MAHA SA 2 Euro Operation & Maintenance Manual Download Page 117

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Eurosystem / Profi-LON

Maintenance / Troubleshooting

5.6

D1 E101BA1-GB09

5.5 Troubleshooting

5.5.1

Shock Absorber Tester / Suspension Tester

Description

Cause

Remedy

Shock absorber tester will not start up.

Shock absorber tester occupied when being
started.

Turn off main switch.
Remove vehicle from test stand.
Turn on main switch again.

5.5.2

General / Brake Tester

Description

Cause

Remedy

READY lamp does not light up after test stand has been switched on.

No power supply

Restore power supply.

Fuse defective.

Contact service.

Lamp defective

Contact service.

Roller set will not start up. Error code 32 / 33 / 34.

Protective motor switches off and/or
defective.

Contact service.

One roller set side starts up and switches off again.

RPM signal missing, proximity switch
defective, protective motor switch on one
side off.

Switch on protective motor switch.
Contact service.

Measurement values not correct.

Zero point / amplification not correct.

Contact service to recalibrate test stand.

No screen display.

Display switched off.

Switch on display.

Cable connection OK?

Check cable.

Summary of Contents for SA 2 Euro

Page 1: ...D1 E101BA1 GB09 Test Lane Eurosystem Profi LON for cars and vans Roller Brake Tester Shock Absorber Tester Side Slip Tester Operation Maintenance Manual English...

Page 2: ...ice These instructions are intended for users with previous technical knowledge in the field of vehicle testing technology as well as basic computer knowledge and MS Windows operating system applicati...

Page 3: ...2 2 7 Combining the MAHA Test Lane with Accessories 2 3 2 8 Spare Parts 2 3 2 9 Safety Features 2 3 2 9 1 Emergency Off Optional 2 3 2 9 2 Lockable Main Switch 2 3 2 9 3 Sensor Rollers Brake Tester 2...

Page 4: ...mer to Vehicle 4 17 4 3 3 Taking Customers into the Queue 4 18 4 3 4 Display Load Customer Data 4 19 4 3 5 Change Expand Update Customer Data 4 20 4 3 6 Delete Customer Data 4 20 4 4 Re Display of Mea...

Page 5: ...4 8 7 4 Gas Test with Eurogas Module 4 68 4 9 Section Office 4 72 5 Maintenance Troubleshooting 5 1 5 1 Shock Absorber Tester Suspension Tester 5 1 5 2 Roller Brake Tester 5 2 5 3 Side Slip Tester 5...

Page 6: ...the use of chip cards Profi LON The safety test lane Profi LON uses modular design and is partly expandable The following function groups are standard equipment Side slip tester Shock absorber tester...

Page 7: ...ed out by every skilled and qualified employee All important data on the harddisk must be backed up before the update MAHA accepts no liability for lost data 1 5 Noise Emission The noise emission duri...

Page 8: ...ne Profi LON is equipped with a multifunctional analogue display The recorded measurement values are displayed at the same moment that the test is done and remain on the display for a certain time 1 I...

Page 9: ...ous measurement values digitally Positions of the LCD displays Measurement values Wheel weight left right if weighing device in the roller set Axle weight centre 1 7 Test Lane Floor Assemblies Functio...

Page 10: ...heel position Red 16 m km Not OK There are no official limit values for side slip The measured values must therefore be interpreted by the inspector The sides slip values are displayed on the left han...

Page 11: ...cle wheels are induced via the test plates The oscillations run through various frequency ranges The reaction of the tire shock absorber functional group to these oscillations is recorded Amplitude Ev...

Page 12: ...and functions in the final evaluation vary from the standard version These variations are explained in section 3 Operation 4 Wheel Drive Mode Optional This mode means that vehicles with a rigid 4 whee...

Page 13: ...W 2 x 4 kW 2 x 4 kW oder 2 x 5 5 kW Test speed 5 km h Measurement range 0 6 kN 0 6 kN oder 0 12 kN Display accuracy 3 of measurement range end value 2 difference between left and right hand side Track...

Page 14: ...rocedure with storage is conducted automatically The complete operation of the test lane can be done using the PC A remote control simply makes usage more convenient e g for test reruns from inside th...

Page 15: ...matically measures the applied force and transmits it to the test stand The pedal force meter is required for brake testing on 4 wheel drive vehicles 1 10 Printer Various printers can be connected to...

