Manual Stand Frane

EDV 905 082 132 Operating Instructions
English
Test Unit Roller Brake Tester

micro brake 813
Documentation Details:
BA micro brake mb 813/Eng/Rev.03/02.07

EDV 905 082 132
First edition: 11.02
Change: 08.05
05.06
02.07
Archiv: \\muefs01\data\5-Prüfen\08\905.082.132-03-mb813-Typ813AN-ENG\Originale\
905082132-03-ba_0_mb813_Typ813AN_ENG.doc
Beissbarth GmbH Automobil-Servicegeräte

Hanauer-Straße 101 80993 Munich Tel. 089/14901-0 Telefax 089/14901-211
REGISTRATION INDEX CARD
CUSTOMER ADDRESS
Company ___________________________
Street ___________________________
Place ___________________________
Country ___________________________
Model tag data
Analogue Display
Model tag number ___________________________
Serial number ___________________________
Brake Test Stand

Model tag number ___________________________
Serial number ___________________________
Side Slip Plate

Model tag number ___________________________
Serial number ___________________________
Startup completed on ___________________________
Startup completed by (Name) ___________________________
(Company) _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
_________________________________________________________________________
Please fold here and send to Beissbarth GmbH in a window envelope!
Response:
Telephone::
Customer Service Department +49 – 89 – 14901 – 233

Postfach 500145
80971 Munich Fax:
Germany +49 – 89 – 14901 – 211

Table of Contents
EC-Declaration of Conformity
Safety Instructions - Lorry A1
Control Cabinet Type 1 B1
Infrared Remote Control JLS-0180 C1
Air Pressure Sensor Cable Version D2
Air Pressure Remote Sensors D3
Analogue Display 30 kN E2
Test Unit Roller Brake Tester micro brake 813 G2
Test Unit Track Plate micro side slip 8400 G4
Test Procedure Roller Brake Test Stands
micro brake 8000/8100/813 I1
1
2
Hanauer Straße 101 D-80993 München
EG-Konformitätsklärung
EC-Declaration of Conformity / EC-Declaration de Conformité
CE-Dichiarazione di conformita / CE-Declaracion de conformidad
CE Declaração de conformidade / EG Conformiteitsverklaring
EC-försäkran om överensstämmelse
Hiermit erklären wir, daß die nachfolgend bezeichnete Maschine/Ausrüstung aufgrund Ihrer Konzipierung
und Bauart sowie in der von uns in Verkehr gebrachten Ausführung den einschlägigen grundlegenden
Sicherheits- und Gesundheitsanforderungen der betreffenden EG-Richtlinie(n) entspricht. Bei einer nicht
mit uns abgestimmten Änderung der Maschine/Ausrüstung verliert diese Erklärung ihre Gültigkeit.
We hereby declare, that the following described machine/equipment as a result of its conception and
construction in all our distributed versions, meets the relevant fundamental health and safety requirements of the
respective EC guidelines. This declaration will lose validity if changes to the machine/equipment are made
without our consent.
Nous déclarons par la présente que les machines et équipements décrits ci-après, sont conçus et
construits pour l´ensemble de la production, au regard des règles fondamentales du cahier des charges
européen. Cette déclaration pert sa validité si des changement sont opérés sur ces machines ou
équipement sans notre conscentement.
Con la presente dichiariamo che la seguente macchina/attrezzatura e il risultato delola sua concezione e
costruzione in tutte le sue versioni distribuite. E conforme ai fondamentall criteri die sicurezza e salute delle
rispettive normative CEE. Questa dichiarazione perderà validità se la macchina/attrezzatura subirà modifiche
senza il nostro consenso.
Por la presente, declaramos que la máquina/equipo descrito a continuación, como resultado de su

concepción y construcción, en todas lasw versiones que distribuÍmos, cumple con las normas de salud y
seguridad descritas en la guÍa de la CE. Esta declaración perderá validez si se realizan cambios en el
equipo/máquina sin nuestro consentimiento.
Pelo presente declaramos que o equipamento/maquina abaixo descrito fui concebido e construido emk todas as
versões disponiveis, de acordo com as normas de segurança exigidas da CE. Esta declara çao perderá toda a
validade se o equipamento/maquina forem alterados.
Hiermede verklaren wij dat de navolgende machine/apparatuur beantwoordt aan de EG-richtlijnen inzake
eisen voor veiligheid en gezondheid zowel op grond van constructie en samenstelling als op grond van
de door ons in het gelodighheid indien zonder overleg met ons wijzigingen in de machine/apparatuur
worden aangebracht.
Vi härmed intygar att följande maskin/utrustning överenstämmer med var ritning och konstruktion i alla vara
distibuerade typer, möter alla de krav pa hälso- och säkerhetskrav i enitgt med EC-Riktlinjer. Denna deklaration
gäller ej om maskinen/utrustingen ändras utan var vetskap.
Bezeichnung der Maschine/Ausrüstung: Machine/Equipment description: Description de la

machine/équipement: Descrizione macchina/attrezatura: Descripcion máquina/equipo: Descriçào
maquina/equipamento: Aanduiding van de machine/aparatuur:
Maskin/utrustning Beskrivning:
Bremsprüfstand- Brace tester- Banc de freins- Banco prova freni- Frenometro- Frenómetro
Remmentestbank- Bromsprovare-
Typ:. micro-brake 8000/8100/813 (mb 8000/8100/813)
3
Gemäß den Bestimmungen der EG Richtlinien:
· EG Maschinenrichtlinie 98/37/EG
· EG Richtlinie Elektromagnetische-Verträglichkeit 89/336/EWG
· EG-Niederspannungsrichtlinie 73/23/EWG
In conformance with the requirements of the following EC Guidelines:

· EC-Machine Standard 98/37/EC
· EC Guidelines for Electro-Magnetic Compatibility 89/336/EWG
· EC Low Voltage Directives 73/23/EC
En concordance avec les exigences des directives CE:

· EC- Standard machine 98/37/EC
· Directive CEE pour la compatibilité‚ electro-magnetique 89/336/CE
· Directive CEE pour la basse tension 73/23/CE
In conformita con le seguenti normative CE:

· CE Macchina Standard 98/37/CE
· Direttiva CEE per compatibilitá elettromagnetica 89/336/CE
· Direttiva CEE per bassa tensione 73/23/CE
Conforme con los requerimientos de las siguientes Guias de la CE:

· CE-Maquina estandar 98/37/CE
· Directiva CE para compatibilidad electro magntica 89/336/CE
· Directiva CE para bajo volaje 73/23/CE
Em conformidade com os seguintes Regulamentos CE:

· CE-Maquina estandar 98/37/CE
· Regulamento CE para compatibilidade electro-magn‚tica 89/336/CE
· Regulamento CE para a baixa voltagem 73/23/CE
Conform de Bepaligen van de EG-Richtlijnen:

· EG-Machinerichtlijn 98/37/CE
· EG Richtlijn elektromagnetische storings gevoeligheid 89/336/CE
· EG Laagspannings-Richtlijn 73/23/CE
I enlighet med EC följande väglednings föreskrifter:

· EC Maskindirektivet 98/37/CE
· EC vägledning för electro-magnetisk förenlighet med 89/336/CE
· EC lag volts vägledning 73/23/CE
Angewandte harmonisierte Normen, insbesondere: Applied harmonious norms, in particular: Application de

l´harmonie d´une norme: Norme particolari applicate: Normas aplicadas, en particular: Normas de harmonia
particulares aplicadas: Toegepaste geharmoniseerde normen, in het bijzonder: Tillverkad i följande
harmoniserande normer:
EN 60204-1; EN ISO 12100-1; EN ISO 12100-2, EN 294;

EN 349; EN 61000-6-1; EN 61000-6-3
Ort: Place: Posto: Lugar:
Datum: Date: Data: Fecha: 05.2006
München: Munich: Monaco di Baviera: Munich:
Hersteller-Unterschrift: Signature of the manufacturer: Signature du constructeur: Firma del costruttore: Firma
del fabricante: Assinatura do fabricante: Handtekening van de fabrikant: Tillverkares signatur:
Hermann Bux
Angaben zum Unterzeichner: Particulars of the undersigned: Fonction du signataire: Particolarità della
controfirma: Detalles del firmante: Cargo do responsável: Details van de ondertekenaar: Namnförtydligande
Director Development
4
English
Chapter: A 1 - 0
Safety Instructions - Lorry
BA Safety Instructions/Eng/Rev.03/05.06
EDV 905 802 052
Change: 08.01
10.02
05.06
Archiv: \\muefs01\data\5-Prüfen\80\905.802.052-03- Safety-Instructions-Lorry -ENG\Originale\

905802052-03-BA-0-A1- Safety-Instructions-Lorry -ENG.doc

2 A1-0
Table of Contents
Operator's Duty of Care 4

Specific Safety Instructions and Symbols Used 5
Basic Safety Measures During Normal Operation 6
Basic Safety Measures During Repair and Maintenance 6
Repairs on Electrical Equipment 7
Follow Environmental Regulations 7
Laws, Guidelines and Standards 7
A1-0 3
Operator's Duty of Care
The equipment has been constructed and built according to the prescribed
harmonization standards and all other technical specifications. It therefore
incorporates all current technology, and hence can be operated with a high
Employment degree of safety.
Protection Act The machine's safety can only be actualised in operational running if all
necessary measures are taken. It is the operator's responsibility to plan
§§ these measures and to ensure that they are carried out.

Brake testers which are erected over or just before or after an inspection pit
must be operated using safety equipment (compulsory in Germany).
The operator must particularly ensure that

• the machine is operated in accordance with the intended use.
• the machine is only operated when it is clearly in good working order
Accident Prevention
and, in particular the safety units are regularly tested to check their
Regulation proper functioning (see chapter on maintenance of the relevant test
s device).
of the • the required protective clothing is available and worn by operating,
maintenance and repair staff.
Trade Association • a complete and legible set of operating instructions is available at the
machine installation site.
• only appropriately authorised and qualified staff operate, repair and
maintain the machine.
• that the staff are instructed before commencing the activities and at
Operating Instructions least yearly thereafter, in all relevant matters about safety at work and
environmental protection, as well as the operating instructions and all
safety guidelines that they contain.
• that all safety and warning notices on the machine itself are in place
and legible.
Special safety instructions are given in the relevant chapters about individual test devices.
4 A1-0
Specific Safety Instructions and Symbols Used
In the following Operating Instructions specific instructions are given to indicate the unavoidable
remaining risks of operating the machine. These risks include dangers to
• people
• products and machines
• environment
The symbols used in the operating instructions aim to draw special attention to the safety instructions!
This symbol indicates particular danger to people.

(danger of death or injury)
Danger
This symbol indicates particular danger to machine, materials and the

environment.
Attention
Danger – in general
The most important aim of the safety instructions is to prevent personal injury.
The use of the symbol cannot replace the text of the respective safety instruction. The text must
therefore always be read in full.
This symbol does not indicate safety instructions, but information

explaining how the machine functions in more detail.
Information
A1-0 5
Basic Safety Measures During Normal Operation
The machine must only be operated by authorised persons who are familiar
with the operating instructions and can work according to them.
Before switching on the machine, examine it and ensure that
leit
un
g
• only authorised people are present at the machine site.
san
tri
eb • nobody can be injured by starting the machine!
Be
Before each use of the machine, check for any visible damage and only
use it if it is clearly in perfect working order! Any defects observed must
immediately be reported!
Each time before starting operations check and ensure that all safety
installations are clearly in perfect working order!
Basic Safety Measures During Repair and Maintenance

Keep to the intervals prescribed for inspection and maintenance in the
Operating Instructions!
Before carrying out maintenance or repair work, do not permit any

unauthorised persons access to the work area! Prominently display a
warning sign to indicate repair and maintenance is taking place!
Before repair and maintenance work take out the main connection plug, or
if there is a built-in supply, turn off the main power supply switch and secure
with a padlock. The key to this lock must remain in the keeping of the
person carrying out the repair or maintenance work.
When replacing heavy machine parts, only use appropriate load
suspension and stop devices in perfect condition!
Dispose any environmentally harmful lubricants, coolants or cleaning

agents properly!
Used Oil
6 A1-0
Repairs on Electrical Equipment
Repair works on the electrical equipment may only be carried out by
qualified electricians!
Check all electrical equipment regularly!
Tighten any loose connections!
Immediately replace damaged wires or cables!
Always keep the housing of electrical equipment closed! Access is only
permitted to authorised persons with keys or opening tool!
Never hose down the housing of electrical equipment for cleaning
purposes!
Follow Environmental Regulations

When any work is carried out on the machine, legal obligations on waste
avoidance and their subsequent proper utilization and disposal must be
observed.
Especially during installation, repair and maintenance work ensure that
water-polluting substances such as
• lubricating grease and oils
• hydraulic oils
• coolants
• cleaning fluids containing solvents
do not contaminate the floor or get into the drains!
Such materials must be kept and transported in suitable containers, into
which they must be returned for disposal!
Laws, Guidelines and Standards

In design and construction of the testing devices, the following guidelines and rules were observed:
• Guideline for the use, assembly and testing of brake testers.

