MAHA 201 50025/144 Assembly And Maintenance Manual
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MAHA 201 50025/144 Assembly And Maintenance Manual

MAHA 201 50025/144 Assembly And Maintenance Manual

Mobile test containers
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ASSEMBLY-TRANSPORT-
MAINTENANCE MANUAL
Mobile Test Containers
Chassis No.: 201 50025 / 144
201 50026 / 145
Translation of the original German text

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Summary of Contents for MAHA 201 50025/144

  • Page 1 ASSEMBLY-TRANSPORT- MAINTENANCE MANUAL Mobile Test Containers Chassis No.: 201 50025 / 144 201 50026 / 145 Translation of the original German text...

  • Page 3: Table Of Contents

    Assembly Transport Maintenance Manual Mobile Test Containers Table of contents ABOUT THES E INSTRUCTIONS ....................... 7 Manufacturer ....................................8 Technical customer service and spare parts sales ........................8 Purpose, use and data of these instructions ..........................8 1.3.1 Purpose...................................... 8 1.3.2 Application and storage ................................
  • Page 4 Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.14 Check the engine cooling water level..........................35 4.2.1.15 Read operating hours meter ............................36 Shut-down..................................... 37 4.3.1 Up to 12 hours ..................................37 4.3.2 Up to 3 months ..................................37 4.3.3 Longer than 3 months ................................38 Commissioning after shut-down..............................
  • Page 5 Assembly Transport Maintenance Manual Mobile Test Containers 8.6.3 Fuses......................................92 Cleaning and care..................................93 8.7.1 Exterior cleaning ..................................94 8.7.2 Cleaning radiator ..................................95 8.7.3 Interior cleaning ..................................95 8.7.4 Cleaning bearing points................................. 95 Air conditioning..................................... 96 Maintenance schedules and maintenance records........................ 97 8.9.1 Maintenance schedules.................................

  • Page 7: About These Instructions

    Assembly Transport Maintenance Manual Mobile Test Containers About these instructions  This manual is a supplement to the operating manual for Mobile Test Container. It contains important information for the safe and proper assembly of the product, its transportation, maintenance and helps prevent accidents. ...

  • Page 8: Manufacturer

    Assembly Transport Maintenance Manual Mobile Test Containers 1.1 Manufacturer MAHA Maschinenbau Haldenwang GmbH & Co. KG Hoyen 20 D-87490 Haldenwang / Allgäu Telephone: 0049 (0) 8374 / 585-0 Internet: www.maha.de E-Mail: maha@maha.de 1.2 Technical customer service and spare parts sales...

  • Page 9: Data

    Assembly Transport Maintenance Manual Mobile Test Containers 1.3.3 Data Editor: Alexander Schier Technical consultants: Warnings (danger, warning, caution): Andreas Köhler Issue: 04/2014 1.3.4 Accompanying documents In addition, the following documents are also required for complete user information:  Operating manual for test container, ...

  • Page 10: Warnings, Symbols And Abbreviations

    Assembly Transport Maintenance Manual Mobile Test Containers 1.4 Warnings, symbols and abbreviations 1.4.1 Warnings DANGER Failure to observe warnings at this danger level results either in death or most severe (irreversible) injuries. WARNING Failure to observe warnings at this danger level can result in death or most severe (irreversible) injuries. CAUTION Failure to observe warnings at this danger level can result in severe or minor (reversible) injuries.
  • Page 11 Assembly Transport Maintenance Manual Mobile Test Containers General warning symbol Risk of fire Risk of crushing Risk of explosion Hot surface, hot fluid High voltage Fall hazard Slip hazard Toxic substance 11 / 123 MPC_201-50025_ATWA_04.2014...
  • Page 12 Assembly Transport Maintenance Manual Mobile Test Containers No smoking Environmental hazard Wear hearing protection. Wear protective gloves. Wear protective goggles. Wear protective gloves. See supplier documentation, additional instructions available 12 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 13: Abbreviations

    Assembly Transport Maintenance Manual Mobile Test Containers 1.4.3 Abbreviations Fig. Figure Sec. Section if nec. if necessary Chap. Chapter LIMA Alternator max. maximum min. minimum e.g. for example 13 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 14: Technical Terms

    Assembly Transport Maintenance Manual Mobile Test Containers 1.5 Technical terms Operating voltage Electrical voltage at which the unit is powered. Unit General designation for test container Operating temperature Air temperature range in which the unit works trouble-free. Measuring height: Measured 1 metre above the road. End position Extreme position (maximum or minimum lifting) for hydraulic cylinders.