Page 16: ...letely complied with can lead to equipment damage Notes provide additional information Safety information is provided to warn about dangerous situations and help prevent damage to equipment and injury...

Page 17: ...ined qualified electricians 1 Before doing any repair maintenance set up work turn off the main switch and secure it against tampering 2 5 Attention When the vehicle is on the brake tester roller set...

Page 18: ...may not be operated when the safety features are defective 2 9 1 Emergency Off Optional Is used for quick switch off during operation Interrupts the power supply to the MAHA safety test lane Eurosyste...

Page 19: ...Eurosystem Profi LON Safety 2 4 D1 E101BA1 GB09...

Page 20: ...the multifunctional display or printed out They remain stored only until the main switch is turned off In most cases the function groups floor assemblies are arranged as follows Side slip tester Shock...

Page 21: ...ve test lane optional Before switching on the test lane it should be visually inspected for satisfactory condition No vehicle may be on the test lane 3 2 1 Switching on the Test Lane 1 Switch on Turn...

Page 22: ...ibed in point 5 if an additional weighing device is integrated in the brake tester 3 Weight display Axle weight is displayed once vehicle is on test plates Example left display indicates 32 or Mm and...

Page 23: ...brake tester correctly a Wait until both rollers are running and the READY lamp lights up b Drive vehicle forward off roller set 2 Repeat test with rear axle Conduct test as described above for front...

Page 24: ...ce gear shift to neutral 1 Wheel must be straight and in centre on test plate to avoid measuring errors especially important when test lane is equipped with FWT suspension tester Wheel to be tested mu...

Page 25: ...eder aktiviert werden Press key of remote control 7 Ovality test if desired See section 3 4 Ovality Test 8 Brake test a Slowly push down brake pedal until rollers switch off at preset slip b Release b...

Page 26: ...ion 3 2 3 11 End Measurement vehicle no longer on the roller set Press the Auto Off key of the remote control The test automatically does the final evaluation IFB3 Profi LON IFB3 Profi Eurosystem Auto...

Page 27: ...Off key on remote control Test stand automatically conducts final evaluation IFB3 Profi LON IFB3 Profi Eurosystem Auto Off key 2 The final evaluation is displayed and can be printed out Measurement va...

Page 28: ...values in kN Press key for axle in question and digit key 1 3 Wheel weight in kg Press key for axle in question and digit key 2 If brake tester is equipped with an additional weighing device weight is...

Page 29: ...cle weight using remote control A vehicle weight of e g 1380 kg is entered with the digit keys 1 3 8 0 Left hand pointer goes to 1 38 kN corresponds with 1380 kg If the wrong weight was entered use th...

Page 30: ...ifference between highest and lowest pointer value is the ovality in kN 3 4 2 Ovality Test with Remote Control 1 Drive onto roller set with desired axle 2 Apply brakes with average force approx 1 kN v...

Page 31: ...properly switched on paragraph 3 2 1 and ready for testing the test procedure can proceed 1 Select single wheel test Select desired vehicle side This setting can be done either before or after drivin...

Page 32: ...otor off c Motor on Once test lane is ready section 3 2 1 proceed as follows 1 Activate single wheel measurement Press any Motor Off key on remote control 2 Pre select single wheel test Press Motor On...

Page 33: ...ws 1 Prepare noise investigation Use single wheel switch to select the desired side 2 Drive onto test plate Test plate on selected side will vibrate until switched off with single wheel switch left ri...

Page 34: ...control Left pointer moves from zero position of side slip tester if present to zero position of shock absorber tester Lamps of analog display blink briefly for confirmation 2 Noise investigation Driv...

Page 35: ...Wheel Drive A distinction is made between rigid and Visco 4 wheel drives Visco 4 wheel drives are subdivided again into hard and soft drives Before brake test is done connect cable of pedal force met...

Page 36: ...right roller set rotates reverse READY lamp lights up when brake test can be started b Slowly apply brake pedal until rollers switch off Roller drive switches off at preset slip Slip is not reached If...

Page 37: ...Store measurement values Measurement values must be allocated to respectively tested axles Press appropriate keys on remote control Vehicle must be on roller set in order to store If vehicle is lifted...

