the transport lock (marked red) with ratchet and extension WAF 17 and dispose of it. The transport lock must be removed on the left and right. 10 Adjust the test bench to the desired level (e.g. level with the floor) using the 4 levelling screws (marked red) with ratchet and extension WAF 17.

  • Page 47: Electrical Installation

    Electrical installation Installation accessories Required cables between roller set and control box (basic variant): a. Motor cable left track +A and right track +B (MAHA # 1404769) Cable 7G 1.5 mm² YSLY-JZ; 15 meters Round plug 7-pin b. CAN data line IFM (MAHA # 1402469) Cable 2x2x0.5 mm²...
  • Page 48 Installation process NOTICE First, carefully place the connectors on the IFM sockets and turn them until the holes snap onto the pins. Only then push the connector on completely. Pull the required cables from the roller set through the empty conduit provided by the customer with the cable ends cut off in the direction of the control box.
  • Page 49 Secure the cable in the reel set using cable ties. Make sure that no cables are under tensile stress. On the control cabinet side, shorten the supplied flexible plastic protective conduit with an inner diameter of 36 mm to the required length, push it over the cables protruding from the empty conduit and allow it to protrude several centimetres into the empty conduit in the floor.
  • Page 50 10 Feed the CAN data line through the cable duct to the ZM connector X1, untwist, strip and connect to the green 4-pin connector X1 without tensile load. To do this, strip 10 mm of insulation from the individual wires and twist them together. While actuating the push-in spring-cage terminal, use a small screwdriver to guide the bare wire into the connector opening.
  • Page 51 • M8 sensor connector mounting/dismounting on IFM Mount by carefully inserting the 3/4-pin connector. It is locked by lightly snapping into place when plugged in. The connector must not be turned under pressure! • M8 protective cap mounting/dismounting on IFM Unused plug-in connections must be fitted with a black rubber protective cap.
  • Page 52 • Motor connector mounting/dismounting Mount by carefully plugging in the 7-pin connector. It is locked by lightly snapping into place when plugged in. The connector must not be turned! For dismounting, use a screwdriver to lightly press the locking lug and pull off the connector while doing so.
  • Page 53 BA023001-en...

  • Page 54: Functional Test

    Functional test The acceptance of the brake tester is carried out by an expert. He checks all functions and safety devices and confirms the result. In addition, a second sheet enclosed with the operating instructions (“Quality Certificate for Installation and Commissioning”) must be completed in full and returned to the manufacturer.

  • Page 55: Calibration / Adjustment

    Calibration / Adjustment Calibration interval: at least every 2 years Adjusting the brake force In the Service technician menu, select “Adjust brake force”. In the control cabinet, set both motor circuit breakers to the “OFF” position. 5.1.1 Adjusting the zero point Perform zero-balance adjustment for the brake force while no vehicle is located on the test bench: press “Adjust”...

  • Page 56: Adjusting Brake Forces With Mjv Ii

    If there are excessive deviations, the adjustment must be performed again. 10 Repeat the process for the right-hand side. 5.1.3 Adjusting brake forces with MJV II See quick reference guide BA020001_003, available for download on the MAHA homepage www.maha.de. BA023001-en...

  • Page 57: Operation

    Operation Safety instructions WARNING • Observe the statutory accident prevention regulations. • Before the vehicle inspection, remove any foreign particles stuck in the tyre tread. • Drive the vehicle on/off/over the test bench with the vehicle slowly (walking speed) and centrally. •...

  • Page 58: Safety Devices

    may be endangered, personal protective equipment must be used. • The operator must not leave the vehicle during the inspection. • Vehicles must never be parked in/on the roller set or on the optional ramps. Park- ing in the security area is not allowed. Safety devices WARNING The safety devices (some of them optional) must be inspected regularly by an author-...
  • Page 59 • Yellow and black marker tape The yellow and black marker tape around the roller set and pit serves to cordon off the test bench and must be replaced if defective. Item no. 19 6014 (38 mm) / 19 6015 (50 mm). •...

  • Page 60: Preparations

    • Switch on PC/NB, log in after booting, open browser. 6.3.3 Establish a browser connection • Call the start page in the browser via the address: http://maha-mbt(.maha). • Once the connection is established, the measurement screen is displayed: BA023001-en...

  • Page 61: Variant 2: Establishing A Wifi Connection

    If the test bench is to be controlled wirelessly, a WiFi router (e.g. TP-Link) can optionally be connected to the ZM (Ethernet X13 MAHA). This creates a separate WiFi for the brake tester and enables networking with corresponding accessories (e.g.