  • Page 15: Basic Safety Instructions

    Assembly Transport Maintenance Manual Mobile Test Containers Basic safety instructions In the different life cycles of the test containers, danger for the personnel or the environment may occur. Refer to the operating manual for safety instructions during operation. Refer to the manufacturer's instructions before making reparations. During assembly of the test containers, during transportation and during maintenance work on the test container the following safety instructions must be strictly observed: ...

  • Page 16: Screw Connections

    Assembly Transport Maintenance Manual Mobile Test Containers 2.5 Screw connections ATTENTION Loose screw connections.  Tighten screw connections with a tested and calibrated torque wrench.  In case of repeated use of key-lock washers, they must be replaced in specified intervals, depending on wear.

  • Page 17: Product Description

    Assembly Transport Maintenance Manual Mobile Test Containers Product description 3.1 General These instructions describe the assembly, transport and maintenance of the test containers. The performance of a vehicle inspection must be carried out according to the EUROSYSTEM CAR or EUROSYSTEM LORRY operating manual.

  • Page 18: Office

    Assembly Transport Maintenance Manual Mobile Test Containers 3.2.2 Office  One-person office,  Floor area of about 2 m  Desk,  Lighting with light switches,  Electrical connections (7x) for PC, etc.  Cashier window,  Door lockable, insulated, including ventilations slits, ...

  • Page 19: Protective Roof

    Assembly Transport Maintenance Manual Mobile Test Containers 3.2.7 Protective roof  Hydraulically extendible and retractable,  Safety support of the lifting roof with hydraulic valve. 3.2.8 Hydraulic supports  Hydraulic supports for the lifting and lowering of the test containers for loading. 3.2.9 Testing equipment Possible test stations*:...

  • Page 20: Emergency Stop Switch

    Assembly Transport Maintenance Manual Mobile Test Containers 3.3 Emergency stop switch To turn off the hydraulic aggregate in emergency situations, the following emergency stop switch (1) is installed in the test container:  on the cable remote control. To switch off the engine aggregate in emergency situations, the following emergency stop switch (2) is installed in the test container: ...

  • Page 21: Fire Protection Parts

    Assembly Transport Maintenance Manual Mobile Test Containers 3.4 Fire protection parts WARNING Fire danger due to missing or damaged fire protection parts.  Check fire protection parts according to maintenance schedule and arrange for repair, if necessary.  Fully assemble all fire protection parts before commissioning. ...

  • Page 23: Commissioning, Decommissioning And Disposal

    Assembly Transport Maintenance Manual Mobile Test Containers Commissioning, decommissioning and disposal WARNING Exploding batteries and corrosive battery acid. Fire, naked light and spark formation can result in explosion of battery.  Avoid fire and spark formation near the batteries.  Observe battery manufacturer's safety instructions. ...
  • Page 24 Assembly Transport Maintenance Manual Mobile Test Containers CAUTION Burns due to hot light bulbs and lamp sockets.  Before replacement, allow light bulb to cool down to approx. 30 °C / 86 °F (lukewarm). 3.7A ATTENTION Environmental pollution. Service fluids can leak into the ground. ...

  • Page 25: Initial Commissioning

    Assembly Transport Maintenance Manual Mobile Test Containers 4.1 Initial commissioning ATTENTION Damage to engine with attached parts due to incorrect operation and maintenance.  Engine manufacturer's operating instructions must be strictly observed. 4.38 Activity  Check the test container for any possible transport damage. ...

  • Page 26: Activities And Checks

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2 Activities and checks The following action items can be performed by trained and authorised operating personnel (see operating manual). Maintenance tasks and the filling of hydraulic oil must be performed by trained and authorized maintenance personnel. Additional daily checks are to be performed by maintenance personnel according to the maintenance schedule (Sec.

  • Page 27: Connecting The Cable Remote Control

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.3 Connecting the cable remote control The cable remote control plug (X12) is inserted into the ENGINE aggregate room.  Insert the cable remote control plug (X12) into the plug socket (X12). MPC_50025_BA05_016 Fig.

  • Page 28: Connect The Internal Supply Power Cable (J31)

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.4 Connect the INTERNAL SUPPLY power cable (J31) The INTERNAL SUPPLY power cable (J31) is plugged into the ENGINE aggregate room  Insert the INTERNAL SUPPLY power cable plug (J31) into the plug socket (1). MPC_50025_BA04_006 Fig.

  • Page 29: Fuel Level

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.5 Fuel level WARNING Flammable fuel. Fire, naked light and spark formation can lead to fuel ignition.  Never start a fire and prevent spark formation in the immediate area around fuel tank, lines, filter, auxiliary heating and open fuel.
  • Page 30 Assembly Transport Maintenance Manual Mobile Test Containers Fuel tank The fuel tank (1) is located in the ENGINE aggregate room underneath the generator. Check  Open filler cap (2).  Check fuel reserve.  If necessary, add fuel. Refilling  Clean the filler cap (2) and the area around the filler opening ...