Page 38: ...t a Select left roller set using Motor On key on remote control Selected left roller set will be blocked READY lamp lights up when test can begin b Put in gear and slowly drive off roller set With a p...

Page 39: ...Eurosystem Profi LON Profi LON Operation 3 20 D1 E101BA1 GB09...

Page 40: ...iption follows The operating instructions guide the user through the automatic testing procedure The screens are shown as they appear in the course of the program A detailed step by step explanation i...

Page 41: ...ata recording will be automatically started at the same time It is possible to intervene at any time in the automatic procedure if measurements are wrong or not correctly filed The description of the...

Page 42: ...ted by mouse click and by pressing the appropriate key on the keyboard Touchscreens offer additional operational possibilities which are particularly user friendly Escape key The Escape key is used to...

Page 43: ...ntly depending on the usage The detailed function key description follows later Backspace Return Delete Deletes the character which was entered last or changes to the previous menu point This key is i...

Page 44: ...er of the key will then be activated Cursor keys Move to the various options and menu points using the cursor keys Confirmation keys Return Enter Used to confirm the entries and carry out the menu poi...

Page 45: ...til they are stored in connection with customer vehicle or until they are overwritten when a new test is conducted The order in which the measurements are filed in the memory is preset and therefore o...

Page 46: ...logous to the front axle test Side slip tester active The screen now includes the values of the rear axle measurement The measurement value in the example is outside the tolerance range i e the side s...

Page 47: ...measurement of the rear shock absorber is done when the rear axle of the vehicle passes over the side slip plates onto the shock absorber test plates 5 In the upper right hand box Testing RA will appe...

Page 48: ...nd proper storage is described after completion of the ovality test and the brake force test Drive slowly and straight onto the brake tester Both sensor rollers must be pushed down Release brake and p...

Page 49: ...rear axle are conducted Then drive onto the brake tester with the rear axle Now the brake force test for the parking brake PB follows This is analogous to the brake force test for the front axle Plea...

Page 50: ...ated with F4 Ovality test Maintain brake force Wait until the timer has run out 4 Delete the temporary storage with DEL Delete temporary measurement values 5 Use F8 to set the displayed measurement va...

Page 51: ...select the defect class As an alternative the class can be entered in this entry mask using the digit keys Enter 01 for class 100 02 for class 200 and so on Subdivisions of the defect classes will ap...

Page 52: ...ically to the screen with the defect classes 10 Enter further defects in the same way 11 Select F8 for storage of all entries The display returns to the defect catagory screen 4 2 5 2 Display of Defec...

Page 53: ...ion 4 3 3 After the automatic testing procedure is completed the main menu will appear on the screen again Use the following steps Test values available store You have already exited the test stand 1...

Page 54: ...nu appears and shows the vehicle license plate in the last line The system is ready New test can begin Drive onto the test lane 2 After the test the instruction line reads Test values available store...

Page 55: ...the customer list 1 Select 6 Customer data The screen which is shown in section Enter customer below appears It is referred to as customer mask in the following The customer mask can also be called up...

Page 56: ...ly However it makes sense to allocate the customer first to the respective vehicle via the VEH database The limit and new values for shock absorber and emission values from the VEH database appear on...

Page 57: ...ueue Measurement created store 3 Use the ESC key to exit the customer mask and return to Office screen 4 Use ESC to exit the Office and return to the main menu 5 Select 1 Select vehicle The measuremen...

Page 58: ...database and not into the customer master list 4 3 4 Display Load Customer Data Call up an existing customer out of the customer master list in order to display customer data Select F3 Load customer...

Page 59: ...ustomer Data Customer data deletion is a somewhat longer process This process adds a measure of safety to prevent data from being unintentionally deleted Carefully consider any data deletion 1 Select...

Page 60: ...ments of this vehicle will be shown In order to select another vehicle use the box F8 New Vehicle and then 3 Measurements The measurement database appears 2 The screen to the left shows the measuremen...

Page 61: ...rear axle Final evaluation brake test Performance tester values Single brake values platform tester Final evaluation Platform tester Shock absorber values front axle Shock absorber values rear axle S...

Page 62: ...procedure Measurement value which are outside the approved limit values are shown in red 3 Select among FA PB or RA to switch between the displays for front rear or parking brake The keys boxes F2 and...