  • Page 62: Variant 3: Integration Of The Test Bench Into Own Network

    • Select TP_LINK_xxxx. • Enter password. If no WiFi device is found, the connection must be set up manually using the SSID and the PIN. Alternatively, free QR code generators can be found on the Internet, which can be used to generate a personal QR code for the CONNECT brake tester. If this is photographed (e.g.

  • Page 63: Carry Out Brake Test With Automatic Sequence

    6.4.2 Carry out brake test with automatic sequence A computer with monitor, a TV or a SmartDevice is required for operation. Test sequence without remote control (automatic sequence selected) Status line*: "Please drive on test equipment" Drive on test rollers (both sensing rollers are actuated) Automatic roller start (approx.

  • Page 64: Carry Out Brake Test With Semi-Automatic Sequence

    6.4.3 Carry out brake test with semi-automatic sequence A computer with monitor, a TV or a SmartDevice is required for operation. Test sequence with remote control/smart device (semi-automatic sequence selected) Status line*: "Please drive on test equipment" Drive on test rollers (both sensing rollers are actuated) Semi-automatic roller start (after sensing roller actuation and release by remote control/smart device)

  • Page 65: Carry Out Four-Wheel Brake Test With Smartdevice/Pc In Automatic Mode

    6.4.4 Carry out four-wheel brake test with SmartDevice/PC in automatic mode Test sequence without remote control (automatic sequence selected) Status line*: "Please drive on test equipment" Drive on test rollers (both sensing rollers are actuated) Automatic roller start (approx. 3 seconds after sensing roller actuation) In the event of increased starting resistance due to the four-wheel drive, the motors switch off again immediately.

  • Page 66: Carry Out Manual Four-Wheel Brake Test With Smartdevice/Pc In Counter-Rotation Mode

    Rollers may stop in case of slippage or pre-trigger! The left-hand indicator moves to the max. braking value. Automatic roller start in counter-rotation (approx. 3 seconds) (motor right forward) Status line*: “Please brake” Brake up to maximum brake force, then release brake again or brake until the wheels lock up (slippage).
  • Page 67 Automatic roller start in counter-rotation (approx. 3 seconds) (motor left forward) Status line*: “Please brake” Brake up to maximum brake force, then release brake again or brake until the wheels lock up (slippage). Rollers may stop in case of slippage or pre-trigger! The left-hand indicator moves to the max.

  • Page 68: Carry Out Four-Wheel Brake Test In Counter-Rotation By Means Of Pushbutton Switch On Control Cabinet

    6.4.6 Carry out four-wheel brake test in counter-rotation by means of pushbutton switch on control cabinet Push button for right motor 1x (lndicator lamp for right motor lights up) Status line*: "Please drive on test equipment" Drive on test rollers (both sensing rollers are actuated) Automatic roller start in counter-rotation (approx.

  • Page 69: Carry Out Manual Single Wheel Brake Test With Smartdevice/Pc

    Rollers may stop in case of slippage or pre-trigger! The right-hand indicator moves to the max. braking value. Status bar*: "Please exit" Slowly drive out of the test bench. *In conjunction with monitor display 6.4.7 Carry out manual single wheel brake test with SmartDevice/PC Preselect test sequence "Single wheel left or right"...

  • Page 70: Carry Out Single Wheel Brake Test By Means Of Pushbutton Switch On Control Cabinet

    (motor left) Status line*: “Please brake” Brake up to the maximum braking force, then release the brake again or brake until the wheel locks (slippage). Rollers may stop in case of slippage or pre-trigger! The right-hand indicator moves to the max. braking value. *In conjunction with monitor display A change of the wheel side left/right is possible by means of SmartDevice/PC when the test bench is in use.
  • Page 71 or brake until the wheel locks (slippage). Rollers may stop in case of slippage or pre-trigger! The left-hand indicator moves to the max. braking value. Automatic roller start (approx. 3 seconds) (motor left) Status line*: “Please brake” Brake up to the maximum braking force, then release the brake again or brake until the wheel locks (slippage).

  • Page 72: Exit The Test Bench

    6.4.9 Exit the test bench Depending on the equipment, the following must be observed when leaving the test bench: NOTICE Do not drive the vehicle out of the test bench with the rollers stationary. Exception: Static extension aid is available. a.

  • Page 73: Results Display

    Results display • In the results display, the customer name (N) and the licence number/VIN (M) can be entered for the current measurement (C), as well as the current mileage status (J) and the permissible total vehicle weight (I). • The last measurements (D) can be redisplayed (up to 10).