• DIN EN 60204-1 Electrical installations of machines
• BGR 157 Vehicle maintenance
A1-0 7
8 A1-0
English
Chapter: B 1 - 0
Control Cabinet Type 1
BA Control Cabinet Type 1/Eng/Rev.03/03.08

EDV 905 802 062
Change: 08.01
09.02
03.08
Archive: Tech.Redaktion_bbmuc001_(H) \ Papier_Dokumentation \

2.2_Bremsprüfstände_LKW_mb8000_bis_stl9000 \ BA_eng \ Einzelanleitungen \
905802062-03-BA-0-B1-Control-Cabinet-Type-1-ENG.doc

2 B1-0
Table of Contents
Product Description 4
Operating Lamp 4
Stop Key 4
Automatic Key 4
Left ON /Right ON key 4
Technical Details 5
Mechanical Dimensions 5
Performance 5
Environmental Conditions 5
Commissioning 6
B1-0 3
Product Description
Using the lockable emergency stop, the system is switched on and off or stopped in the case of an
emergency.
Furthermore, the user finds a printer drawer and numerous connections for options.
The key board controls the test procedure of the brake test stand. Principally, however, we
recommend to use the IR remote control.
Operating lamp
Stop key
Right ON key
Left ON key
Automatic key
Operating Lamp
The green operating lamp is lit when the display has been switched on.
Stop Key
During the operation of the test stand, using the stop key, the motors can be deactivated and the plant
can be stopped. Moreover, this key is used as a navigation function in the service mode.
Automatic Key
The automatic mode can be activated using the automatic key. Moreover, this key is used as a
navigation function in the service mode.
Left ON /Right ON key

This is the ON key to activate the test procedure of an axle or a wheel.
4 B1-0
Technical Details
Mechanical Dimensions
Dimensions L x W x D (mm) 600 x 850 x 370
Weight approx. 15 kg
Performance
Power supply 3 x 400 V (AC)
Power supply cable 5 x 10 mm²
Fuse 3 x 50 A
Breaking capacity of main switch 63 A
Power supply input 90 to 264 V
Power supply unit exit 12 V / 30 VA
Environmental Conditions
Protective degree (according to DIN 40 050) IP 54
Admissible air humidity (relative without moisture) up to 85 %
Operating temperature -10 to +60 °C
Storage temperature -10 to +60 °C
B1-0 5
Commissioning
Lift control cabinet from the packing and place in the intended position above the empty pipes.
Remove the cover of the control cabinet and lift the plate to the side.
Lay the connecting cable KA-0213 (Pos. 2) and the grounding wire (Pos. 3) from the control cabinet to
the display box (are connected in the control cabinet).
Connect the grounding wire to the earth busbar and the connecting cable KA-0213 to the SI-240 and
fasten both in the mounting clip.
RS 485 driver card Drawing EDV-915804001 S 485 driver card

SI 240 SI 240
In the control cabinet In the control cabinet
g
n
u
rd
E
un)
1(bra
Sch ir m ( blau)
2(grün)
4( gelb) 3(weiß )
3( weiß) 4(gelb)
2(g rün)
aun)
1( br
Connecting
cable KA-0213
Lay the sensor cable of the right roller set to the left roller set and connect to the sensor connection
socket GSA-0025 (Plan EDV-).
Lay the sensor cable of the left mechanics to the control cabinet and connect it to the sensor
connecting cable KA-0120 Pos. 15 (Plan EDV-915804002).
6 B1-0
Drawing EDV-915804002
8 7 6 5 4 3 2 1
17
18
16
9
15
10
19
Sensor cable
MB8000
To assembly board 11 12 13 14 To display cabinet
Item Quantit Unit Designation Item number / standard abb. Remarks:

y
1 1 pc RS-232-Converter SI-205/K Item No 935693002
2 1 pc Sensor connecting cable KA-0170 Item No 935803027
3 1 pc Key board PT-2010 Item No 935603026
4 1 pc Flat cable KV-1080 Item No 935603024
5 1 pc Central computer NC-2051 Item No 935603004

+ EPROM „LKW-ZR 1.0a“

+ EPROM „LKW-DS 1.0a“
8 1 pc Power supply cable KA-0213 Item No 935603018
9 1 pc Power supply VP-3020 Item No 935603009
11 1 pc Relay card QR-2010 Item No 935603008
14 1 pc Driver card printer QD-2020 Item No 935603007 Assembly optionally at

the control cabinet side
17 1 pc RS-485-driver card SI-240 Item No 977255144
18 1 pc Wiring cable H05V-K Item No 935803043

Length = 100 mm
19 1 pc Connecting cable KA-0213 Item No 935803028
B1-0 7
Fasten sensor cable and the connecting cable KA-0213 to the mounting clip on the right side of the
assembly board.
Lay the grounding wire of the right roller set to the left roller set and fasten it to the earthing screw.
Lay the grounding wire of the left roller set to the left roller set and fasten it to the earthing busbar.
Lay the two motor cables to the control cabinet and fasten them (Plan 945801001).
The pegs on the gear tops must be replaced by the gear ventilation screws.
Lay the supply cable to the control cabinet and clamp it to the main switch.
Important:
Use a rotating field instrument to check whether a “right-hand rotation field” exists as wiring is
designed for this.
8 B1-0
English
Chapter: C 1 - 0
Infrared Remote Control
JLS-0180
BA Infrared Remote Control JLS-0180/Eng/Rev.02/10.02

EDV 905 802 112
Change: 08.01
10.02

905802112-02-BA-0-C1-IR-Sender-JLS-0180-ENG.doc

2 C1-0
Table of Contents
Technical Details 5
Mechanical Dimensions 5
Performance 5
Commissioning 6
Coding of the IR Remote Control 7

General 7
Setting of the Remote Control Address 7
Test Stand 8
Operation 9
Modes of Operation 9
Test Programs 10
Weight Entries 10
Entries of Calculated Pressures 11
Memory Functions 11
Display Repetition 12
Printing Variations 13
Delete 13
Display Switching – Additional Sensors for Deceleration 14
Switching of Additional Sensors PM/PX/Pedal Force Tester 14
PM/PX 14
Stop Entries 15
Entries for Trailers 15
Appendix 16
Spare Parts List 16
C1-0 3
Product Description
Using the infrared remote control, control commands, data entries and changes in the program are
nd
entered. The keys are partially occupied several times with 2 functions.
The key assignment of the remote control can be seen on the picture of the cover of this Chapter.
With direct solar insulation on the infrared-receiver, problems as regards the radius of action may
result.
4 C1-0
Technical Details
Mechanical Dimensions
Dimensions L x W x D (mm) 180 x 67 x 15
Weight approx. 100 g
Performance
Power supply 6V compound battery
Life at least 1 year
Work area 10 - 20 m
Operating temperature 0 to +60 °C
C1-0 5
Commissioning
Unpack infrared remote control and open the cover of the battery box.
Unpack battery and position it with correct polarisation in the battery box.
Important: Do not press any key for approx. 5 sec. as the remote control runs a reset.
Mount the cover of the battery box again.
Press each key individually and check whether the red LED of the remote control blinks.
6 C1-0
Coding of the IR Remote Control
General
If several test lines or individual test stands are to be used in one hall it is necessary to code the
remote controls differently in order to avoid mutual interference of the test stands.
Setting of the Remote Control Address

11 variations can be set (default is 0).
The coding can be changed as follows:
Remove battery from the remote control.
Insert battery again.
Press the STOP key 5x consecutively.
Enter the desired address within 5 seconds.

e.g.: Address 4
If the battery is changed again later, addressing

has to be carried out again if the desired address
is not 0.
C1-0 7
Address table
Address 1
Address 2
Address 3
Address 4
Address 5
Address 6
Address 7
Address 8
Address 9
Address 10
Test Stand
Select step 17 in the configuration routine. The set or entered value is shown in the centred 4-digit
LCD at the right side. On the left side, the code of the remote control is shown for a short time.
As usual for other configuration steps, the desired value is entered and confirmed with “ENTER”.
Note:
During standard operation, the test stand reacts only to the remote control commands with the
configured address. During special routines, however, the address setting is not taken into account.
8 C1-0
Operation
Modes of Operation
The function which is triggered by pressing the remote control keys is described by this part of the
operating instructions.
Individual wheel test left
Individual wheel test right
Standard operation (sequence of the two keys

variable)
Vehicle is positioned on the test stand:

The key “left ON” and “right ON” are simulated;
the brake test starts in standard operation.
Vehicle is not positioned on the test stand:
Automatic on
Four-wheel test left side
Four-wheel test right side
Automatic off
Imbalance measuring
Stop roller set
C1-0 9
Test Programs
After switching on the test stand using the main switch, the test stand starts with the Program 1
Depending on the software version, the following test programs can be activated, for example:
1 = truck train
2 = semitrailer truck
3 = bus
4 = passenger car
The test programs distinguish themselves mainly by the evaluation of the measurement results.
If the braking test stand is non-operative, the current program number is shown at the right LCD
display (e.g. P3).
The entry is made as follows:
Start program selection
Press key until the desired program appears on

stepper motor and LCD display.
Confirm entry
Weight Entries
The weights entered have priority over the value measured. E.g. an axle weight of 2000 kg is
measured by existing weighers. An axle weight of 2,200 kg can be entered via the remote control. For
the calculation of deceleration and overall weight, an axle weight of 2,200 kg is used.
The value entered using a numeric keyboard is displayed on the stepper motor as well as on the left
LCD display.
Overall weight empty
Overall weight loaded
Axle weight empty (must be saved after the test,

but executed before the saving of the axle data!)
10 C1-0
Entries of Calculated Pressures
If no calculated pressure has been entered, extrapolation is effected using a value of 6.5 bar.
If for certain axles differing calculated pressures are used, the entry can be made axle by axle.
Entry of calculated pressures (applies to the entire

vehicle)
Entry of calculated axle pressure (must be saved

after the test, but executed before the saving of
the axle data!)
Memory Functions
Saving is always made in three steps:
• Select braking system (service brake or parking brake)
• Correct axle number, if required,
• Confirm with “ENTER”.
When pressing the service brake or parking brake saving key, the next free memory space is shown
on the left LCD display and on the stepper motor, i.e. there is no need to enter the axle via the remote
control during the standard test operation.
Example:
The first and second axle of the service brake have already been saved. The test for the third axle was
implemented and is to be stored as well now. After pressing the service brake memory key, the
allocation of the third axle appears on the LCD display and on the stepper motor (3 kN = axle 3). In
order to save, only confirm with ENTER.
Service brake (standard test sequence is

maintained).
Operating brake (number of axles is increased by

2);
st
e.g. the third axle is checked first (display 1 axle
==> increase axle number by 2!)
Service brake (number of axles is decreased by

1);
e.g. the same axle is stored again.
Parking brake (standard test sequence is

maintained).
C1-0 11
Display Repetition
On the display repetition of the axle results, the axle saved last is offered, after the repetition display
has been activated. The number of axles can be changed when saving.
The display repetition can be stopped with “STOP”.
Operating brake (axle saved last)
Operating brake (axle saved last but one)
Parking brake (axle saved last)
Axle weight empty (only current axle possible)
Computational pressure
Imbalance (only currently tested axle possible)
Deceleration service brake empty
Deceleration service brake loaded
Deceleration parking brake empty
12 C1-0
Deceleration parking brake loaded
Printing Variations
Standard print with final evaluation of towing
vehicle.
Standard print with final evaluation of trailer and/or

semi-trailer.
Standard print with final evaluation and graphic of

complete train (service brake)

towing vehicle

semi-trailer
Axle graphics of service brake with EC range of

complete train plus list print-out.
Delete
The values saved can generally be overwritten by entering a new value for the same allocation and/or
for the same braking system and the same axle again.
The total memory is also deleted when one or several printouts have been made and a new measuring
has been saved.
Delete last measuring
Delete entire memory
C1-0 13
Display Switching – Additional Sensors for Deceleration
After switching on the test stand, the LCD display shows the measurement values of the additional
sensors during the test operation.
If the display of the deceleration and the braking force difference is desired, this key combination must
be used:
Switching of additional sensors to deceleration

and vice versa.
If the vehicle is not in the test stand and if the test stand is in the basic condition, the following LCD
display variations show the type of the measurement values which are shown on the LCD display
during the test operation.
left LCD right LCD Measured value left LCD Measured value right LCD
display display
- - - - P1 PX PM
µ - - - P1 Deceleration Braking force difference
Switching of Additional Sensors PM/PX/Pedal Force Tester