Page 63: ...pedal force graphic Use ESC to exit this screen and return to the brake force value screen 4 4 1 2 Pedal force graphic Pay attention that in order to conduct this measurement the pedal force meter and...

Page 64: ...creen and return to the selection display again Total weight not recorded The brake test was conducted as the only test on a brake tester without weighing device 2 The screen opposite will appear It s...

Page 65: ...system variables are displayed in red 3 In the box Testing in the right hand corner of the screen FA appears for front axle Simultaneously the front axle of the vehicle outline below will be highlight...

Page 66: ...r test appears 2 Select 1 to redisplay the speedometer test The screen shows the target and actual speeds 3 Use ESC to exit this screen and return to the selection display 4 Use F12 to print out the m...

Page 67: ...led operation manual 4 4 7 4 Gas Test 1 Select A to re display the 4 gas test 2 The measured emission values are displayed 3 Use ESC to exit the screen and return to the selection display 4 Use F12 to...

Page 68: ...fects 1 Select M to re display the visual defects 2 The evaluation catalogue of defects appears 3 Use F6 to call up the list of defects After the fact changes are not possible 4 Use ESC to exit the sc...

Page 69: ...lignment 1 Select 3 to redisplay the wheel alignment The measurement values of the wheel alignment are displayed 2 Change to the rear axle with F5 3 Use ESC to exit the screen and rturn tot he selecti...

Page 70: ...pter explains how to enter new vehicles and include them in the vehicle database how to call up load existing vehicles how to change expand and update vehicle data how to delete vehicles out of the ve...

Page 71: ...r is free to decide if the remaining masks are to be used 3 Move to the next page with the key see the screen below On page two the dataset for limit and new values for shock absorbers and brakes can...

Page 72: ...absorber limit values in percentage are evaluated as defective If no limit values are registered or no customer vehicle is linked before the test begins the shock absorbers will be evaluated on the b...

Page 73: ...m with RETURN or F4 The VEH is loaded into the customer mask Fn keys or enter data The data of the desired vehicle will be shown Page through the data set pages using the or keys Use ESC to exit the v...

Page 74: ...search word in the upper line using the keyboard 4 Confirm with RETURN or F4 The following inquiry will appear Delete vehicle 5 a Use ESC to exit the screen the vehicle will not be deleted or b Use t...

Page 75: ...e menu appears 2 Select one of the sub points in the Office menu using the cursor key and confirm with RETURN 4 6 1 Database Administration Some of the functions from the database administration are d...

Page 76: ...ds The screen returns to menu Database administration 6 Use ESC to exit the database administration and return to menu Office 4 6 1 2 6 Delete tests via date 1 You have selected function 6 Delete test...

Page 77: ...the database is compressed the next time see section 4 6 1 4 Within this period there is the possibility to restore the dataset 1 In the Administration menu select 2 to restore customer data 4 to res...

Page 78: ...ction 8 Compress everything in the database administration The screen opposite appears 2 a Select F5 to compress Wait until the procedure is completed or b Exit the screen with ESC and return to the m...

Page 79: ...rinted out as required It is also possible to print out a daily report However the program has to be coupled with the spreadsheet Excel 1 Select the sub point 4 Database printer menu in the Office men...

Page 80: ...F5 Test Equipment in the administration menu Following screen appears 2 In menu Test Equipment select the desired sub point using the cursor keys and confirm with RETURN 4 6 3 1 Display print test equ...

Page 81: ...dline in months Column 4 Column 5 with next calibration date is automatically created Switch between the input lines using the cursor keys or the Enter key 4 Double click on the desired input line to...

Page 82: ...has been introduced The Quality Control documentation covers following areas Naming of the qualified personnel skilled workers responsible persons and AU authorized Emission Testing Training planning...

Page 83: ...variables for the connected floor assemblies can be displayed and printed out These variables may be changed by MAHA service technicians only Please note that any unskilled changes to the variables ca...

Page 84: ...e here The user also has language selection and optical selection available 1 If function 2 Settings is selected in menu Miscellaneous the password menu will appear 2 Exit this with ESC and return to...

Page 85: ...questions please contact our service hotline On the corresponding screen of Profi Eurosystem an additional box F8 Profi options is available 4 7 2 2 Path Database ES_IN ES_OUT In this sub function the...