  • Page 74: Measured Value Display

    Up to 10 measurements are saved, new measure- Saved measurements ments overwrite the oldest. Save Saves the current measurement results. Saves the current measurement results locally as a Print PDF PDF. Licence number/VIN Entry field for the official licence number/VIN Name Entry field for customer name Mileage...
  • Page 75 Status line The status line serves as a user prompt. Indicates the set direction of rotation of the test rollers Direction arrows (both forward/reverse or counter-rotation). Indicates whether automatic mode is activated or manu- Automatic/manual al mode (then hand symbol). Settings Click on the cogwheel to open the settings menu.

  • Page 76: Settings

    Settings Clicking on the gear symbol in the MAHA logo opens the settings menu. This menu contains the following sub- menus. BA023001-en...

  • Page 77: Support

    6.7.1 Support This sub-menu contains information on the test bench that may be helpful for support when contacting the MAHA hotline, e.g. the test bench’s serial number and the latest version of the connected assemblies and their software status. 6.7.2 Language The preferred language can be selected here.

  • Page 78: Network

    "Operation > Preparations > Variant 3: Integration of the test bench into own network". To change the configuration of one of these interfaces, it is necessary to log in to the Service technician menu. The Ethernet interface X13 is permanently configured on the central module “MAHA” and cannot be changed! 6.7.4...

  • Page 79: Test Report

    6.7.5 Test report Here the content of the test report can be determined, depending on the installed options. BA023001-en...

  • Page 80: Machine Data

    6.7.6 Machine data Various information about the test bench operation is available here, including a fault memory and detailed machine data. 6.7.7 Calibrating brake force This sub-menu displays the calibration values for the brake forces. If the test bench needs to be adjusted, login is required in the Service technician menu –...

  • Page 81: Diagnostics Brake Tester

    6.7.8 Diagnostics Brake tester This sub-menu displays test bench sensor values, such as the speed of test roller and sensing roller. This view is used to diagnose problems (such as defective sensor, cable interruption, etc.). Once the user has logged in as service technician, the motors can also be started from this menu.

  • Page 82: External Devices

    The Service technician menu can be opened. However, this menu is only accessible to persons who are registered with MAHA and have an access account or a software key ("maha-key"). These keys are limited in time (usually one week after issuance) and are only valid for a specific test bench.

  • Page 83: Service Technician Menu

    MAHA Service Center after MAHA training has been completed. Offline activation If the test bench is not online, the user can log in by means of a software key ("maha- key"). This file must be downloaded to the end device beforehand and can be imported into the test bench here using the "Browse"...

  • Page 84: Account Management

    6.8.2 Network The central module has two Ethernet interfaces: X13 MAHA and X12 EXT. The current configuration of these interfaces can be seen in the network area of the Service technician menu. The designation of the X12 EXT interface is "Customer network", that of the X13 MAHA interface "MAHA network".
  • Page 85 X12 EXT interface can be configured according to customer requirements. It is recommended to carry out the configuration of the X12 EXT interface via a device that is directly connected to the X13 MAHA port. •...
  • Page 86 Calling up the WebApp of the central module via a web browser. The central module can be reached either via the IP 192.168.201.1 or via the name of the central module + .maha (in the delivery state, this would be e.g. http://maha-mbt.maha).

  • Page 87: Adjusting The Brake Force

    X13 MAHA The X13 MAHA interface is primarily used to connect a MAHA access point so that the test bench can be reached via the access point's WiFi. The network interface at X13 MAHA tries to obtain IP addresses via DHCPv4/v6 for 30 seconds when the central module is started (or a cable is plugged in).

  • Page 88: Options Overview

    6.8.5 Options overview An overview of the available test bench options is shown here. If the slide switch is moved to the right, the option is highlighted in blue, is now active and can be used, provided that no mechanical changes/add-ons are necessary for this. 6.8.6 Software update Software updates can be performed here.

  • Page 89: Input/Output Test

    6.8.7 Input/output test A test of the inputs and outputs of the central module can be performed here. BA023001-en...

  • Page 90: Deceleration Table

    Deceleration table Permiss. Axle braking force in kN axle load in kg 1000 1100 1200 1300 1400 1500 1600 Deceleration in % BA023001-en...

  • Page 91: Inspection And Maintenance

    Inspection and maintenance Safety instructions WARNING • Installation and initial commissioning of the device may only be carried out by specially trained personnel who are provided with a detailed technical manual. Such specialist staff include authorised, trained specialists employed by the manu- facturer, the authorised dealers and the relevant service partners.