  • Page 31: Engine Oil Filling Level

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.6 Engine oil filling level CAUTION Risk of serious burns from hot parts.  Pay attention to radiant heat.  Allow parts to cool down to approx. 30 °C / 86 °F (lukewarm) before touching them. 3.10B ATTENTION Filling levels that are too high or too low can cause malfunctions and damage parts in the motor and the...

  • Page 32: Hydraulic Oil Fill Level On Hydraulic Tank

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.7 Hydraulic oil fill level on hydraulic tank The hydraulic oil tank (1) is located in the HYDRAULIC aggregate room. Requirements:  Support legs are retracted,  Oil temperature: 20 °C / 68 °F. Check ...

  • Page 33: Tightness Of Hydraulic System

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.8 Tightness of hydraulic system WARNING Flammable hydraulic oil. Escaping hydraulic oil can ignite if it comes into contact with other hot parts (e.g. exhaust system, engine) and cause a fire.  Stop immediately in case of loss of hydraulic engine oil. ...

  • Page 34: Lighting System

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.10 Lighting system CAUTION Burns due to hot light bulbs and lamp sockets.  Before replacement, allow light bulb to cool down to approx. 30 °C / 86 °F (lukewarm). 3.7A Check  All components for damage, function and cleanliness. ...

  • Page 35: Check The Engine Cooling Water Level

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.14 Check the engine cooling water level CAUTION Scalding due to hot coolant. When opening the coolant expansion reservoir, hot coolant can escape.  Coolant hoses can burst due to excessive engine temperatures. ...

  • Page 36: Read Operating Hours Meter

    Assembly Transport Maintenance Manual Mobile Test Containers 4.2.1.15 Read operating hours meter  Engine start.  Read operating hours on operating hours counter (1). MPC_50025_BA04_005 Fig. 15: Read operating hours meter 36 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 37: Shut-Down

    Assembly Transport Maintenance Manual Mobile Test Containers 4.3 Shut-down ATTENTION Damage to engine with attached parts due to incorrect operation and maintenance.  Engine manufacturer's operating instructions must be strictly observed. 4.38 4.3.1 Up to 12 hours WARNING Test container spills during unilateral lowering of leaking supports. ...

  • Page 38: Longer Than 3 Months

    Assembly Transport Maintenance Manual Mobile Test Containers 4.3.3 Longer than 3 months  Operate test container for short periods in intervals of max. 6 weeks.  Perform same operating steps as in Sec. 4.3.2. In addition:  Remove batteries or connect to special battery charger with trickle charge (ask manufacturer). ...

  • Page 39: Commissioning After Shut-Down

    Assembly Transport Maintenance Manual Mobile Test Containers 4.4 Commissioning after shut-down ATTENTION Additional documents are available for operation and maintenance.  The manufacturer's operating instructions must be strictly adhered to. 4.42A  See Sec. 4.1 and Sec. 4.2. 4.5 Disposal of components WARNING Exploding batteries and corrosive battery acid.

  • Page 41: Controls

    Assembly Transport Maintenance Manual Mobile Test Containers Controls The test container controls are explained and shown in this chapter. 5.1 Cable remote control MPC_50025_BA05_001 Fig. 16: Cable remote control Position Symbol Designation Function Description Switch EMERGENCY Switching on STOP  Press EMERGENCY STOP switch (1). ...
  • Page 42 Assembly Transport Maintenance Manual Mobile Test Containers Position Symbol Designation Function Description Pilot light DOWN-TIME DOWN-TIME pilot light (2) lights up during the following malfunctions:  Incorrect torsion spring,  Lack of oil in the hydraulic aggregate,  HYDRAULIC AGGREGATE motor protection switch has tripped.
  • Page 43 Assembly Transport Maintenance Manual Mobile Test Containers Position Symbol Designation Function Description Switch EXTEND RAMPS  Select retracting ramp with RAMP LEFT / RIGHT switch (8).  Press and hold EXTEND RAMPS switch (10).  Selected ramp are extended. MPC_50025_BA05_010 Switch EXTEND LIFTING ...
  • Page 44 Assembly Transport Maintenance Manual Mobile Test Containers During the transport from the test container, the cable remote control is in the ENGINE aggregate room (1). MPC_50025_BA05_014 Fig. 17: ENGINE aggregate room (1) 44 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 45: Engine Aggregate Room

    Assembly Transport Maintenance Manual Mobile Test Containers 5.2 Engine aggregate room Position Designation Internal power supply connector / cable ENGINE AGGREGATE main switch Plug socket / cable remote control plug MPC_50025_BA05_015 Fig. 18: ENGINE aggregate room MPC_50025_BA05_016 Fig. 19: ENGINE aggregate room 45 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 46: Turn On / Off Engine Aggregate Main Switch (Q1)

    Assembly Transport Maintenance Manual Mobile Test Containers 5.2.1 Turn on / off ENGINE AGGREGATE main switch (Q1) ATTENTION Damage to electrical system due to incorrect disconnection sequence. Sequence:  Stop engine.  Switch off ignition.  Turn off the BRAKES TEST STAND main switch (S32). ...