Page 86: ...ction key 4 7 2 3 RS232 Section Chip Card Psion This sub function organizes the usage of the COM interfaces Please note that unskilled changes can cause malfunctions in the program These are not cover...

Page 87: ...bles in the setting menu The screen opposite will appear 2 Use ESC to exit the screen without changing the existing settings Please contact our service hotline if you have further questions 4 7 2 5 So...

Page 88: ...OUT Printer These settings refer to databanks interfaces and printer Please note that unskilled changes can cause malfunctions in the program These are not covered by the warranty 1 Select the functio...

Page 89: ...s Please contact our service hotline if you have further questions 4 7 2 8 Optics Selection If the color design of the screen is not ideal for your needs it can be changed in this sub function 1 Selec...

Page 90: ...ction 9 System variables in the setting menu The screen opposite will appear 2 The first column shows the variable number not all numbers are assigned The second column is a detailed description of th...

Page 91: ...elect 3 in menu Miscellaneous and confirm with RETURN The password menu will appear 2 Use ESC to exit this screen without entering a password The screen returns to the menu Miscellaneous or Enter a pa...

Page 92: ...possible to correct minor malfunctions by telephone via our hotline 08374 585 260 2 Select the function 1 Devices in the diagnostic menu The screen opposite appears 3 The connected devices appear as...

Page 93: ...r the other in the middle column 3 The next cycle inquires about the components readiness Cyclical inquiry about the LON nodes The readiness appears with yes or no in the first column one after the ot...

Page 94: ...e the button F5 BENCHMARKTEST The following screen appears 2 Test graphic performance Button GRAPHIC F5 Test hard disk performance Button HARD DISK F6 4 7 4 4 Program Configuration The fourth sub func...

Page 95: ...gans 1 Select 7 Customer promotion in menu Miscellaneous The screen opposite will appear 2 Switch between the boxes with the cursor or return key 3 Enter the text using the keyboard 4 Use F5 to confir...

Page 96: ...to the right shows which external programs are integrated Select the Acrobat Reader with 1 3 Confirm with RETURN 4 Acrobat Reader appears over the Eurosystem surface and can be used 5 End the Acrobat...

Page 97: ...rallel with other functions Setting the Acrobat Reader Arobat Reader is installed standard unter program path C Programme Window versions in other languages may have the Acrobat Reader installed under...

Page 98: ...d in section 3 5 4 8 2 Noise Investigation Use the noise investigation mode to detect noise sources and possible damage on wheel and suspension Only one plate at a time is started on the shock absorbe...

Page 99: ...he left test plate is started The right test plate is started The current frequency is stored An automatic procedure starts in which the frequency increases from 5 Hz to 50 Hz in increments of 0 5 Hz...

Page 100: ...llating unloaded test plates 2 The left or the right or both test plates start The pre set start frequency is 20 Hz This frequency can be changed at any time 3 The frequency can be manually raised or...

Page 101: ...d or Visco 4 wheel drive control ASR anti slip regulation and ASD automatic locking differential checks are also possible Please note that a pedal force meter and a remote control Tele BPS are require...

Page 102: ...e tester records the exact wheel rotations A Reflex strips B Light barrier The motor regulation records the exact rpm of the forward rotating rollers and transfers this to the backwards rotating rolle...

Page 103: ...st if desired see paragraph Ovality test c Slowly press the brake pedal until the rollers switch off The roller drive switches off as soon as the pre set slip is reached Slip is not reached If the bra...

Page 104: ...he remote control The max brake force is displayed by the right hand bar c Release brake pedal immediately The measured max brake force is shown by the right hand bar The left hand bar shows the brake...

Page 105: ...ive mode with F9 2 Prepare function test a Drive onto the brake tester with the driven axle Both sensor roller of the roller set must be pressed b Press the clutch or place the gear in idle Place auto...

Page 106: ...gas tester 2 Use F4 to start the MDO2 LON software It will take a few seconds until the measurement screen appears for the diesel emission test Eurosystem continues to run in the background 3 See the...

Page 107: ...the Eurogas module must be switched on at the same time Wait for the entire start sequence to be run through and pay attention to the messages on the screen Continue as always 1 After switch on bootin...

Page 108: ...asurement screen to the right shows the Multex Eurogas module 5 The Eurogas Module always runs through a warm up phase and a leakage test See the Multex operating manual for more detailed information...