Using MB813, the braking pressures can be assigned to the braking forces during a brake test.
For this purpose you need special pressure sensors, which are connected to the test stand either via
cable or radio transmission.
Depending on the vehicle type and/or brake system, the user can choose between the following
different pressure measurement systems before each test.
1. PM/PX Air pressure:

PM (vessel) 0..0.13 bar
PX (cylinder pressure) 0..0.13 bar
2. PD/PH Pedal pressure & hydraulic pressure

Pedal pressure 0...100 kg
Hydraulic pressure 0...200 bar
3. PM/PX Hydraulic pressure:

PM (vessel) 0...200 bar
PX (cylinder pressure) 0...200 bar
The selection of additional sensors is possible by the following key combination. (example for test
program 1)
This key combination opens the selection dialogue

for the activation of different pressure
measurements:
14 C1-0
With these keys, the corresponding pressure
sensor can be selected.
The three measuring methods are shown on the
or LCD display and the visualisation as follows:
left LCD right LCD STL9000

PM/PX air pressure:
1 - - - P1 PD/PH pedal pressure & hydraulic pressure
2 - PD P1 PM/PX hydraulic pressure:
3 - PH P1
Current setting is activated using the ENTER key.
Stop Entries
All entries and displays can be stopped using the STOP key.
Stop entries or displays
Entries for Trailers

Activate the trailer key first, before entering or saving data for a trailer. All further entries are made as
described above; here two examples:
Entries for total weight empty for trailer
Saving of parking brake for trailer
C1-0 15
Appendix
Spare Parts List

Item Article Designation Short Name IT No
1 Infrared remote control JLS-0180 935 802 006
2 6V compound battery 4LR61 977 251 100
16 C1-0
English
Chapter: D 2 - 0
Air Pressure Sensor Cable Version
CFD-0103/v
BA Air Pressure Sensor Cable Version Unit/Eng/Rev.00/09.2002

EDV 905 802 162
Change:

905802162-00-BA-0-D2-Pressure-Sensor-Cable-ENG.doc

2 D2-0
Table of Contents
Principle of Functioning 4
Intended Use 4
Safety Instructions 4
Measured Values Display 4
Technical Details 5
Mechanical Dimensions and Operating Data 5
Performance 5
Measuring System 5
Commissioning 6
Scope of Supply 6
Maintenance 7
Service 7
D2-0 3
Product Description
Principle of Functioning
The air pressure sensors CFD-0103/v are two sensors to obtain pneumatic pressure values in the
braking system of commercial vehicles or trailers.
In addition there is a sensor which determines the pedal or hand force when the service brake or the
parking brake is operated.
The measured values are recorded in CFD-0103/v and transferred via a 20m connection cable online
to the receiver unit in the control cabinet.
In addition, the CFD-0103/v sensors can also be used for ALB setting work and tension alignment. The
corresponding scope of functions is offered by Beissbarth software test programs.
Basically, both CFD-0103/v can be used universally. It is important that the user applies the
correspondingly connected sensor for the right measuring task due to the letters PM / PX on the
control cabinet.
The measurement range (0-20 bar) is the same for all the pressure sensors. The sensor allocations
can not be mixed.
Intended Use
The sensors must under no circumstances be subject to higher pressures than those predetermined
by their measurement range Only 15% overload is allowed, for higher pressures there is the risk of
destroying the sensors.
Correct method of working:

• The proper connection of the sensors to the right place of the braking system has to be ensured to
guarantee the correct data evaluation. The PX1e.g. has to be connected to the axle 1, the PM to
the control output of the pedal-operated brake valve etc.
• Before the connection to the pressure valve make sure the measurement range can not be
exceeded.
• The sensors are mounted on the vehicle so that they can not be run over by mistake if their removal
has been forgotten.
• CFD-0103/v is a measuring instrument which has to be treated as such. In spite of the robust
construction, do not throw or drop the sensors.
• The housing has to be cleaned from oil and other dirt from time to time.
• The sensors must not be submerged in any liquid.
Safety Instructions
• During the measuring processes, nobody must be near the brake test stands.
• Work on the electronics must only be carried out by an authorised service technician.
• When connecting others sensors, the axle, on which a sensor is attached, must not be situated
above the brake test stand (Danger to life due to unexpected start of the roller set).
Measured Values Display

The results of the measuring are displayed on the following modules:
- Analogue display - during the brake test or in the special ALB test programme
- Print-out - maximum values of the PM/PX in the tabular test protocol, list print-out
- PC visualisation - during the brake test or in the special ALB test program
4 D2-0
Technical Details
Mechanical Dimensions and Operating Data
Sensor:
Housing: HxØ 30 mm, Ø 40 mm
Materials Aluminium
Weight 200 g
Compressed air supply outlet Compressed air quick fastener NW 7,2

Storage -25 to +85 °C
Performance
Sensor
Distribution voltage via connecting cable 12 V (DC)
Measuring System
Alu membrane beam with strain gauge (DMS)
Calibration must be carried out with the calibration check function by commissioning. Automatic zero
point correction is active.
Air pressure measurement

Maximum load bar 23 bar
Measuring range bar 0-20 bar
Measuring range receiver bar 0-12.8 bar (optional 20 bar)
Accuracy % < +/-0.4% FS
Measured values resolution bar 0.026 bar
D2-0 5
Commissioning
Scope of Supply
Pressure sensor with connection 2x
cable 935 802 014
CFD-0103/v
Connecting hose 2x
935.803.060
20 m sensor extension cable (5 poles) 2x

for PM/PX/PD sensors 935 802 011
(KVB-0020)
10 m sensor extension cable 935.802.010
(5 poles) for PM/PX/PD sensors
(KVB-0010)
Adapter cable for connection to the 935 803 027

computer circuit board
(KA-0170)
Label PM/PD PZ/PH 935.805.086
Washer A4,3-ST-VZ 975 130 031
Protection cap for flange receptacle 2x

974 085 169
Sheet metal screw 975 120 289
BZ2,9*9,5
Calibration must be carried out with the calibration check function by commissioning. Automatic zero
point correction is active.
6 D2-0
Maintenance
Service
 1999, Beissbarth GmbH.
Hanauer Str. 101
D-80993 Munich
Tel.:+49 (0)89-14901 233
Fax: +49 (0)89 14901 211
Email: Service@beissbarth.com
WWW: http://www.beissbarth.com
The system is almost maintenance-free. Before each use, check the connection cable for damage
such as contusions. All the components must be regularly cleaned. Special attention must be paid to
the following areas:
- Sensor housing and air pressure connection area
- Connecting plug
D2-0 7
8 D2-0
English
Chapter: D 3 - 0
Air Pressure Remote Sensors
MESRA 2.0
BA Air Pressure Remote Sensor Unit/Eng/Rev.00/10.02

EDV 905 802 172
Change:

905802172-00-BA-0-D3-Remote-Pressure-Sensor-ENG.doc

2 D3-0
Table of Contents
Intended Use 5
Measured Values Display 5
Technical Details 6
Mechanical Dimensions and Operating Data 6
Performance 6
Measuring System 7
Commissioning 8
Charging station 8
Receiver 10
Transmitter 11
Maintenance 12
Service 12
D3–0 3
Product Description
The MESRA 2.0 is a measurement system to detect pneumatic and hydraulic pressure values in the
braking system of commercial vehicles or trailers.
In addition, there is a sensor, which determines the pedal or hand force when the service brake or the
parking brake is operated.
The measured values are recorded via the remote sensors and transferred online to the receiver unit.
In addition, the MERSA 2.0 system can also be used for ALB setting and tension alignment. The
corresponding scope of functions is available in the test programs of Beissbarth software.
Basically, MESRA 2.0 consists of a range of sensors with sending units which communicate with a
receiver via the radio. Each sensor has a predefined measuring task:
- Pressure measurement in the air-brake reservoir I /II / III,
- Control pressure PM
- Axle brake pressure PX for axle 1, axle 2 or axle 3 etc.
- Pedal force
The measuring range is the same for all the pressure sensors. The sensor allocation must not be
mixed.
The majority of the lorries has a pneumatic braking system, only a few are based on a hydraulic
system. An appropriate sensor system is available for both types. The hydraulic system is not be
further described in this document.
Air pressure sensors 0-20 bar

Hydraulic sensors 0-200 bar
The receiver controls now continuously all the sensors connected to the lorry according to their
measured values and passes them on to the connected system (test stand control).
The following sensors are available.
Serial No. Short Name Description

1 PD Radio pedal pressure sensor
2 PY Free selectable allocation
3 PM Control pressure produced via pedal-operated brake valve
4 PX1 Air pressure sensor for axle 1
4 D3-0
Intended Use
The sensors must under no circumstances be subject to higher pressures than those of their
measuring range only 15% overload is allowed, in case of higher pressures there is the risk of
destroying the sensors.

• The proper connection of the sensors to the right place of the braking system has to be ensured to
guarantee the correct data evaluation. The PX1e.g. has to be so connected to the axle 1, the PM to
the control output of the pedal-operated brake valve etc..
• Before the connection to the pressure valves make sure the measuring range can not be exceeded.
• The sensors are mounted on the vehicle so that they can not be run over by mistake if their removal
has been forgotten.
• MESRA 2.0 is a measuring instrument which has to be treated as such. In spite of their robust
construction, do not throw or drop the sensors.
• The housing has to be cleaned from oil and other dirt from time to time. The contact areas must
always be kept clean in order to avoid errors when recharging.
• The sensors must not be submerged in any liquid.
• In order to improve the reaction time on measuring start (among others, important for quick values
measuring), operate shortly the system and brake slightly before the actual measuring. Finally, the
measuring has to begin within 80 seconds.
• Hang back the sensors into the charging station after measuring.
• The sensors have to charged during the night. Make sure that the charging station remains voltage-
carrying at night and e.g. not switched off via the main switch.
Safety Instructions
• During the measuring nobody may be near the brake test stands.
• Work on the electronics must only be carried out by an authorised service technician.
• When connecting other sensors, the axle, on which a sensor is attached, must not be situated
above the brake test stand (Danger to life due to unexpected start of the roller set).
Measured Values Display

The results of the measuring are displayed on the following modules:
- Analogue display - during the brake test or in the special ALB test programme
- Print-out - maximum values of the PM/PX in the tabular test protocol, list print-out
- PC visualisation - during the brake test or in the special ALB test program
D3–0 5
Technical Details
Mechanical Dimensions and Operating Data

Sensor:
Housing: H x Ø 299 mm, Ø 60 mm
Materials PA 6 (polyamid 6)
Weight 1200 g
Air pressure connection Compressed air quick fastener NW 7,2

Hydraulic pressure connection M16 x 1.5 (internal thread)

Storage without accumulator -25 to +85 °C
Storage accumulator (optimal) +10 to +30 °C
Storage accumulator (tolerance) -20 to +45 °C
Radio data:
Transmission power 5 mW
Transmitting frequency 433.20 - 434.65 MHz
approved by postal authorities,
BZT:17TR2100
Range of transmission Highly dependent on the environment. Inside
of reinforced concrete buildings, a range of
transmission of 80m can be expected (approx.
180m outside)
Receiver
Housing: (H x W x D) 250 x 160 x 60 mm
RS232 Transmission rate 9600 baud
Entire system
Sensors parallel operation Part 10 Transmitters
Signal output delay ms 100 ms ( signal delay time)
Response time ms 70-200 ms (wake-up function)
Performance
Receiver
Voltage supply (plug power supply unit) 230 V (DC)
Voltage supply receiver electronic 12-14 V (DC)
Charging station
Voltage supply (plug power supply unit) 230 V (DC)
charging unit voltage supply 12 V (DC)
Sensors are hung into a charging base. Each of the 5 bases are fed by a separate power supply unit
(220VAC/12VDC). An intelligent charging electronic provides optimal charging cycles.
Sensor
Supply voltage via accumulator pack 4.8 - 5.2 V (DC)
6 D3-0
Measuring System
Alu membrane beam with strain gauge (DMS)
Calibration is carried out in the factory. Automatic zero point correction is active.
Air pressure measurement

Measuring range bar 0 - 20 bar
Measuring range receiver bar 0 - 12.8 bar (optional 20 bar)
Measured value resolution bar 0.026 bar
Hydraulic pressure measuring

Measuring range bar 0-200 bar
Measuring range receiver bar 0-200 bar
Measured value resolution bar 0.3 bar
D3–0 7
Commissioning
Charging station
Charging station module for pressure 977 165 287
sensor
(USL-0010)
Power supply unit for charging station 977 251 173

(USN-0040) power supply unit for 230 V
Connection cable to the charging station
module
Fastening set MS0040