  • Page 92: Care Instructions

    Care instructions • The machine should be cleaned at regular intervals and treated with a machine care product. • Any damage to the paintwork should be repaired immediately to prevent corro- sion. • To prevent damage, cleaning work must not be carried out with harsh cleaners or with high and steam pressure equipment.

  • Page 93: Cleaning The Chains

    Wear check by means of a chain wear gauge 2 % (MAHA order no. 1400079). • The chain wear gauge is suitable for all chains of the MAHA test benches. It can be used for type 12B 3/4" and type 16B 1" chains.

  • Page 94: Retensioning The Chains / Replacing The Test Rollers

    7.4.3 Retensioning the chains / Replacing the test rollers Check chain slack: It should be possible to move the chain up and down by hand by approx. 5 mm. If the chain is too lightly tensioned, proceed as follows: Loosen the fastening screws of the pedestal bearings on both sides. Adjust the chain to the correct tension using the adjusting screw.
  • Page 95 Tightening torques of the bearing screws CAUTION Check the strength labelling on the screws before using them. Tightening Required for Test bench type Thread Strength Position torque chain tension 50 Nm Roller C_MBT 3.5/4.0/5.0 120 Nm Motor bearing Tightening Test bench type Thread Strength Position...

  • Page 96: Lubricating The Chains

    The service life of the chain is directly dependent on the lubrication. If the lubricating film is permanently maintained, the wear of the chain can be reduced to a minimum. Suitable lubricant: LongLub adhesive lubricant (MAHA Art. No. 35 1020) •...

  • Page 97: Lubricating The Sensing Roller Hinges

    7.4.5 Lubricating the sensing roller hinges Maintenance interval: 200 operating hours / 12 months Remove cover plate from roller set. Treat lubrication points (arrow) with sprayable lubricant. While doing this, move the sensing roller up and down. Carry out the procedure on both sensing rollers. Re-mount the cover plate on the roller set.

  • Page 98: Trouble Shooting And Error Resolution

    Trouble shooting and error resolution Safety instructions WARNING • Installation and initial commissioning of the device may only be carried out by specially trained personnel who are provided with a detailed technical manual. Such specialist staff include authorised, trained specialists employed by the manu- facturer, the authorised dealers and the relevant service partners.

  • Page 99: Error Codes

    Error codes Description: Error codes have a 5-digit notation according to the scheme "YY0XX" • YY stands for the error code group (e.g. 32 "Speed sensor of the left sensing roller) • 0 serves here as separator • XX stands for the subcategory of the respective fault code group (e.g. 00 for cable break) •...
  • Page 100 Description CAN ID error Possible solution Switch off the entire system Check and set the CAN IDs Switch on the entire system Error code 11004 Description Configuration error Split roller set Possible solution Switch off the entire system Check and set the CAN IDs Switch on the entire system Error code 11005...
  • Page 101 Possible solution Backup of event logging and machine data Forward data and information about the situation to the software de- velopment department Error code 22000 Description Motor protection switch "OFF" Possible solution Both motor protection switches must be set to "ON". Error code 32000 Description...
  • Page 102 Possible solution Switch off the entire system Check the wiring of the speed sensor on the interface module Error code 35001 Description Cable break at the speed sensor of the left test roller Possible solution Switch off the entire system Check the wiring of the speed sensor on the interface module Error code 35002...
  • Page 103 Possible solution Switch off the entire system Check the wiring of the Namur sensor on the interface module Error code 41002 Description One side occupied, detected on the left Possible solution Drive on test bench on both sides, if this error is not yet displayed (only info via status line) Exit from the test bench Error code...
  • Page 104 Possible solution Vehicle is on the test plate (drive off), restart the entire system Readjustment of the system Error code 71000 Description Short circuit at Namur sensor Drive-on side Possible solution Switch off the entire system Check the wiring of the Namur sensor on the interface module Error code 71001 Description...

  • Page 105: Repair

    The technician key must not be older than the software image! It is recommended to always download key and software at the same time. Both can be downloaded from https://www.maha.de/de/software CONNECT DOWNLOADS. The following steps must be observed when replacing the control unit: Replace the central module with the main switch switched off.
  • Page 106 Logging into the Service technician menu (see section "Operation > Settings > Login Service technician menu") is then no longer possible online, but only via a software key (maha-key). If the central module has never been installed, a reset is not necessary and also not possible.