Page 109: ...1 The customer mask appears with an additional box F7 AU Data 2 Enter the customer data as usual four obligatory boxes see paragraph 4 3 1 Enter new customer and store 3 Move the marking by pressing t...

Page 110: ...ng See the Multex operating manual for the proper procedure 4 8 7 4 Redisplay of the Measurements The redisplay of the measurements is already described in detail in paragraph 4 4 Redisplay of Measure...

Page 111: ...n purposes Customer oriented service and advice Optimum test preparation Immediate test begin after calling up customer Acceleration of the test procedure by concentrating on the vehicle Central admin...

Page 112: ...authorized service technicians recommended interval 24 months National guidelines for measurement accuracy are to be complied with at all times The following maintenance instructions of the safety tes...

Page 113: ...either direction 1 Remove middle cover plate on the roller set 2 Remove fastening screw D 3 Adjust tightening screw E until chain tension is correct 4 Tighten fastening screw D 14 days after commissio...

Page 114: ...te to open side slip tester 3 Remove any residue from ground pan 4 Remove roller bearings from slides 5 Remove spacer rollers from slides 6 Clean slides 7 Clean spacer rollers and roller bearings 8 Ge...

Page 115: ...Eurosystem Profi LON Maintenance Troubleshooting 5 4 D1 E101BA1 GB09 1 Slides 2 Slides 3 Slides 4 Sensor 5 Slides 6 Slides 7 Ground pan Side view...

Page 116: ...ontact service 3 2 Slip switch off left side defective Contact service Only limited operation possible 3 3 Slip switch off of both sides does not function Contact service Test stand without function 3...

Page 117: ...nd has been switched on No power supply Restore power supply Fuse defective Contact service Lamp defective Contact service Roller set will not start up Error code 32 33 34 Protective motor switches of...

Page 118: ...ctive Contact service Deviation of test plate is not or incorrectly displayed Sliding potentiometer defective Replace sliding potentiometer Connecting cable between sliding potentiometer and control d...

Page 119: ...Eurosystem Profi LON Maintenance Troubleshooting 5 8 D1 E101BA1 GB09...

Page 120: ...25 7 Brake tester Brake force difference limit value red If the difference of the brake forces is larger than this value an error message will appear 50 Belgium mode only 8 to 10 not used 11 Brake tes...

Page 121: ...ly stored and switched to the next axle 0 5 kN 31 Brake tester Difference threshold The brake force difference will only be displayed when the brake force on both sides exceeds this value 0 5 kN 32 Br...

Page 122: ...10 km h 58 Speedometer tester 8th target speed This variable sets down the eighth target speed which the test vehicle s speedometer should approach 220 km h 59 Speedometer tester 9th target speed This...

Page 123: ...te the Ireland Dublin Mode 0 0 inactive 1 active 94 Ireland Dublin Mode Shock absorber tester Limit value difference of the values 30 95 Ireland Dublin Mode Brake tester Limit value MIN per wheel brak...

Page 124: ...e Test method TRK light 9 DM 123 New Price Test method CAR 8 DM 124 New Price Test method Motorcycle 7 DM 125 New Price Test method Special price 6 DM 126 New Price Test method TRK heavy 5 DM 127 New...

Page 125: ...r test stand has been driven onto 25 1 10 s 139 Platform tester Screen display after the test The time during which the screen display remains on the screen after the test has been completed if in the...

Page 126: ...scale 1000 170 Brake tester Scale right calibration factor Only with the own scale 1000 171 Brake tester Scale 2 channels Only with the own scale 0 0 no 1 two channel 172 not used 173 Speedometer test...

Page 127: ...torage after completion only if ES_IN ES_OUT active 1 0 no 1 yes 198 Motorcycle test 0 0 Manual start 1 Automatic 199 4 gas test channel 1 request with F11 key 0 0 automatic 1 active 200 Test Equipmen...

Page 128: ...Appendix Eurosystem Profi LON D1 E101BA1 GB09 6 9 6 2 Short Instructions...

Page 129: ...Eurosystem Profi LON Appendix 6 10 D1 E101BA1 GB09...

Page 130: ...lly the same Select Work Order Function 1 in the main menu when Werbas or Vaudis is connected These work orders have been previously created in the external software and put at disposal in a database...

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