For fastening the charging station,
connection of the power supply
- Check delivered material for any transportation damage and for completeness.
- The installation and the commissioning must be carried out by an authorised service
technician.
5 4 7 3 2 1 7 4 8
1st
1 .Charging
first a d e s t aStation
Lcharging- tion Last
L e t zcharging
t e L a d e sstation
tation
6
station
- Unscrew the screws in Pos.2 and connect all the charging stations using connecting screws
Pos. 3.
- The connecting screws must not be removed because otherwise the charging contacts fall off
their guide.
- A maximum of 5 charging stations can be connected to the power supply unit. For 6 or more
charging stations, a further power supply unit is always necessary.
- Only the Beissbarth original power supply unit may be inserted. The use of another unit will
possibly destroy the accumulator.
- The forked terminals Pos. 6 must be mounted onto the connecting screws of the first charging
station between the serrated distance rings Pos. 4. First, the washer Pos.7 has to be mounted.
Finally, fix the connection cable with one nut Pos.5 each.
8 D3-0
- Finally, screw together the charging stations using the screws Pos.8 , the serrated distance
rings Pos.4 and the washer Pos.7 and fix them using the charging station screws Pos.2.
emounting
Wallmounting
mounting
fu gpoints
npoints
e s t i g upoints
spunkte
- Now the entire system must be mounted horizontally using the wood screws, washers and
dowels on both outer wall mounting points at a suitable position
- Mount the power supply unit USN-0040 in a protected place and check the setting of the line
voltage selector (set on 12 V). Now the power supply unit may be connected.
- The sensors can be hung up in the charging station. Overloading is not possible electronically
so that the sensors remain longer without any problem in the charging station.
- Basically, the sensors should be immediately hung up again in the charging station after
measuring so that the accumulator lasts longer.
- If the sensors remain longer as 1.5h outside the charging station, they switch off automatically.
The sensors can only be reactivated via a shortly hanging them up in the charging station.
Caution: The sensors should not remain a long time (ca. 3 weeks) outside the charging station to
avoid a drain of the accumulators. In this case, reactivation is not possible and the accumulators must
be sent in for reparation.
D3–0 9
Receiver
Radio receiver unit complete 935 802 022
(MESRA1015)
Radio receiver circuit board 977 251 174
(JE-1020)
Connection cable 977 235 105
Flat ribbon cable between radio receiver
and computer circuit board of the test stand
control
BNC cable extension 977 235 106
(KV-6501)
Radio aerial 977 251 175
with BNC coupling (JFA-0010)
Fixing material
• During assembly take care that the receiver station is at least 5 m away from the sensors as
otherwise channel cross-talk appears. The sensors should have a distance of at least 1m to one
another. If channel cross-talk appears (e.g. signal from PX3 on PX4), try to improve the reception
by unplugging the aerial or removing the receiver position.
• Reception optimization can be achieved by positioning the aerial downwards.
• See the documents of the test unit for more details on the control electronics.
10 D3-0
Transmitter
Transmitters are usually delivered with accumulators connected. If both modules are still separate,
connect the accumulator connection cable with the plug to the main module and fully close the screw
fitting.
Pressure sensor PM 935.803.090

BFD-2xxx
Pressure sensor PX1 935.803.091

BFD-2xxx
Connecting hose
935.803.072
In addition to the actual pressure text, the first function test can also be carried out using LED signals.
Yellow LED is lit continuously Sensor is recharged in the charging station.

Yellow LED is blinking Sensor is in the charging station and is completely recharged
(charge conservation mode)
Green LED lights up ca. 3 seconds. The sensor is removed from the charging station and makes
automatically a zeroing.
Yellow LED is blinking The sensor is ready for operation.
Important:
If the sensor remains more than 90 min. outside the charging
station without measuring, it switches off to avoid a drain of the
accumulators (visible when the green LED switches off).
Position the sensor into the charging station for a few seconds to
be able to measure again (Wake-up function).
Red LED is blinking Accumulator is completely discharged, no measuring is possible
any longer. The sensor has to be hung up in the charging station
for several hours (until the yellow LED blinks)
• The sensors are calibrated in the factory so that no further calibration is necessary.
D3–0 11
Maintenance
Service
Hanauer Str. 101
D-80993 Munich
Tel.:+49 (0)89-14901 233
Fax: +49 (0)89 14901 211
The system MESRA 2.0 is almost maintenance-free. Check at regular intervals that charging station is
clearly in good working order. If the sensors' edges are knocked off after a while, the charging contacts
may be pushed backwards when inserting the sensors in the charging station and charging is no
longer possible. In this case, regrind the edge (clean edges are important) and bend the charging
contacts outwards. If necessary, order new contacts.
All the components must be regularly cleaned. Special attention must be paid to the following areas:
- Sensor charging contacts (if necessary spray with contact spray)
- Charging contacts of the charging station (if necessary, spray with contact spray)
- Receiver's aerial
- Power supply unit
We recommend acquiring an additional accumulator on intensive use of the system so that one
accumulator is always ready for use and therefore sensors can be continuously exchanged.
12 D3-0
English
Chapter: E 2 - 0
Analogue Display 30 kN
BA Analogue Display 30kN/Eng/Rev.02/0710.02

EDV 905 802 242
Change: 08.01
10.02

905802242-02-BA-0-E2-Analogue-Display-30kN-ENG.doc

2 E2-0
Table of Contents
Summary 4
Green and Red LED Arrow 4
LED Evaluation Block 4
Infrared Receiver 5
Measured Value Range 5
Area Switching 5
6-Segment Displays 5
Equipment Identification 5
Technical Details 6
Indicators 6
Housing 6
Performance 6
Commissioning 7
Wall Bracket 7
General 7
Configuration Properties 8
Maintenance 10
Service 10
Safety Inspection 10
E2-0 3
Product Description
Summary
The analogue display cabinet of the intelligent test line has the following display elements:
LCD displays
15 Track value scale
Brake force range 10 3 20

2 0 4
mm/
+12 m -12
Area switching
1
kN 5
5 25
0 -6 LED evaluation block
LED arrow green 0 6
0 30
LED arrow red
Green and Red LED Arrow

The arrows blink when the currently operating test equipment and/or test program is in a dangerous
condition. Dangerous conditions are, as a rule, the turn-on phase of the motors or other decisive
moments during which the user must initiate action. In addition, error conditions must be signalised.
The arrows are lit if one of the automatic operating modes is activated, because in these modes the
test equipment may start on its own.
LED Evaluation Block

These three-coloured LED lines are used for the display of automatic conditions, remote control
acknowledgements and for the evaluation of measurement and calculation results.
The LED evaluation block consists of only one colour range with the usual traffic light colours and is
used for assessing the test results. The colours have the following meaning:
• Red The test result does not fulfil the legal requirements and/or is unsatisfactory.
• Yellow The test result just fulfils the legal requirements and/or is critical.
• Green The test result fulfils the legal requirements and/or is in order.
With the aid of the evaluation range, operating conditions or error states are also shown. Details can
be found in the operating instructions of the individual test equipment and/or test programs.
4 E2-0
Infrared Receiver
The infrared signals of the remote control are directly received and evaluated in the analogue display.
A valid remote control entry is acknowledged by a "flickering" of the entire LED block and further
processed.
An invalid remote control entry is acknowledged by a "flickering" of the red LED display and rejected.
The validity of the remote control entry depends on the currently operating testing unit and/or test
program.
Measured Value Range

The measured value range has three scales:
• Internal force scale from 0kN to 6kN
• External force scale from 0kN to 30kN
• Track value scale from -12mm/m to 12mm/m
Area Switching
The area switching is lit when the internal measurement scale (0-6 KN) is active. As soon as the 6 kN
are reached, the LEDs switch off and the external measurement scale is applicable.
6-Segment Displays
The analogue display has one four-digit and one two-digit segment display. With these display
elements, characters, figures and symbols are shown. The multifunctionality enables the depiction of
measured values, operating conditions, error states, equipment identification and texts. Details can be
found in the operating instructions of the individual test equipment and/or test programs.
Equipment Identification
The operator can identify the currently activated equipment of the lorry test line through the pointer
position of the display.
• Basic position of the pointer at the measurement scale.
Example 1: Roller brake tester mb813 Example 2: Track plate MSS8300
15 15
10 3 20 10 3 20
2 0 4 2 0 4
mm / mm /
+12 m -12 +12 m -12
1
kN 5 1
kN 5
5 25 5 25
0 0 -6
6 0 0 -6
6
0 30 0 30
Both pointers in ”Zero” position Red pointer in ”Zero” position

Green pointer at 15KN and/or 0 mm/m
E2-0 5
Technical Details
Indicators
Brake:
Scaling Measuring range Smallest scale Character size
∅ 255; 300° 0 to 6 kN 200 N = 10° 19 mm
∅ 375; 300° 0 to 30 kN 1,000 N = 10° 33 mm
Track plate:
∅ 240; 100° +12 – 0 -12 mm/m 3 mm/m = 12.5° 12.5 mm
Digital display:
4 and/or 2 digit Figure size: 76 mm
Resolution:
Weight 1 kg
Displayed values per sec. 6,25
Housing
Rectangular (L x W x D) 600 x 380 x 890 mm
Performance
Power supply 12 V (DC)
Power supply cable 4 x 1.5 mm²
6 E2-0
Commissioning
Wall Bracket
Install the wall bracket at the intended position.
General
Unpack the display box, remove the back cover and position the display box on wall bracket and fasten
it with screws.
Lay the connecting cable KA-0213 (Pos. 2) and the grounding wire (Pos. 3) from the control cabinet to
the display box (are connected in the control cabinet).
Connect the grounding wire to the earth busbar and the connecting cable KA-0213 to the SI-240 and
fasten both in the mounting clip.
RS 485 driver card Drawing EDV-915804001 RS 485 driver card

SI 240 SI 240
In the control cabinet in the display cabinet
g
n
u
rd
E
u n)
1(bra
S ch i r m ( b l a u )
2 (grün )
4 ( ge l b) 3(weiß )
3( w ei ß ) 4( ge l b)
2 (g rün )
a un)
1( br
Connection cable
KA-0213
Mount back cover again and align display box in the direction of the roller set.
E2-0 7
Configuration Properties
Each test and display unit has various standard settings which are to be defined depending on the
scope of the product and the model. The detailed procedure is explained in the Chapter "Configuration
Routine”.
Step Description Values Standard

1 Motor type 0 = Star –delta motor 0
1 = Dahlander motor
2 End value of the inner analogue scale (entry in kN) 8
3 End value of the outer analogue (entry in kN) 40

scale
4 Printer selection 0 = Olivetti DM109 1

1 = Seikosha
5 Slip control 25 %
6 Language selection (Standard: German) 0
7 Compensation of mechanical left - green 0

tolerance of left analogue display
8 Compensation of mechanical right - red 0
tolerance of right analogue display
9 not used -
10 Special version The system obtains all legal default values of the 0
country selected after the enter key has been
pressed.
11 Tyre load in the print 1= wheel loads printed in hardcopy 1
0= no
12 Print axle graphics 1= Print axle graphics and list 1
0= Print only list
13 Application MESRA PY (hydraulics) 1= MESRA sensor exists 0
1= MESRA sensor does not exist
14 Application MESRA PD (pedal force) 1= MESRA sensor exists 0
15 Duration of peak value display Value range: 0...9999 ms 4000
All entries in [ms]: The number keys 1000, 100,
10 to enter milliseconds
Example: LCD value: 1000 = 1000 ms = 1s
500 = 500 ms = 0,5 s
16 Automatic modus, activated on start 0= standard mode 0
1=automatic mode (only admitted for official
testers
17 Entry of IR address of remote control 0
(0 - 10)
18 Delivered type 0= Beissbarth Logo 0
0= FACOM Logo
On the installation of the visualisation and/or data
base for the CAR test line, the parameter /
FACOM must be entered into the command line
(Windows designation: target) (or later when
linked to an icon: right mouse properties) in order
to obtain the FACOM logo with the unit
description CLS700.
19 Reset of the ON counter 0= no function -
1= reset to zero
20 Bidirectional operation 0=standard operation 0
1=bidirectional operation
21 Enable brake type pre-selection Preselection of the brake type enabled during 0
roller resistance measuring (SV Poland)
0=No
1=Yes
8 E2-0
22 MESRA duration of the error display Value range 0..9999s 30
All entries in seconds
The number keys 1000, 100, 10 to enter seconds
23 Control of pit protection via 0=No 0

sensoring rollers 1=Yes
24 Control of low voltage device via IR 0=No *not yet finished* 0
remote control 1=Yes
25 Area limit for track display green Value range 0-9.9 mm 3,0
*Beginning of the yellow area* All entries in mm
26 Area limit for track display yellow 6,0

*Beginning of the red area*
27 Centro display Display with two clocks 0

0=standard display
1=Centro display
28 Definition of calculated pressure Value range 0..0.9 bar 6,5
All entries in bar
29 Definition of admissible total weight Value range 0..9999 kg * 10 0
All entries in kg * 10
The number keys 10000, 1000, 100, 10 used for
entries. Example: 4500 = 45000 Kg = 45 t
0500 = 5000 Kg = 5 t
30-99 Legal values and limit values
30 Braking force service
difference brake
31 Difference parking
brake
32 Difference auxiliary
brake
33 Deceleration service
brake
34 Deceleration parking
brake
35 Deceleration auxiliary
brake
36 PD service
brake
37 PD food parking
brake
38 PD hand parking
brake
39 Imbalance global
40.....
E2-0 9
Maintenance
Service
Hanauer Straße 101
D-80993 Munich
Tel.:+49 (0)89-14901 233
Fax: +49 (0)89 14901 211
The display cabinet is almost maintenance-free.