  • Page 47: Hydraulics Aggregate Room

    Assembly Transport Maintenance Manual Mobile Test Containers 5.3 Hydraulics aggregate room Position Designation Hydraulic oil drain screw HYDRAULICS aggregate room MPC_50025_BA05_023 Fig. 22: Hydraulic oil drain screw (1) MPC_50025_BA08_002 Fig. 23: HYDRAULICS aggregate room 47 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 48: Office

    Assembly Transport Maintenance Manual Mobile Test Containers 5.4 Office Position Designation AIR CONDITIONING remote control BRAKES TEST STAND main switch MPC_50025_BA05_019 Fig. 24: BRAKES TEST STAND main sw itch (S32) 48 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 49: Brakes Test Stand Main Switch (S32)

    Assembly Transport Maintenance Manual Mobile Test Containers 5.4.1 BRAKES TEST STAND main switch (S32) ATTENTION Damage to electrical system due to incorrect disconnection sequence. Sequence:  Stop engine.  Switch off ignition.  Turn off the BRAKES TEST STAND main switch (S32). ...

  • Page 50: Air Conditioning

    Assembly Transport Maintenance Manual Mobile Test Containers 5.4.2 Air conditioning* CAUTION Contact with refrigerant of air conditioning could cause eye injuries or frostbite. Toxic gasses (phosgene) are generated when refrigerant comes in contact with fire.  Wear protective goggles when performing work on air conditioning system. ...
  • Page 51 Assembly Transport Maintenance Manual Mobile Test Containers  The air conditioning (1) is mounted on the office roof.  The AIR CONDITIONING system remote control (2) hangs in the office next to the BRAKES TEST STAND main switch (S32). MPC_50025_BA05_018 Fig.

  • Page 52: Electrical Switchbox

    Assembly Transport Maintenance Manual Mobile Test Containers 5.5 Electrical switchbox Position Designation Electrical switchbox Switch box BOX 10 - main fuse Fig. 29: Electrical sw itchbox 52 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 53: Emergency Stop Switch

    Assembly Transport Maintenance Manual Mobile Test Containers 5.6 Emergency stop switch Position of emergency stop switches:  EMERGENCY STOP switch (1) on the cable remote control  EMERGENCY STOP switch (2) on the control panel in the ENGINE aggregate room. EMERGENCY STOP switch (1).

  • Page 54: Signage

    Assembly Transport Maintenance Manual Mobile Test Containers 5.7 Signage WARNING Unmarked hazard sources. Hazards might not be noticed in time due to missing or illegible labels.  Keep labels clean and legible.  Replace missing or illegible warning signs with new ones. 2.27E 54 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 55: Assembly / Dismantling

    Assembly Transport Maintenance Manual Mobile Test Containers Assembly / dismantling WARNING Toxic exhaust vapours and exhaust dust from engines.  When the engine is running in closed rooms, place the hose from the exhaust outside.  Keep distance to exhaust pipe. 2.1D WARNING Inhalation of exhaust and fuel fumes.
  • Page 56 Assembly Transport Maintenance Manual Mobile Test Containers CAUTION Hearing loss can be caused by noise sources with a noise level of more than 80 dB(A).  Wear hearing protection when engine is running.  Observe technical data regarding vehicle acoustics. 3.25D CAUTION Hot hydraulic oil.

  • Page 57: Loaded Test Container

    Assembly Transport Maintenance Manual Mobile Test Containers Loaded test container WARNING Damage caused to persons or property by falling, loose objects.  Before loading stow or completely remove any loose objects in the test container.  Remove snow and ice from the lifting roof. Do not step onto the lifting roof. 2.273 WARNING Risk of falling when working on the lifting roof and on the air conditioning.

  • Page 58: Lifting Points

    Assembly Transport Maintenance Manual Mobile Test Containers 6.1.1.1 Lifting points The test container is equipped with 4 lifting points (1).  Insert crane hooks into all 4 lifting points (1).  Crane hooks must be positioned vertically above SNr 107344-A attachment points (1).