  • Page 107: Check Sensor Function

    Check sensor function WARNING • For functional tests on the roller set, it is imperative that the motor protection switches are switched off. • During the test of the sensor functions, the main switch may only be operated by authorised and trained personnel. •...

  • Page 108: Releasing Motors With Mechanical Brake

    Releasing motors with mechanical brake The brake motors are equipped with a flange-mounted spring-applied brake. When the voltage is switched off, the motor is blocked. A special motor connection cable can be used to release the brake and allow the motor to be rotated by hand for service purposes.
  • Page 109 • Option 1 for brake release Equipment needed: Brake release adapter MAHA # 1404314 Connect as follows: Disconnect the motor supply cable plug from the motor in the roller set. Connect the motor plug of the brake release adapter to the motor.
  • Page 110 • Option 2 for brake release Equipment needed: Brake release adapter MAHA # 1403248 Connect as follows: Disconnect the motor supply cable plug from the motor in the roller set. Connect the motor plug from the brake release adapter (jack) to the motor.

  • Page 111: Enabling The Test Rollers Via The Service Technician Button

    The Service technician button may only be used by authorised and trained techni- cians for the period of time absolutely necessary. Then unplug again immediately. Equipment needed: Service technician button MAHA # 1402226 Connect as follows: If necessary, disconnect the existing plugs at the central module ZM -X4 and -X14.

  • Page 112: Decommissioning, Dismantling And Disposal

    Decommissioning, dismantling and disposal The device may only be taken out of operation and disassembled by specially authorised and trained personnel. Such specialist staff include authorised, trained specialists employed by the manufacturer, the authorised dealers and the relevant service partners. Observe the product and safety data sheets of the lubricants used.

  • Page 113: C_Msa (Maha Universal Analogue Display)

    11.3 C_MSA (MAHA universal analogue display) 11.3.1 Description The C_MSA (CONNECT_MAHA simultaneous display) is used to display measured values generated by a brake tester. The LEDs are used for user guidance and indicate whether the display is in operation and connected, and whether the pointers refer to the small or the large measuring range.

  • Page 114: Scope Of Delivery

    The wall mount is suitable for holding all MAHA-CONNECT display units as well as the most common TV screens/Smart TV according to the specified VESA standard. The swivel arm can be locked to the wall bracket by means of a locking bolt with pull cable.
  • Page 115 NOTICE These dowels are suitable for concrete, solid brick, sand-lime brick. For other materi- als, suitable fastening systems must be used on site! Cable fastening Cable tie Locking Swivel arm Adjustment VESA mount Mark the upper drill holes on the selected wall according to the sketch and using a spirit level.
  • Page 116 (VESA = Video Electronics Standards Association). • 4x fastening holes M6 internal thread, max. 10 mm screw-in depth • 4 pcs. M6x12 fastening screws are supplied with the optional MAHA wall mount. • Weight of the display approx. 13 kg •...

  • Page 117: Status Leds

    4x M6 x 12 mm Wall mount with installed pointer display 11.3.5 Status LEDs Meaning of the LED status display System status LED Ready for LED Small meas- LED Large meas- braking uring range uring range No WiFi connection Fast flashing WiFi connection being established Slow flashing No connection to central module ZM Off...

  • Page 118: Setup

    Establishing a WiFi / LAN connection • Option 1: Direct LAN connection to the central module Connect the analogue display to the MAHA port (X13) of the central module using a LAN cable. • Option 2: Connection via a router connected to the central module •...
  • Page 119 NOTICE • A network hub is recommended for commissioning with the "LAN connection" variant. The network hub enables the simultaneous connection of the analogue display and the service PC for coupling with the control board ZM (central module) at the X13 port. •...
  • Page 120 Checking the function of the LEDs • Click on the "Adjust" button in the "External devices" view. • Between the left and right hand there are three buttons for the respective LED of the analogue display. • By clicking the buttons the LEDs can be switched on and off. •...
  • Page 121 Adjusting the pointer • Log in to the Service technician menu. • Click on the "Adjust" button in the "External devices" view. • The analogue display now carries out a pointer initialisation. • Select the desired pointer by clicking on it. •...

  • Page 122: Function Test

    Adjusting the end value • Click on the "End value" button if the pointer in the WebApp is not set to 8 kN/70 %. • Move the pointer of the analogue display to 8 kN/70 % by repeatedly clicking the "Step +"...