Clean the display only with a damp and fluff-free cloth.
Repair work must only be carried out by authorised service technicians. The safety measures for
maintenance and repair are to be adhered to as described in the Chapter "Safety Instructions".
Safety Inspection
The operator has to check the safety-relevant units of the system at least once per year (BGV
A1, §39 Para. 1 and 3).
As the installed electronic equipment checks these functions whenever it is switched on, the operator
only needs to implement a visual examination.
10 E2-0
English
Chapter: G 2 - 0
Test Unit Roller Brake Tester
micro brake 813
BA mb 813 Unit/Deu/Rev.02/10.02
EDV 905 082 142
Change: 08.01
10.2002

905082142-02-BA-0-G2-mb813-Test-Unit-ENG.doc

2 G2-0
Table of Contents
Intended Use 4
Unintended Use 5
Equipment Identification 5
Technical Details 6
Mechanical Dimensions and Weights 6
Display Cabinet 6
Control Cabinet 6
Dimensions per Roller Set 6
Operating Data of Roller Set 6
Roller Surface 6
Display of the Measuring 7
Analogue Display in Display Cabinet 7
Digital Display in Display Cabinet 7
Electrical Data 7
Motor data 7
Connection Values 7
Ambient Conditions 7
Commissioning 8
Roller Set with Weigher 8
Wiring 9
Maintenance 10
Service 10
Routine Test 10
Short Operating Instructions 10
Appendix 11
Electric Circuit Plans 11
Sensor List 15
Configuration Properties 15
G2-0 3
Product Description
The track rollers are provided with a plastic-corundum coating which is extremely abrasion-resistant,
yet easy on the tyres at a high friction factor and it secures a long life. The roller pairs are driven by an
electric motor each which (depending on the type) achieves a nominal current of 6 -9 kW. The
frictional direction between the test rollers of one side is realised by chain drive.
The reaction forces during braking are recorded via state-of-the-art sensor components. The
integrated microprocessor control evaluates the measured results so that the user has detailed
information on the braking behaviour of the entire vehicle.
The left and right sensing roller controls the running (sliding test) and position of the tyre and takes
over the switching and safety function of the test stand. Underneath the sensing rollers, there is an
anti-skid protection. It prevents the feet from sliding into the devices and provides grip.
The micro brake 813 is connected to the analogue display via the field bus system (RS485-Standard).
The user controls the test sequence by infrared remote control or by pressing the function button of
any display unit.
The measured data can be depicted on one display unit. In addition, the test stand supplies all data of
a brake test required by official test authorities.
If a printer module is integrated in the system, it is possible to print-out the result data in lists and in a
graphic print-out.
Intended Use
The device is a roller brake tester to test the brake system of double-tracked vehicles up to a
maximum axle load to 10t for which main examinations pursuant to § 29 StVZO [Traffic Ordinance] in
connection with Annex VIII are stipulated.
The right and left brakes are tested independent of each other. The tester can switch on and off the
drive motors of the roller sets using the remote control. Moreover, it is possible to implement brake
tests in the "automatic operation" modus.
Underneath the sensing rollers, there is an anti-skid protection. It prevents the feet from sliding into the
devices and provides grip.

• A brake test must not be carried out before both tyres of an axle of the vehicle press down the
sensing rollers within 5 seconds.
• If the vehicle leaves the roller set during the brake test and/or if the sensing rollers move upwards,
the drive rollers are automatically switched off.
• If the braking force is higher than the friction force between tyre and the test rollers, the tyre starts
to slip (block) The test stand control automatically switches off the drive rollers. If the difference
between roller and tyre speed is too great (>25 %), the braking force is no longer measured, but
the friction force between tyre and test roller. This measuring result is of no use for the brake test.
In addition, the slip shutdown prevents the tyre from being damaged.
4 G2-0
Unintended Use
• Transverse driving so that one tyre rubs against the frame of the test stand.
• Rushed driving across the rollers (max. 10 km/h)
• Rushed movements when checking the front axle.
• Exceeding the admissible test and crossing load (see techn. data).
• Testing of single-track vehicles (motor bikes etc.)
• Driving out of the test stand without switching on the electric motors (This is bound to lead to
damage to the bearing).
• Caution: The process is not necessary if the test stand is equipped with engine brakes.
If the roller brake tester is not used as intended, the safe operation of
the device cannot be guaranteed.
For any damage caused to property or persons due to unintended use
or improper handling as well as to unauthorized restructuring or
changing of the unit by the operator, the operator of the roller brake
tester and not the manufacturer shall be responsible.
Equipment Identification
During the measuring operation, the micro brake 813 is controlled by a display unit. The figures below
help to select and to recognise the criteria.
Roller brake tester mb813
15
10 3 20
2 0 4
mm /
+12 m -12
1
kN 5
5 25
0 0 -6
6
0 30
Both pointers in ”Zero” position
G2-0 5
Technical Details
Mechanical Dimensions and Weights
Display Cabinet
Display cabinet W x D x H (mm) 600 x 380 x 890
Control Cabinet
Control cabinet W x D x H (mm) 600 x 380 x 890
Optional printer cabinet W x D x H (mm) 600 x 380 x 305
Dimensions per Roller Set

Divided frame with 1000 mm roller length L x W x D (mm) 1310 x 1160 x 540
Weight (with 1000 mm roller length) approx. 520 kg
Roller length 1,000 mm
Roller diameter 250 mm
Largest test width (pit) 2,900 mm
Smallest test width (pit) 900 mm
Roller axle distance 470 mm
Elevation of rear rollers against front rollers 50 mm
Difference in height between roller upper edge front to shop floor 15 mm
Admissible test axle load 10,000 kg
Admissible max. driving load 13,000 kg
Smallest testable tyre size 145 R14 (ca. Ø 450mm)
Largest testable tyre size 1400 R26 (ca. Ø 1,640 mm)
Operating Data of Roller Set

Test speed 2,6-5,2 km/h
Sliding coefficient dry 0,7
Sliding coefficient wet 0,5
Nominal rating of drive motors 2 x 6.5 and/or 8.5 KW
Gear reduction i = 1 / 16,52
Number of roller revolutions 9 1/min and/or 18 1/min
Measuring System Flexible beam with strain gauge(DMS)
Maximum brake force: 20,000 N
Noise emission LW A <70 dB (A)
Roller Surface
Plastic crystal coating Spaces filled with plastic
Coating ca. 1mm over expanded metal
Crystal grain size 2.0 to 3.2 mm,
Roller colour black
Expanded metal according to DIN 791
6 G2-0
Display of the Measuring
Analogue Display in Display Cabinet

Internal area 355 0, 300° 0- 8kN 200N=23 mm 20 mm
external area 375 0, 300° 0 -35kN 1000N=24,5 mm 32 mm
Digital Display in Display Cabinet

LCD - displays -2 plus 4 digit Height of figures 76 mm
-LCD Type 7-Segment Display
-Display value per second 5
Electrical Data
Motor data
VN 230V/400V
IN 14,6 / 17,0 Amp
cos φ 0,80 / 0,90
N 1440 / 2860
Connection Values
Power supply 3 x 400 V (AC)
Admissible nominal voltage fluctuations ± 10 %
Fuse 3 x 50 A
Power supply cable 5 x 10 mm²
Motor cable 7 x 2.5 mm
Ambient Conditions
Operating temperature -10° to +60°
Printer - operating temperature +15° to +35°
-relative humidity of air 15% to 85%
G2-0 7
Commissioning
Roller Set with Weigher

Check delivered material for any transportation damage and for completeness.
Check work to be performed on the site and dimensional stability of the foundation plan EDV-
915800009.
Check that the conduits are open.
Weld flat bar and IPB carrier according to assembly plan EDV-915800007. Clean assembly pit.
Set up supports Pos. 1 on IPB 140 carrier according to assembly plan EDV-915800006.
Remove cover plates and motor cover.
Lift roller sets at the brackets for the cover plates using a ”web sling” and suitable lifting equipment
into the assembly pit.
The hoist should be rated for a carrying

capacity of min. 1,000 kg.
Take care of sensor and motor cables!
The elevated side is the access side!
Set the roller sets to 750 mm roller distance.
Average roller sets in direction of travel. Fix position using stop screw M16 Pos. 17, secure with nut
Pos. 18. Air gap between stop screw and IPB carrier approx. 1 mm. The roller sets must be installed in
an exact right angle to the direction of travel. The brake rollers of the left and right test stand must be
positioned on an axle.
The stops Pos. 8 and the supports Pos. 1 are to be attached using a spot welding seam according to
assembly plan EDV-915800006.
To secure the electronic parts, lift roller sets out of the assembly pit.
The stops Pos. 8 and the supports Pos. 1 are to be welded according to assembly plan EDV-
915800006.
Lift the roller sets back into the assembly pit as described in Item 8 and 9.
Fix position using screw M16 Pos. 10, secure with nut Pos. 9. Air gap between screw M16 and
weighing sensor approx. 1 mm. Level the test stand using screw Pos. 4 and Pos. 11. Upper part cover
plate (for low roller) must be flush with the floor. Counter screws using nuts.
Dowel screwed support Pos. 13 according to the assembly plan EDV-915800006. A space of approx.
5 mm should be between the side part and motor carrier.
Dowel cover Pos. 19 according to the assembly plan EDV-915800006.
Mount the cover plates, motor covers and covers again.
8 G2-0
Wiring
The sensor cable of the sensor box (GSA-0030) of the right roller set is connected to the sensor box
(GSA-0025) of the left roller set according to the installation plan.
Lay the motor cable through the conduit DN 70 to the control cabinet.
Pull the sensor line through the conduit to the control cabinet as well.
G2-0 9
Maintenance
Service
Hanauer Str. 101
D-80993 Munich
Tel.:+49 (0)89-14901 233
Fax: +49 (0)89 14901 211
The roller set of the micro brake 813 is almost maintenance-free with and without weigher.
Only the drive chain is regularly checked as to correct tension (10 mm clearance at the longest
position) and sufficient greasing (usual chain grease) and, if necessary, re-tensioned or re-greased.
Sweep or vacuum dirt (e.g. stones) off the roller set (do not use high-pressure cleaner) in order to
enable faultless operation
In particular, care must be taken that any water is drained freely and any drainage cannot be blocked.
Repair work must only be carried out by authorized service technicians. The safety measures for
Important:
If the motor is defective, the roller set must be lifted out of the assembly pit.
Safety Inspection
The operator has to check the safety-relevant units of the system at least once per year. (Trade
Association Regulation BGV A1, §39 Para. 1 and 3).
Routine Test
A routine test must be carried out by an authorised service technician before commissioning.
It must be repeated every two years.
The routine tests must be implemented after the repair of the test stand when component groups
pertinent to measuring have been exchanged.
The test stand must not be used for brake testing according to §29StVZO and Annex VIII StVZO
in connection with §41 StVZO before the elimination of the faults.
The routine test must be repeated within four weeks after the repair.
The date for the next routine test must be made visible at the test stand in a suitable place.
Short Operating Instructions

The user has to provide short operating instructions for the operators on the basis of the operating
instructions.
10 G2-0
Appendix
Electric Circuit Plans
G2-0 11
12 G2-0
G2-0 13
14 G2-0
Sensor List
Error-free measuring requires correct calibration of the sensors. The following table shows all possible sensor
components.
No. Designation Remarks: Limit values / value area at calibration

1 Slip sensor left 25 -150 Digit / 750 – 980 Digit
2 Slip sensor right 25 -150 Digit / 750 – 980 Digit
3 Touch sensor left 25 -150 Digit / 750 – 980 Digit
4 Touch sensor right 25 -150 Digit / 750 – 980 Digit
5 Brake force sensor left 25 -250 Digit / 750 – 980 Digit

6,000 N (maximum value)
6 Brake force sensor right 25 -250 Digit / 750 – 980 Digit
6,000 N (maximum value)
7 Weigher sensors left 25 -250 Digit / 750 – 980 Digit
8 Weigher sensors right 6,600 kg maximum value –8point weigher

7,500 kg maximum value –4point weigher
Configuration Properties
Each test and display unit has various standard settings which are to be defined depending on the
scope of the product and the model. The detailed procedure is explained in the Chapter "Configuration
Routine”.
Step Description Values Standard

1 Motor type 0 = Star –delta motor 0
1 = Dahlander motor
2 End value of the inner analogue scale (entry in kN) 8
3 End value of the outer analogue scale (entry in kN) 40
4 Printer selection 0 = Olivetti DM109 1