  • Page 59: Loading With Support Legs

    Assembly Transport Maintenance Manual Mobile Test Containers 6.1.2 Loading with support legs Requirements:  Test container is dismantled.  Place of loading / dismantling of the test container is flat.  Load-bearing capacity of the ground is guaranteed.  Lifting and lowering range of the test container is free from obstacles.
  • Page 60 Assembly Transport Maintenance Manual Mobile Test Containers ATTENTION Damage to engine with attached parts due to incorrect operation and maintenance.  Engine manufacturer's operating instructions must be strictly observed. 4.38  Turn off all EMERGENCY STOP switches.  Turn and pull EMERGENCY STOP switch (15). ...
  • Page 61 Assembly Transport Maintenance Manual Mobile Test Containers  Connect the INTERNAL SUPPLY (J31) power cable (Sec. 4.2.1.4).  Turn on the ignition on the ignition lock (16).  Press start button (17).  Engine is started.  Wait until the frequency (18) has adjusted to 50 Hz. 16 17 MPC_50025_BA06_016 Fig.
  • Page 62 Assembly Transport Maintenance Manual Mobile Test Containers  Push the polyamide slide (19) up the suspension.  Unlock suspension (20) with LOCKING DEVICE (21) handle.  Swivel out suspension about 90°.  Lock suspension (20) with LOCKING DEVICE handle (21). ...
  • Page 63 Assembly Transport Maintenance Manual Mobile Test Containers  Remove locking device ramps (24) on both ramps (2 locking devices per ramp = 4 locking devices per side). MPC_50024_BA06_006 Fig. 44: Remove locking device ramps (24)  Push the polyamide slide (19) up the suspension. ...

  • Page 64: Transport

    Assembly Transport Maintenance Manual Mobile Test Containers 6.2 Transport DANGER Test container tilting or shifting while driving. In the event of an incorrect attachment no centring and locking device between test container and vehicle is possible.  Only drive with locked test container. ...

  • Page 65: Unloading / Assembly

    Assembly Transport Maintenance Manual Mobile Test Containers 6.3 Unloading / assembly ATTENTION Technical defects can cause damage to the test container.  Have technical defects repaired before commissioning. Requirements:  Place of loading / assembly of the test container is flat. ...
  • Page 66 Assembly Transport Maintenance Manual Mobile Test Containers ATTENTION Damage to engine with attached parts due to incorrect operation and maintenance.  Engine manufacturer's operating instructions must be strictly observed. 4.38  Turn off all EMERGENCY STOP switches.  Turn and pull EMERGENCY STOP switch (1). ...
  • Page 67 Assembly Transport Maintenance Manual Mobile Test Containers  Connect the INTERNAL SUPPLY (J31) power cable (Sec. 4.2.1.4).  Turn on the ignition on the ignition lock (16).  Press start button (17).  Engine is started.  Wait until the frequency (18) has adjusted to 50 Hz. ...
  • Page 68 Assembly Transport Maintenance Manual Mobile Test Containers  Push the polyamide slide (19) up the suspension.  Unlock suspension (20) with LOCKING DEVICE (21) handle.  Swivel out suspension about 90°.  Lock suspension (20) with LOCKING DEVICE handle (21). ...
  • Page 69 Assembly Transport Maintenance Manual Mobile Test Containers  Unlock ramps plate (20) from the outside.  Extend ramps plate (20) upwards and set to one side.  Dismantle ramps plates (20) on both sides. MPC_50024_BA06_007 Fig. 58: Ramps plate (20) ...
  • Page 70 Assembly Transport Maintenance Manual Mobile Test Containers  Per side, have each of the 4 plastic rollers (25) and 4 folding split pins (26) readily available.  Assemble the plastic rollers (25) and secure with folding split pins (26). MPC_50024_BA06_008 Fig.
  • Page 71 Assembly Transport Maintenance Manual Mobile Test Containers ATTENTION Damage to the ramps, when ramps are not resting on the floor.  Take off plastic rollers.  Comply with the maximum angle of -3° between the longitudinal beam and ramp. 4.127 2.
  • Page 72 Assembly Transport Maintenance Manual Mobile Test Containers  Extend all 3 spindle supports (30) down to the ground. Required Toolkit (31):  1x socket SW30,  1x extension,  1x ratchet. MPC_50024_BA06_013 Fig. 67: Extend spindle support (30). MPC_50024_BA06_014 Fig. 68: Spindle support (30) extended. ...
  • Page 73 Assembly Transport Maintenance Manual Mobile Test Containers  Turn the ENGINE AGGREGATE main switch (S31) to position (0)  ENGINE AGGREGATE main switch (S31) is turned off. MPC_50025_BA05_021 Fig. 71: ENGINE AGGREGATE main sw itch (S31) is in the OFF position 73 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 74: Dismantlement

    Assembly Transport Maintenance Manual Mobile Test Containers 6.4 Dismantlement The dismantlement of the test container is performed in the reverse order of assembly. 74 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 75: Operation During Extreme Operating Temperatures

    Assembly Transport Maintenance Manual Mobile Test Containers 6.5 Operation during extreme operating temperatures The units have been approved by the manufacturer for a specified operating temperature range (see Technical data). Outside of this temperature range, there is no operating permit from the manufacturer. ATTENTION Damage to engine with attached parts due to incorrect operation and maintenance.