  • Page 123: Update

    11.3.8 Update If an update is available for the analogue display, an update button appears in the "External devices" view. After clicking on this button, a window appears with the currently installed and available software version. After confirming this window by clicking on "Continue", the update is carried out. After a successful update, the analogue display restarts.

  • Page 124: C_Box

    The C_BOX is the digital counterpart to the analogue display. It serves as an interface between a standard TV set or a monitor and a brake tester of the CONNECT series. The displays can be connected to the C_BOX via an HDMI cable, which in turn is connected to the test bench via LAN cable or WiFi.

  • Page 125: Scope Of Delivery

    11.4.2 Scope of delivery • Network module (LAN/WiFi), model: C_BOX • 2 m network patch cable • 1 plug-in power supply unit 5 V DC 11.4.3 Display requirements The TVs or monitors used as displays must have an HDMI input. NOTICE It is recommended •...

  • Page 126: Connecting The C_Box With The Brake Tester

    11.4.5 Connecting the C_BOX with the brake tester To connect a C_BOX with a brake tester of the CONNECT series, two steps are necessary. These steps are identical for new and already set up devices. Integrate the C_BOX into the network of the test bench.

  • Page 127: Coupling With The Brake Tester

    Coupling with the brake tester Call up the website of the test bench (e.g. http://maha-mbt.maha). Call up the Service technician menu (click on the gearwheel in the MAHA logo). Select the "External devices" menu item. o There all reachable C_BOXes in the network are displayed including status (connected, busy, coupling active, free).

  • Page 128: Error Handling

    This prevents unwanted coupling. 11.4.8 Software update Download update from the support area of the MAHA homepage www.maha.de. Connect C_BOX to PC/notebook via LAN cable. o The network interface of the computer must be configured as a DHCP client.
  • Page 129 In the browser, navigate to http://connect-box.maha. Click the "Select" button in the "Upload update" input field. Select and confirm the update (C_BOX_xxx.swu) in the dialogue box that opens. The update is uploaded and checked, please wait. BA023001-en...
  • Page 130 When the update has finished uploading, the version number is displayed in the "Name" field. o If the wrong file has been uploaded, another update can be selected by clicking in the input field again. o Once the desired version has been uploaded, click the blue "Update" button. Confirm security prompt.
  • Page 131 10 After a successful update, press the button to restart. 11 The board will now reboot and the update will be applied. This reboot takes a little longer than a normal reboot. NOTICE Do not disconnect the C_BOX from the power supply during the reboot! 12 The update is complete when the configuration page appears in the browser.

  • Page 132: Radio Remote Control Reco S

    11.5 Radio remote control RECO S 11.5.1 Description The RECO S radio remote control is considered to be an "operator's station" and enables presettings to be made in the test bench. In addition, it can also be used to manually start the test rollers, as is required in some countries, especially for truck brake testers.

  • Page 133: Operation

    • Pairing with NFC a. Hold the NFC symbol on the bottom of the back of the remote control against the corresponding symbol on the charging box. If the NFC symbol of the remote control is held again at the symbol on the charging box, the pairing is released again and another remote control can be paired.
  • Page 134 b. Use the Up (˄) and Down (˅) buttons to scroll between functions. The selected symbol can be confirmed by pressing the (ok) key. The function icons are displayed highlighted. If a remote control is logged into the test bench, the <Burger menu> button will be highlighted after a restart and selection of "New Vehicle".
  • Page 135 b. Reverse direction of rotation/measurement Select "Reverse direction of rotation/measurement" in the burger menu using navigation keys Up (˄), Down (˅) and confirm with (ok). (Slide switch in burger menu goes ON.) Single wheel left Select "Single wheel left" in the burger menu using navigation keys Up (˄), Down (˅) and confirm with (ok).
  • Page 136 Pressing the (ok) button switches to the corresponding brake type and assigns the next braking operation to this selection. Exiting the field is possible by pressing the Up (˄) or Down (˅) navigation buttons. BA023001-en...

  • Page 137: Content Of The Declaration Of Conformity

    Content of the declaration of conformity MAHA Maschinenbau Haldenwang GmbH & Co. KG hereby declares as the manufacturer and on its sole responsibility that the design and construction of the product described below comply with the basic safety and health requirements of the EC directives mentioned here.

  • Page 138: Annex

    Annex 13.1 Naming convention BA023001-en...

This manual is also suitable for:

C_mbt c 3.5 w220C_mbt s 3.5 w220C_mbt c 3.5 w250C_mbt s 3.5 w250C_mbt c 4.0 w220C_mbt s 4.0 w220 ... Show all

Table of Contents

Save PDF