1 = Seikosha
5 Slip control 25 %
6 Language selection (Standard: German) 0
7 Compensation of mechanical tolerance left - green 0

of left analogue display
8 Compensation of mechanical tolerance right - red 0
of right analogue display
9 not used -
10 Special version The system obtains all legal default values of 0
the country selected after having pressed the
enter key.
11 Tyre load in the print 1= wheel loads printed in hardcopy 1
0= no
12 Print axle graphics 1= Print axle graphics and list 1
0= Print only list
13 Application MESRA PY (hydraulics) 1= MESRA sensor exists 0
14 Application MESRA PD (pedal force) 1= MESRA sensor exists 0
G2-0 15
15 Duration of peak value display Value range: 0...9999 ms 4000
All entries in [ms]: The number keys 1000, 100,
10 to enter milliseconds
Example: LCD value: 1000 = 1000 ms = 1s
500 = 500 ms = 0,5 s
16 Automatic modus, activated on start 0= standard mode 0
1=automatic mode (only admitted for official
testers
17 Entry of IR address of remote control (0 0
- 10)
18 Delivered type 0= Beissbarth Logo 0
0= FACOM Logo
On the installation of the visualisation and/or
data base for the CAR test line, the parameter /
FACOM must be entered into the command line
(Windows designation: target) (or later when
linked to an icon: right mouse properties) in
order to obtain the FACOM logo with the unit
description CLS700.
19 Reset of the ON counter 0= no function -
1= reset to zero
20 Bidirectional operation 0=standard operation 0
1=bidirectional operation
21 Enable brake type pre-selection Preselection of the brake type enabled during 0
roller resistance measuring (SV Poland)
0=No
1=Yes
22 MESRA duration of the error display Value range 0..9999s 30
All entries in seconds
The number keys 1000, 100, 10 to enter
seconds
23 Control of pit protection via sensing 0=No 0

rollers 1=Yes
24 Control of low voltages device via IR 0=No *not yet finished* 0
remote control 1=Yes
25 Area limit for track display green 3,0
*Beginning of the yellow area* Value range 0-0.9 mm
All entries in mm
26 Area limit for track display yellow 6,0

*Beginning of the red area*
27 Centro display Display with two clocks 0

0=standard display
1=Centro display
28 Definition of calculated pressure Value range 0..0.9 bar 6,5
All entries in bar
29 Definition of admissible total weight Value range 0..9999 kg * 10 0
All entries in kg * 10
The number keys 10000, 1000, 100, 10 used
for entries. Example: 4500 = 45000 Kg = 45 t
0500 = 5000 Kg = 5 t
30-99 Legal values and limit values
30 Braking force service brake
difference
31 Difference parking brake
32 Difference auxiliary brake
33 Deceleration service brake
34 Deceleration parking brake
35 Deceleration auxiliary brake
36 PD service brake
37 PD food parking brake
38 PD hand parking brake
39 Imbalance global
40.....
16 G2-0
English
Chapter: G 4 - 0
Test Unit Track Plate
micro side slip 8400
BA mss 8400/Eng/Rev.01/07.2005
EDV 905 832 022
Change: 07.05
Archive: \\muefs01\data\5-Prüfen\83\905.832.022-01-Bedienungsanleitung-MSS8400-ENG\Originale\
905832022-01-BA-Operating-Manual-MSS8400-ENG.doc

Hanauer Straße 101 80993 Munich Tel. 089/14901-0 Telefax 089/14901-211
2 G4-0
Table of Contents
Intended Use 4
Unintended Use 5
Technical Details 6
Commissioning 7
Mechanical Equipment 7
Control Cabinet 8
Wartung 10
Service 10
Short Operating Instructions 10
G4-0 3
Product Description
The device is a track plate to test the track setting of double-tracked vehicles up to a maximum wheel
load to 8.0 t for which main examinations pursuant to 29 StVZO [Traffic Ordinance] in connection with
Annex VIII are stipulated.
The track plate consists of a laterally movable plate.
If the examiner drives with the vehicle's tyre over the test plate, the test plate can move laterally due to
the influence of the forces exerted by the rolling tyre. Lateral forces are created as the tyre is partially
laterally drawn across the lane when the track value is not correctly set.
When driving across the track plate, the deviation of the axle geometry from the set value is recorded
via state-of-art sensor components. The integrated microprocessor control evaluates the measured
results so that the user has detailed information on the axle geometry of the entire vehicle.
The measured result shows the mm distance by which the tyre is laterally shifted when the vehicles
travels one metre. As a result a positive value (toe-in) or a negative value (toe-out) can be
measured.
Due to experience values, the following limit value table serves for the evaluation of the measured
results.
Smaller +/- 4 [mm/m] Track value okay

+/-4 to +/- 6 [mm/m] Track value in the limit area
More than -/- 6 [mm/m] Electronic axle measuring recommended
The limit values can slightly fluctuate due to vehicle-specific tolerance areas and different tyre-
diameters.
The results are shown on the 4-digit LCD display (option) with the red pointer of the MB800.
Intended Use
The track of a vehicle is tested axle by axle. Drive over test stand with a regular speed of max. 15
km/h.
• Driver over track plate with a regular speed of max. 15 km/h.
• Do not steer when driving across the track plate.
• Do not accelerate or hesitate when driving across the track plate.
4 G4-0
Unintended Use
• Transverse driving across the test stand.
• Steering movements when driving across the track plate.
• Acceleration or deceleration when driving across the track plate.
• Rushed driving across the track plate (max. 15 km/h)
• Exceeding the admissible test and crossing load (see techn. data).
• Testing of single-track vehicles (motor bikes etc.)
If the track plate is not used as intended, the safe operation of the
device cannot be guaranteed.
For any damage caused to property or persons due to unintended use
or improper handling as well as to due to unauthorized restructuring or
changing of the unit by the operator, the operator of the track plate and
not the manufacturer shall be responsible.
G4-0 5
Technical Details
max. 15 km/h (wheel load) 8t
Measuring range ±12 mm/m
Length 995 mm
Width 800 mm
Fitting depth 36mm
Noise emission value <70 dB (A)
Weight: approx. 80 kg
6 G4-0
Commissioning
Mechanical Equipment
• Check delivered material for any transportation damage and for completeness.
• Check work to be performed on the site and dimensional stability of the foundation plan
(drawing No 925830002).
• Clean assembly pit.
• Unscrew both M6x20 screws on the cover.
• Take off the cover on the sideslip tester plate.
• Lift the side slip plate in the pit and align it in driving direction (arrow).
• Use nut M12 and washer Ø13 (included in delivery) to fasten the side slip plate with 85 Nm.
• Lay sensor cable and earth wire trough the ductwork to the control cabinet.
• Use M5x10 oval head screw Pos. 8 and the two serrated lock washer Ø5,3 Pos. 7 to fasten
the earth wire as seen on the picture below.
• Fasten the measurement amplifier Pos. 10 with two M3x16 oval head screws Pos. 11 and two
Ø3,2 serrated washers Pos. 12 to the brackets. Connect the earth wire of the measuring
amplifier with lens head screw M4x12 and two serrated washer Ø4,3 to Pos. A.
• Fasten the lever Pos. 9 with M4x12oval head screw Pos. 2 and M4hexagonal nut Pos. 3 to the
plate spring Pos. 4 and attach it to the measurement amplifier.
• Fasten the sensor cable with cable tie on the 3 installation bases.
• Fit the cover on the sideslip testing plate and fasten it with two M6x20 screws.
• Take care that the cover clicks into the leaf spring.
There should be a space of up to 0.5 mm in the longitudinal direction.
• Swing the cover fully to the left and right and check for soft running and levelling to the centre
position.
G4-0 7
Control Cabinet
• Carefully unpack electronic parts and for any transportation damage and for completeness.
Item Quantity Unit Designation Item number / standard abb. Remarks:
1 1 pc Central computer NC-2050 Item No 935603005 n.a. if additional sensor

set or DINA4
2 1 pc EPROM „LKW-DS 1.0 a or b“ Set exists
4 4 pc Spacerr LCBS-6-01
• Remove the cover of the control cabinet and lift the plate to the side.
• Insert the corresponding Eprom into the central computer (7) and mount to the electric
assembly board using 4 spacers (drawing No 935833003).
• Mount the sensor cable (15) on left beside the printer card (14) at the mounting angle and
connect to central computer (7) or to sensor cable KA-0170 (2) (if applicable).
(drawing No 93 5833003).
• Connect flat ribbon cable KV-1018 (6) to the central computer (7) and the central computer (8)
(drawing No 935833003).
Drawing 935.833.003
8 7 6 5 4 3 2 1
17
18
16
9
15
10
19
Sensor cable
To the display
To the elctric MSS 8400 cabinet
assembly board 14
Connection
11 12 15 13 Connection MB 8000
Printer
8 G4-0
• Connect the sensor cable MSS 8400 to the sensor connection cable KA-0120 at the electronic
assembly board (drawing No 935833003) and fix into fastening clamps at the right side of the
electric assembly board.
• Clamp the earth wire to the earth rail at the rear side of the control cabinet.
• Mount the cover of the control cabinet again.
Item Quantity Unit Designation Item number / standard abb. Remarks:
1 1 pc RS-232-Converter SI-205/K Item No 935693002
3 1 pc Key board PT-2010 Item No 935603026

+ EPROM “LKW-ZR 1.0a”

+ EPROM “LKW-DS 1.0a”
9 1 pc Power supply VP-3020 Item No 935603009
11 1 pc Relay card QR-2010 Item No 935603008
14 1 pc Driver card printer QD-2020 Item No 935603007 Assembly optionally at

the control cabinet side
16 1 pc Flat cable KV-3037 Item No -935803022
17 1 pc RS-485-driver card SI-240 Item No 977255144
18 1 pc Wiring cable H05V-K Item No 935803043

Length = 100 mm
19 1 pc Connecting cable KA-0213 Item No 935803028
G4-0 9
Wartung
Service
Hanauer Str. 101
D-80993 München
Tel.:+49 (0)89-14901 233
Fax: +49 (0)89 14901 211
The system MSS 8400 is almost maintenance-free.

Check regularly whether the plate can be moved to both sides.
The balls should be relubricated every two years. The lubrication could be done in the course of a
routine test.
In general, the mechanical parts must be regularly cleaned (in particular the lateral deflection areas) in
to guarantee trouble-free operation.
In particular, care must be taken that any water is drained freely and any drainage cannot be blocked.
Repair work must only be carried out by authorized service technicians. The safety measures for
Safety Inspection
The operator has to check the safety-relevant units of the system at least once per year. (Trade
Association Regulation BGV A1, §39 Para. 1 and 3).
Short Operating Instructions

The user has to provide short operating instructions for the operators on the basis of the operating
instructions.
10 G4-0
English
Chapter: I 1 - 0
Test Procedure Roller Brake Test Stands
micro brake 8000/8100/813
Documentation data:
BA mb 8000/8100/813 Prüfablauf/Eng/Rev.02/09.02
EDV 905 802 331
Change: 08.01
11.01
09.02

902802332-02-BA-0-I1-mb8000-8100-813-Test-Sequence-ENG.doc

2 I1–0
Table of Contents
General Information 5
Overview of the Modes of Operation 5
Requirements for the Measuring Operation 5
General Set-up Settings 6
Use of Additional Sensors 6
Set Up Test Programs 7
Switching on of Test Stand 8

General 8
Connection of Additional Sensors (Cable Version) 8
Handling of Additional Sensors (Remote Version) 8
Select Test Program 9
Standard Test Programs 9
Special Programs (Description see Test Sequence Special Programs) 9
Introduction to Display Status 10

Bi-directional Test Operation (Reverse) 10
Normal Operation – Vehicle is Not Positioned on Roller Set 10
Normal Operation – Vehicle is Positioned on Roller Set 11
Turning on of Test Rollers 11
Measuring Operation – Standard 12
Measuring Operation – Additional Sensors 12
Peak Value Display 13
Overview of the Modes of Operation 14

General Information 14
Normal Operation 14
Test Sequence for Single-Axle Brake Test 14
Single Wheel Operation 17
Test of the Opposite Wheel: 18
Four-Wheel Operation 19
Automatic Operation 21
Bi-directional Test Operation 22
Working with Additional Functions 23

Display Repetition 23
Weight Entries 24
Selection of Extrapolation Method 24
Printing Variations 25
Delete 25
Entries for Trailer 26
Test Protocols and Evaluations 27

I1–0 3
Result Printout - tabular 27
List Printout 27
Axle Graphics 27
Total Graphics 27
Notes to the Evaluation 27
Braking force difference 27
Deceleration 27
Ovality 28
Extrapolation Service Brake 28
Selection of Extrapolation Method 28
Two-point Extrapolation 29
Calculation of the extrapolated braking forces for each axle: 29
Addition of extrapolated total brake forces: 29
Calculation of the total deceleration in %: 29
Printout of the values: 30
One-point Extrapolation (SP Test) 31
Calculation of the extrapolated braking forces for each axle: 31
Addition of extrapolated total brake forces: 31
Calculation of the total deceleration in %: 31
Extrapolation – parking brake 32
Parking brake slipped? 32
Test Sequence Special Programs 33

Test Program 6 33
TachoControl 33
Semmler Program 33
General 33
Operation 34
Other Tachometer Control Programs 34
Test Program 7 35
Air pressure checking of the pressures applied / ALB measurement 35
MESRA System Messages: 36
Start of Air Pressure Test 36
Print View and Printing of the Results 36
Printer Configuration 38
Printer Seikosha SP – 2400 (standard printer) 38
DIP switch setting: 38
Error Handling 40
4 I1–0
General Information
Safety Instructions
Please observe the following areas in the Chapter "Roller brake tester micro
brake 8000/8100/813" of the Operating Instructions.
• Principle of functioning
• Intended use
The provisions and regulations as well as the technical specifications and
notes contained in this document must be adhered to without exception.