  • Page 77: Trouble Shooting Support

    Assembly Transport Maintenance Manual Mobile Test Containers Trouble shooting support The purpose of the following information on possible vehicle malfunctions is to help you find and eliminate the source of the malfunction. If the malfunction support does not provide the needed help, we ask you to contact our customer service. Telephone: Central office 0049 (0)731 4098-0...

  • Page 78: Lifting Roof Not Working

    Assembly Transport Maintenance Manual Mobile Test Containers 7.1.2 Lifting roof not working Malfunction Possible cause Measures Operator Cable remote control Cable remote control not plugged in Insert cable remote control into plug without function (X12) (ENGINE aggregate room) EMERGENCY STOP switch (1) is EMERGENCY STOP switch (1) is turned turned on off.

  • Page 79: Engine

    Assembly Transport Maintenance Manual Mobile Test Containers 7.1.7 Engine ATTENTION Damage to engine with attached parts due to incorrect operation and maintenance.  Engine manufacturer's operating instructions must be strictly observed. 4.38 Malfunction Possible cause Measures Operator ENGINE AGGREGATE main switch Turn off the ENGINE AGGREGATE main Engine does not start (S31) is turned off,...

  • Page 81: Maintenance

    Repair work, during and after the warranty period, must therefore be coordinated with MAHA-customer service. Repairs on the test container must be performed by MAHA or by a specialist company approved by MAHA. WARNING Toxic exhaust vapours and exhaust dust from engines.
  • Page 82 Assembly Transport Maintenance Manual Mobile Test Containers CAUTION Injuries to eyes and burns due to hot oil during oil change.  Allow oil to cool down to approx. 30°C / 86 ° F (lukewarm oil sump / tank) before performing oil change.

  • Page 83: Hose Lines

    Assembly Transport Maintenance Manual Mobile Test Containers 8.1 Hose lines WARNING Defective hose lines. Hydraulically or pneumatically controlled functions can fail due to leaking, damaged or aged hose lines.  Check hose lines for damage and tightness according to maintenance schedule. ...

  • Page 84: Welds

    Assembly Transport Maintenance Manual Mobile Test Containers 8.2 Welds ATTENTION Flying sparks from welding or grinding cause damage to chromed surfaces.  During welding or grinding jobs, properly protect chromed surfaces (piston rods of hydraulic cylinders) against flying sparks. 4.29 ATTENTION During welding jobs, electrical and electronic components can get damaged.

  • Page 85: Hydraulic System

    Assembly Transport Maintenance Manual Mobile Test Containers 8.4 Hydraulic system WARNING Injuries to eyes and skin due to escaping hydraulic oil. Leaks or repairs to the hydraulic system can result in hydraulic oil escaping into the environment under high pressure. ...

  • Page 86: Replacing Hydraulic Oil

    Assembly Transport Maintenance Manual Mobile Test Containers 8.4.1 Replacing hydraulic oil The HYDRAULIC OIL drain screw (1) is located in the HYDRAULIC aggregate room (2) at the bottom of the hydraulic tank.  Open HYDRAULIC OIL drain screw (1).  Completely drain hydraulic oil. ...

  • Page 87: Replace Hydraulic Filter

    Assembly Transport Maintenance Manual Mobile Test Containers 8.4.2 Replace hydraulic filter The hydraulic filter (1) is located in the HYDRAULIC aggregate room (2).  Clean area surrounding hydraulic filter (1).  Take off cover (3) of the hydraulic filter (1). ...

  • Page 88: Lubrication

    Assembly Transport Maintenance Manual Mobile Test Containers 8.5 Lubrication 8.5.1 Ramps cylinder  Take off cover plates (1).  Lubricate ramp cylinder with grease nipple.  Lubricate the bearing eye of the ramps cylinder.  Put on cover plates (1). MPC_50025_BA08_001 Fig.

  • Page 89: Electrical System

    Assembly Transport Maintenance Manual Mobile Test Containers 8.6 Electrical system DANGER Electrical high voltage!  Check all electrical connections for damage before grid operation.  Replace damaged electrical connections before mains operation.  Keep electrical connections dry and clean.  Separate electrical connections from the test container after grid operation. ...

  • Page 90: Battery

    Assembly Transport Maintenance Manual Mobile Test Containers 8.6.2 Battery The battery (2) is located in the ENGINE aggregate room (1) on the left side. Charge battery (2):  Use the battery charging device according to the charger manufacturer operating instructions. ...
  • Page 91 Assembly Transport Maintenance Manual Mobile Test Containers WARNING Exploding batteries and corrosive battery acid. Fire, naked light and spark formation can result in explosion of battery.  Avoid fire and spark formation near the batteries.  Observe battery manufacturer's safety instructions. ...

  • Page 92: Fuses

    Assembly Transport Maintenance Manual Mobile Test Containers 8.6.3 Fuses ATTENTION Incorrect or repaired electric fuses and automatic circuit breakers. During replacement of fuses and automatic circuit breakers, spark formation and cable fire can occur.  Before working on electrical fuses and automatic circuit breakers, disconnect all electrical loads. ...

  • Page 93: Cleaning And Care

    Assembly Transport Maintenance Manual Mobile Test Containers 8.7 Cleaning and care ATTENTION Environmental pollution. Service fluids can leak into the ground.  Collect service fluids in a suitable tank.  Absorb spilled fluids with binding agent.  Dispose of service fluids, filters and binding agents in an environmentally sound manner. ...

  • Page 94: Exterior Cleaning

    Assembly Transport Maintenance Manual Mobile Test Containers 8.7.1 Exterior cleaning Dirt and de-icing salt damage components and painting.  Park test container in a suitable washing area with oil separator.  Stop engine.  Turn off the BRAKES TEST STAND main switch (S32).

  • Page 95: Cleaning Radiator

    Assembly Transport Maintenance Manual Mobile Test Containers 8.7.2 Cleaning radiator ATTENTION Damage to radiator fins Compressed air or water jet cause damage to radiator fins  Point compressed air, water or steam jet on radiator at right angle. Dirty radiator fins impair the cooling capacity. The radiator fins must be free from dirt.

  • Page 96: Air Conditioning

    Assembly Transport Maintenance Manual Mobile Test Containers 8.8 Air conditioning WARNING Risk of falling when working on the lifting roof and on the air conditioning. The lifting roof is not accessible!  Use suitable scaffolding or a hydraulic ramp to work on the lifting roof. 2.274A CAUTION Contact with refrigerant of air conditioning could cause eye injuries or frostbite.

  • Page 97: Maintenance Schedules And Maintenance Records

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9 Maintenance schedules and maintenance records 8.9.1 Maintenance schedules It is imperative that maintenance work on engine is performed according to manufacturer's specifications, and is therefore considered only in part in the following maintenance schedules. ATTENTION Damage to engine with attached parts due to incorrect operation and maintenance.

  • Page 98: Activities Prior To Maintenance Work

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.2 Activities prior to maintenance work Requirements:  Test container is parked on level, solid subsoil.  Environment is clean and free from dust,  Test container is secured from access by unauthorized persons, ...

  • Page 99: Maintenance Work - One-Off After 50 Operating Hours

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.4 Maintenance work - one-off after 50 operating hours Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded. ...

  • Page 100: Maintenance Work After 50 Operating Hours Or Weekly

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.5 Maintenance work after 50 operating hours or weekly Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded. ...

  • Page 101: Maintenance Work After Every 500 Operating Hours

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.6 Maintenance work after every 500 operating hours Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded.  In addition to maintenance work after 50 operating hours, perform the following weekly maintenance work. Serial number / VIN: Type: Operating hours:...

  • Page 102: Maintenance Work Every 1,000 Operating Hours Or Bi-Annually

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.7 Maintenance work every 1,000 operating hours or bi-annually Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded. ...

  • Page 103: Maintenance Work Every 2,000 Operating Hours Or Annually

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.8 Maintenance work every 2,000 operating hours or annually Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded. ...

  • Page 104: Maintenance Work Every 3,000 Operating Hours Or Every 2 Years

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.9 Maintenance work every 3,000 operating hours or every 2 years Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded. ...

  • Page 105: Maintenance Work After Every 4,000 Operating Hours

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.10 Maintenance work after every 4,000 operating hours Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded.  In addition to maintenance work after 3,000 operating hours, perform the following maintenance. Serial number / VIN: Type: Operating hours:...

  • Page 106: Maintenance Work Every 6,000 Operating Hours Or Every 3 Years

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.11 Maintenance work every 6,000 operating hours or every 3 years Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded. ...

  • Page 107: Maintenance Work Every 12,000 Operating Hours Or Every 6 Years

    Assembly Transport Maintenance Manual Mobile Test Containers 8.9.1.12 Maintenance work every 12,000 operating hours or every 6 years Warranty claims can only be asserted if the following maintenance records have been kept without interruption. The serial number / VIN must be recorded. ...

  • Page 109: Technical Data And Service Fluids

    Assembly Transport Maintenance Manual Mobile Test Containers Technical data and service fluids 9.1 Technical data All data refer to maximum specifications. Dimensions are subject to toleranced dimensions. For technical data of the floor assembly, see the EURO SYSTEM CAR and LORRY operating manual. Dimensions Length [mm]...
  • Page 110 Assembly Transport Maintenance Manual Mobile Test Containers Metal sheeting Bulb plate, EN 10025 S235JRG2, thickness 5 mm +1 up to 2 mm water height Sanded drive-on ramps Voltage supply Voltage supply 3 x 380 V, 50 Hz Grid connection or built-in electric generator Overload and surge protection Climatic conditions Ambient temperature...

  • Page 111: Service Fluids - Filling Levels

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2 Service fluids – filling levels WARNING Toxic service fluids. Hydraulic oil, fuel, coolant, motor oil, lubrication grease, and transmission oil are chemical products that can cause harm to organs when coming in contact with eyes or if swallowed. ...

  • Page 112: Fuel

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2.1 Fuel ATTENTION Different fuel qualities and dirt in fuel system. Increased sulphur content in fuel reduces intervals for engine oil changes.  Observe engine operating instructions.  Only use fuels approved by the engine manufacturer. That applies in particular to biodiesel. ...

  • Page 113: Engine Oil

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2.2 Engine oil ATTENTION Engine damage due to wrong engine oil or too long of intervals between oil changes.  Strictly observe engine manufacturer's instructions on filling levels, oil quality and change intervals. ...

  • Page 114: Coolant

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2.3 Coolant ATTENTION Use of incorrect antifreeze, insufficient coolant concentration or mixing different antifreezes together can cause component damage to the engine and cooling system.  Use coolant in specified mixing ratio with fresh water in cooling system year-round. ...

  • Page 115: Mixing Ratios

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2.3.1 Mixing ratios Antifreezer [%] Fresh water [%] Protection against cold [°C] / [°F] Min. 35 -22 / -7.6 -28 / -18.4 -35 / -31 Max. 50 -41 / -41.8 To fulfil its protective function, the antifreeze content in the coolant may not be above or below the value specified in the table.

  • Page 116: Lubricant

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2.4 Lubricant ATTENTION Bearing damage due to the use of incorrect lubricant or the mixing of different lubricants. Cleaning with a high-pressure cleaner can flush the grease out of the bearing points.  Use lubricant filled in by manufacturer in the factory (refer to Service fluids). ...

  • Page 117: Hydraulic Oil

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2.5 Hydraulic oil ATTENTION Parts damage on hydraulic components due to insufficient filtering or incorrect hydraulic oil or mixed hydraulic oils. Original filter elements and filter cartridges ensure optimal filtration.  Use original manufacturer spare parts. ...

  • Page 118: Oil Analysis

    Assembly Transport Maintenance Manual Mobile Test Containers Factory-filled hydraulic oils are specified in the spare parts catalogue. Vehicles with hydrostatic drive systems can be filled with several different hydraulic oils for the drive system, steering and suspension. 9.2.5.1 Oil analysis The oil change interval of the hydraulic oil can be extended by an oil analysis.

  • Page 119: Hydraulic Oil Hydraulic Aggregate

    Assembly Transport Maintenance Manual Mobile Test Containers 9.2.6 Hydraulic oil hydraulic aggregate Specification / standard Filling ex factory Material No. DIN 51524 T3 HVI ISO VG 32 See spare parts catalogue 9.2.7 Refrigerant air conditioning* Specification / standard Filling ex factory Material No.

  • Page 120: Tightening Torque For Screw Connections

    Assembly Transport Maintenance Manual Mobile Test Containers 9.3 Tightening torque for screw connections Use these tightening torques only if maintenance and supplier documentation as well as spare parts catalogue contain no other tightening torques. Strength class Metric Surface 10.9 12.9 thread lb inch lb inch...

  • Page 121: Circuit Diagrams

    Assembly Transport Maintenance Manual Mobile Test Containers 10 Circuit diagrams 121 / 123 MPC_201-50025_ATWA_04.2014...

  • Page 123: Supplier Documentation

    Assembly Transport Maintenance Manual Mobile Test Containers 11 Supplier documentation 123 / 123 MPC_201-50025_ATWA_04.2014...

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