• A brake test must not be carried out before both tyres on an axle of the vehicle press down the
sensing rollers.
• If the vehicle leaves the roller set during the brake test and/or if the sensing rollers move upwards,
the drive rollers are automatically switched off.
• If the braking force is higher than the friction force between tyre and the test rollers, the tyre starts
to slip (block) The test stand control automatically switches off the drive rollers. If the difference be-
tween roller and tyre speed is too great (>25 %), the braking force is no longer measured, but the
friction force between tyre and test roller. This measuring result is of no use for the brake test. In
addition, the slip shutdown prevents the tyre being damaged.
Overview of the Modes of Operation

Measuring operation with the roller test stand can be effected in the following mode of operations:
Mode of Operation Remark Practice

Normal Operation Both test rollers are started by remote Universal test
"Single axis" control and the measured values of the
left and right tyre are displayed .
Normal Operation A test roller is started by remote control Universal test, brake forces are
“Single wheel” and the measured value is displayed. higher than with "single axle"
test.
Four-Wheel Operation A test roller of the measuring side is Universal test, necessary for the
"Change of rotation" started by remote control and the testing of vehicles with perma-
measured value is displayed. The nent four-wheel drive.
other test roller runs in the "change of
rotation" mode.
Automatic operation If a vehicles is positioned on the roller No remote control necessary.
set the test rollers are automatically Quick test for vehicles.
started. The brakes are tested axle by
axle. After the end of the measuring, No evaluation with hardcopy
the test rollers start again, if the vehicle results possible!
has not left the roller set.
Ovality measuring Ovality measuring can be activated in all test programs during measuring.
Brake forces must be > 500 N (car program) and/or > 1000 N (all other
programs).
The ovality measuring can be indefinitely repeated during a test. The last
three measurements are always stored.
Requirements for the Measuring Operation

Measuring operations require the correct calibration of the sensors and a system in good working or-
der.
I1–0 5
General Set-up Settings
These functions of the operating system settings have been pre-set by the service technician during
the initial installation.
1. Hardware configuration
2. Calibrating sensors
Use of Additional Sensors

During the brake test, additional sensors are required in order to measure the pedal force or the
pressure applied (PX) to the wheel brake cylinder. It is also recommended to measure the supply
and control pressure (PM) of the break system of a towing vehicle/trailer.
Pedal force sensor Air pressure sensor Air pressure sensors remote
(cable/remote) (cable version) version
0-100 kg 0-20 bar 0-20 bar
PM PX Connection
hoses with
standard closure
Note: sensors are also available for a hydraulic brake system.
The use of additional sensors is obligatory to carry out the calculation of the total braking in relationship
to the admissible total weight of the vehicle. For this purpose different projection methods are applied.
- 1-point extrapolation (Germany: safety inspection)
- 2-point extrapolation
To ensure the correct extrapolation of the braking forces with respect to the calculated pressure (e.g.
safety inspection) the following test sequence must be adhered to:
1. Single axle brake test with PX sensor (pressure applied at the braking cylinder)
2. Enter calculated pressure using remote control (single axle or valid for entire vehicle)
3. Enter admissible total weight of the vehicle using the remote control.
4. Print-out of test protocol or display of overall deceleration via LCD
Axle load weigher:

For the automatic measuring of the wheel weights and/or the axle weights, a 4-point or 8-point weigher
is required. The 8-point weigher offer a higher precision.
- The calculation of the axle deceleration and total deceleration of the current vehicle is possible.
- A realistic towing adjustment (=axle graphics) requires the measuring of the axle weight.
6 I1–0
Set Up Test Programs
Each test unit can be operated via several test programs. The test programs have to be correctly con-
figured by the user or service technicians. Only then will measuring and testing with correct evaluation
be possible.
The operating system service “Configuration” includes the following test programs with limit values for
the evaluation methods:
General test programs without configuration
parameters
Special vehicles
Special vehicles
Special vehicles
Special vehicles
Special vehicles
Special vehicles
P6 = TachoControl
vehicle/trailer
Trailer/semi-
P7 = ALB air pressure test
Towing
trailer
Bus
Car
No. Designation P1 P2 P3 P4 P5 P8 P9 P10 P11 P12
Step number for conf. routine:: 30... 40... 50... 60... 70... 80... 90... 100... 110... 120...
0 Braking force difference 25% 25% 25% 25% 25% - - - - -

- service brake
1 Braking force difference 30% 30% 25% 25% 25% - - - - -
- parking brake
2 Braking force difference - - - - - - - - - -
- auxiliary brake
3 Total deceleration 45% 43% 50% 50% 40% - - - - -
- service brake
4 Total deceleration 16% 16% 16% 16% 16% - - - - -
- parking brake
5 Total deceleration - - - - - - - - - -
- auxiliary brake
6 Pedal force limit value (foot-operated) 70dN - 70dN 50dN 70dN - - - - -
- service brake
7 Pedal force limit value (hand-operated) 60dN 60dN 60dN 40dN 60dN - - - - -
- parking brake
8 Pedal force limit value(foot-operated) 70dN - 70dN 50dN 70dN - - - - -
- parking brake
9 Ovality 25% 25% 25% 25% 25% - - - - -
I1–0 7
Switching on of Test Stand
General
The test stand is switched on using the main switch on the left side of the control cabinet. The switch-
ing routine is carried out and, at the same time, the printer supplied with voltage. During this period, the
test stand must be free from load, i. e. no vehicle or other object must be on the mechanics!
If the LEDs have stopped to light and if the pointers have returned to the zero position, the brake test
stand is ready for operation.
After the equipment has been switched on, the test stand is in the standard operation! If a track plate
exists, the red pointer moves into the “12-o’clock position” (see also Item 6!).
In case a pit protection exists, release it using the key. If the lights do not change from red to green,
check whether there are any persons or objects in the protected field. In the case of a swivel arm,
check whether is locked in the correct position.
If all LED displays blink after the switching on routine and if the pointers do not return to the zero posi-
tion, an error is recognised in the system. This is also shown on the LCD displays, if they exist.
Please check in this case first whether the mechanical parts are really free from load.
Using the STOP key, the errors recognised by the test stand can be acknowledged. Through this entry,
the test stand is again ready for operation, however, only as far as admissible by the error.
Connection of Additional Sensors (Cable Version)

The additional sensors PM/PX and/or PD/Hydr. should be connected before switching on the control
cabinet so that a correct zeroing can be made.
To the two connections for additional sensors (round plug at the control cabinet), either
• PM and PX or
• pedal force and hydraulic pressure = PD and PH
can be connected.
When switching to the car program, PD and PH are automatically activated. All other programs switch
to PM and PX.
Each program can be switched between PM/PX or PD/PH using the remote control.
Handling of Additional Sensors (Remote Version)

The additional sensors (PM, PX or pedal force sensor) should be returned into the charging station if
not in use in order to recharge.
Before a brake test of a vehicle, the tester removes the respective sensors from the charging station
to connect the sensors to the test connections for axle brake pressure and control pressure. The cor-
rect zeroing for each sensor is automatically carried out within approx. 2 seconds after their removal
for the charging station
Via the IR remote control, the respective remote sensor can be activated during the single-axle brake
test.
Important: If the sensors remain longer as 1.5h outside the charging station, they switch automatically
off. The sensors can only be reactivated via a short hang-up in the charging station.
Caution: If the sensors remain a long time (approx. 3 weeks) outside the charging station, the accu-
mulator risks to drain. In this case, reactivation is not possible and the accumulators must be returned
for reparation.
8 I1–0
Select Test Program
Before testing a vehicle, the selection of the correct test program is important in order to define the
correct limit values for the deceleration and brake force difference for the evaluation of the brake data.
Standard Test Programs
1 = truck train – tractor truck and tractor combination
2 = trailer and semi-trailer

3 = bus
4 = passenger car
5 = special vehicles
Special Programs (Description see Test Sequence Special Programs )
6 = Semmler / TachoControl – program for speedometer test (Semmler)

7 = Air pressure checking
Program for pressures applied / ALB measurement outside the test stand
A test program can be selected using the following remote control commands.
press
press so often until the desired program is shown
confirm using the Enter key
No of test program
I1–0 9
Introduction to Display Status
Valid for test programs 1- 5 !
Bi-directional Test Operation (Reverse)
Normal Operation – Vehicle is Not Positioned on Roller Set
Move pointer of "measuring scale" to the begin-

ning of scale.
The bi-directional test operation can be activated

from the test stand using the remote control.
This is shown to the user by the cyclically blinking

message " t u r n " in the left 4-digit LCD
display.
The " µ" signalises the following to the user:

1. No compressed air /hydraulic pressure sen-
sors are connected
"turn" = bi-directional
2. The display mode deceleration (left LC) and
test operation is acti-
the brake force difference (right LCD) are vated.
activated.

Move pointer of "measuring scale" to the beginning of scale.
The " µ" signalises the following to the user:

3. No compressed air /hydraulic pressure sensors are con-
nected
4. The display mode deceleration (left LC) and the brake
force difference (right LCD) are activated.
Switching of additional sensors to standard display mode.
In the left LCDs „ - - - - “ appears when the sensor selection

is set at 0=compressed air (PM/PX) or 2=hydraulic pressure
(PM/PX).
In the left LCDs „ P d - - “ appears when the sensor selection

is set at 1=pedal force/hydraulic pressure sensor.
Absolute prerequisite:
- Additional sensors (PM/PX/PD) are connected
- Remote receiver is installed in the control cabinet and
ready for operation
10 I1–0
Normal Operation – Vehicle is Positioned on Roller Set
Green indicator of "measured value scale" shows the axle

weight
In addition to the test program P1, the LCD display shows the
axle weight in tons.
As in "normal operation – vehicle is not positioned on the roller

set", the only difference is that the "left and right arrows" and
the red LEDs on the difference block are lit.
Turning on of Test Rollers
Pointer of "measuring scale" is at the beginning of the scale

and the roller resistance measuring shows the corresponding
brake force value.
In single wheel mode or 4x4 mode, the corresponding pointer
(= passive side) remains on the beginning of the scale.
LED arrows blink during the switching-on phase of the motors.
I1–0 11
Measuring Operation – Standard
Pointer of "measuring scale" shows the corresponding brake

force.
In the difference block, the current brake force difference is
evaluated.
If the brake force exceeds the internal final value of the scale,
the LEDs of the range switching are no longer lit.
LCD display mode
- left LCD: Deceleration [%]
- right LCD: Braking force difference [%]
Ovality measuring: Switching of additional sensors to

The digital values are shown in the left and right LCD. standard display mode:
(also possible during measuring

operation)
Measuring Operation – Additional Sensors
Pointer of "measuring scale" shows the corresponding brake

force.
evaluated.
If the brake force exceeds the internal final value of the scale,
the LEDs of the range switching are no longer lit.
Sensor selection 0=compressed air or 2=hydraulic pressure:

- left LCD: PX [bar]
- right LCD: PM [bar]
Sensor selection 1=pedal force/hydraulic pressure sensor:

- left LCD hydraulic pressure PH [bar]
This key combination opens the
- right LCD pedal force [kg]
selection dialogue for the activation
of different pressure measurements:
Absolute prerequisite:
Additional sensors are connected and/or remote receiver is
installed in the control cabinet and ready for operation
(only possible in the standby mode)
12 I1–0
Peak Value Display
Pointer of "measuring scale" shows the corresponding maxi-

mum brake force value.
evaluated.
In addition, the left or right LED arrow is lit if the slip shutdown
has been analysed on the respective side.
LCD display mode
Standard
- left LCD: Deceleration [%]
- right LCD: Braking force difference [%]
Sensor selection 0=compressed air or 2=hydraulic pressure:

- left LCD: PM [bar] Switching of additional sensors to
- right LCD: PX [bar] standard display mode:
Sensor selection 1=pedal force/hydraulic pressure sensor:

- left LCD pedal force [kg]
- right LCD hydraulic pressure PH [bar]
I1–0 13
Overview of the Modes of Operation
General Information
On principle, the brake test stand can be operated without remote control by using the keyboard at the
control cabinet. This is possible in the automatic, normal and in single wheel operation. Normal and
single-wheel operations are only possible in two-man operation.
Individual wheel test left
Individual wheel test right

variable)
Automatic on
Automatic off
Stop roller set
Normal Operation
Normal operation is the standard test program of the micro brake 8000/8100/813 and is applied for
users with individual tests for test vehicles.
After the brake test of an axle, the user can decide whether the result data of the service or parking
brake are to be memorised on the front or rear axis of the respective vehicle. Thus the resulting data
are available in the memory fields of a display device and/or print module after a new tests have been
made as well. After the testing of the entire braking system of a vehicle, the stored brake data can be
evaluated and printed.
Test Sequence for Single-Axle Brake Test
Connection of additional sensors

The proper connection of the sensors to the right place of the
braking system has to be ensured to guarantee the correct
data evaluation.
- Fit PX1 sensor to the „Braking cylinder axle 1“ connection
- PM sensor for control pressure connection trailer
14 I1–0
Set sensor selection in the program This key combination opens the selection dialogue
for the activation of different pressure measure-
ments.
Standard setting = air pressure measuring

+
With these keys, the corresponding pressure sen-

sor can be selected.
The three measuring procedures are shown on
or the LCD display and the visualisation as follows:
left LCD right LCD STL9000

PM/PX air pressure:
1 - - - P1
PD/PH pedal pressure & hydraulic pressure
2 - PD P1
3 - PH P1 PM/PX hydraulic pressure:
Current setting is activated using the ENTER key.
Move vehicle onto roller set Drive into the test stand with the front or rear axle.
If the test stand is equipped with a weighing system, the axle

weight can be read on the display unit.
Select PX air pressure sensor If the MESRA air pressure sensor is used the tester has to select
the respective axle and/or the sensor connected.
The green pointer of the analogue display shows the current air
pressure sensor or PX-6. The 1000N steps of the inner analogue
display scale are relevant. 1000N = PX1, 2000 N = PX2, 3000 N=
or PX3 etc.
Start test stand By activating the remote keys left on and right on, the left and right
roller set starts.
After the test speed has been reached and the roller resistance
has been ascertained, the actual measuring operation starts.
+ Note:
When the vehicle is in the test stand, the left and right roller set
can be switched on by pressing the automatic key.
There is no activation of the automatic condition.
I1–0 15
Measuring operation The tester must now press the brake pedal slowly and continu-
& ously until reaching maximum brake force. The display unit shows
Ovality measuring: the brake effect.
The test stand is switched off on the following conditions:
• slip control
• sensing rollers no longer pressed down
• Manual abortion of tester by pressing STOP key
Ovality measuring:
If the brake forces of the left and right side are more than 500 N
and/or 1000 N, an ovality measuring can be activated. This meas-
uring can be indefinitely repeated, however the last three meas-
ured values are stored.
Data is stored at the end of the brake test of an axle by the global
saving command.
Peak value display After termination of the test process, the peak values are auto-
matically displayed on the display unit.
The peak value display can be prematurely aborted by pressing

the stop key or by selecting a memory key.
Saving When pressing the service brake and/or parking brake saving key,
the next free memory space is shown on the left LCD display and
Saving is always made in three on the stepper motor, i.e. there is no need to enter the axle via the
steps: remote control during the standard test operation.
• Select braking system (service Example:
brake or parking brake) The first and second axle of the service brake have been saved.
• Correct axle number, if re- The test for the third axle was implemented and is to be saved as
quired. well now. After pressing the service brake memory key, the alloca-
• Confirm with “ENTER”. tion of the third axle appears on the LCD display and on the step-
per motor (3 kN = axle 3). The saving process only needs to be
confirmed with ENTER.
Service brake (standard test sequence is maintained).
Operating brake (number of axles is increased by 2);

st
e.g. the third axle is checked first (display 1 axle ==> increase
axle number by 2!)
Service brake (number of axles is decreased by 1);

e.g. the same axles is stored again.
Parking brake (standard test sequence is maintained).
16 I1–0
Single Wheel Operation
The single wheel test runs parallel to the normal operation with the difference that each tyre can be
tested individually. Please observe that the results of a page must be saved after each test.

the corresponding roller set starts.
The side which is not active remains switched off.
Note:
or On a single wheel test of the left and right side of an axle, higher
brake forces are achieved as the vehicle is not so easily shifted
out of the brake tester.
Measuring operation The tester must now press the brake pedal slowly and continu-
Ovality measuring: the brake effect.
• slip control
Ovality measuring:
If the brake forces of the left or right side are more than 500 N
saving command.

Saving The next step is to save the brake test of this wheel.
See “Single axle” test above!
I1–0 17
Test of the Opposite Wheel:
the corresponding roller set starts.
The side which is not active remains switched off.
or Note:
When a single wheel test of the left and right side of an axle,
higher brake forces are achieved as the vehicle is not so easily
shifted out of the brake tester.
Measuring operation See above

&
Ovality measuring:
Peak value display See above
18 I1–0
Four-Wheel Operation
The micro brake 8000/8100/813 may optionally contain a four-wheel drive program. In this program the
left and right test-rollers operate in opposite directions, and the brake forces are measured on the side
which is currently turning in forward motion. This program is useful for four-wheel drive vehicles, be-
cause it minimises any false measurement readings that may result from overruling of forces and the
locking differential is protected against overload. The saving procedure is carried out in the same way
as for individual wheel control.
To evaluate the differential between the left and right side, a pedal force measuring device must be
used.
Please pay attention to testing instructions in the operating constructions of the vehicle under test!
Connection of additional sen- The proper connection of the sensors to the right place of the
sors braking system has to be ensured to guarantee the correct data
evaluation.
- Use pedal force sensor.
or:
Select PX air pressure sensor If the MESRA air pressure sensor is used the tester has to select
the respective axle and/or the sensor connected.
The green pointer of the analogue display shows the current air
pressure sensor or PX-6. The 1000N steps of the inner analogue
display scale are relevant.
or 1000N = PX1, 2000 N = PX2, 3000 N= PX3, etc.

Test of the left wheel:

nd
Start test stand By activating the remote keys 2 and left on the left and right roller
set starts.
The right rollers will rotate in the opposite direction!
I1–0 19
Measuring operation left The tester must now press the brake pedal slowly and continu-
ovality measuring: the brake effect.
• slip control
Ovality measuring:
If the brake forces of the left or right side are more than 500 N
saving command.

Saving When pressing the service brake and/or parking brake saving key,
the next free memory space is shown on the left LCD display and
Saving is always made in three on the stepper motor, i.e. there is no need to enter the axle via the
steps: remote control during the standard test operation.
• Select braking system (service Example:
brake or parking brake) The first and second axle of the service brake have been saved.
• Correct axle number, if re- The test for the third axle was implemented and is to be stored as
quired. well now. After pressing the service brake memory key, the alloca-
• Confirm with “ENTER”. tion of the third axle appears on the LCD display and on the step-
per motor (3 kN = axle 3). The saving process only needs to be
confirmed with ENTER.
Service brake (standard test sequence is maintained).
Operating brake (number of axles is increased by 2);

st
e.g. the third axle is checked first (display 1 axle ==> increase
axle number by 2!)
Service brake (number of axles is decreased by 1);

e.g. the same axles is stored again.
Parking brake (standard test sequence is maintained).
20 I1–0
Test of the right wheel:
nd
Start test stand By activating the remote keys 2 and right on , the left and right
roller set starts.
The left side will rotate in the opposite direction!
Measuring operation right See above

&
Ovality measuring:
Peak value display See above
Automatic Operation
The automatic operation program is especially efficient for quick tests, as, without remote control, the
vehicle can be driven into the test stand, which starts automatically. In the automatic operation, the
automatic lamp is lit, if no vehicle is positioned on the roller set.
If the test stand is in automatic operation and the measured values are to be saved, the STOP key
must be pressed before restart of the motors. Only then, saving is possible.
Note:
When activating the automatic operation, the vehicles must not be positioned on the roller set of the
brake tester.
I1–0 21
Bi-directional Test Operation
The bi-directional test operation can be necessary under the following conditions:
1. Test hall is not large enough to test a towing vehicle with trailer.
2. The test stand should be entered from both sides to enable a universal test sequence.
On activation of the bi-directional test operation, motors and sensor elements are mirror-inverted con-
trolled and/or analysed.
The measured values and results in the result print-out are to be interpreted from the view of the user
in the vehicle’s direction of travel.
The use of a mobile display and/or a portable touchscreen PC is obligatory, as, depending on the di-
rection of travel, the display should be visible for the tester.
Example:
Due to the special situation, the second axle of the trailer can no longer be tested in the standard test
direction. The user activates the bi-directional test operation and turns the truck trailer. Then the
second rear axle of the trailer is positioned on the roller set. On starting the motors, the direction of
rotation of the left and right motor is changed and, from the view of the tester, (view from the driver’s
cabin into the direction of travel) the brake force values appear on the display cabinet.
Standard test direction "Reverse" test direction
Activation of the selection function
+
Control selection backwards / for-
wards
or
"turn of" "turn on"
= standard operation = bi-directional test opera-
tion
Saving
22 I1–0
Working with Additional Functions
Display Repetition
On the display repetition of the axle results, the axle saved last is offered, after the repetition display
has been activated. The number of axles can be changed when saving.
The display repetition can be stopped with “STOP”.
Operating brake (axle saved last)
Operating brake (axle saved last but one)
Parking brake (axle saved last)
Axle weight empty (only current axle possible)
Computational pressure
Ovality (only currently tested axle possible)
Deceleration service brake empty
Deceleration service brake loaded
Deceleration parking brake empty
I1–0 23
Deceleration parking brake loaded
Weight Entries
The weights entered have priority over the value measured. E.g. an axle weight of 2000 kg is meas-
ured by existing weighers. A axle weight of 2200 kg can be entered via the remote control. For the
calculation of deceleration and overall weight, an axle weight of 2200 kg is used.
The value entered using a numeric keyboard is displayed on the stepper motor as well as on the left
LCD display.
Axle weight empty (must be saved after the test,

but executed before the saving of the axle data!)
Selection of Extrapolation Method

Activation of selection function
+
Control selection backwards /
forwards
"C a l c 2 P" "C a l c 1 P"

= 2-point extrapolation = 1-point extrapolation
or
Saving
24 I1–0
Printing Variations
The measured values must be saved (see saving process)
A standard printout is possible on the Olivetti DM 109 or Seikosha SP-2400 printers via the optional
printer variation.
Standard print with final evaluation of towing vehi-

cle.

semi-trailer.

complete train (service brake)

towing vehicle

semi-trailer.
Axle graphics of service brake with EC spectrum

of complete train plus list print-out.
(see Two-Point-Extrapolation)
Delete
The values saved can be generally overwritten by entered a new value for the same allocation and/or
for the same braking system and the same axle again.
The total memory is also deleted when one or several printouts have been made and a new measuring
has been saved.
Delete last measuring
Delete entire memory
I1–0 25
Entries for Trailer
Activate the trailer key first, before entering or saving data for a trailer. All further entries are made as
described above; here two examples:
Entries for total weight empty for trailer
Saving of parking brake for trailer
26 I1–0
Test Protocols and Evaluations
Result Printout - tabular
List Printout
Axle Graphics
The axle graphics of the towing vehicle and/or trailer/semi-trailer are depicted only graphically if the
following dimensions were measured and/or have been entered:
• Axle weights towing vehicle and/or trailer/semi-trailer (wheel load weigher/remote control)
• Control pressure PM
Total Graphics
The total deceleration of the towing vehicle resp. trailer/semi trailer (empty and loaded) is shown
graphically only if the following sizes are measured or stated:
• Total weight for towing vehicle and/or trailer/semi-trailer empty

• Total weight for towing vehicle and/or trailer/semi-trailer loaded
• Control pressure PM
• Computational pressure
Notes to the Evaluation

CAUTION:
To guarantee the correct evaluation of the axle graphics and lists, the time (approx. 5-15 seconds) and
the usual procedures for a single-axle brake test must be followed to.
Braking force difference

Measured with maximum brake force:
Fli/re,max – Fli/re min Fli/re,max = maximum brake force of left or right wheel
Fdiff = ---------------------------- * 100 % Fli/re,min = maximum brake force of left or right wheel
Fli/re max
Fdiff,= Brake force difference with Fli/re,max
Deceleration
Fli + Fre [N] Fli = brake force left wheel

Z = ------------------------------------------- Fre = brake force left wheel
2
MAchse [kg] * 9,81 [m/s ] MAchse = axle weight – statically
Z = axle deceleration
∑ (Fi,Rad,li + Fi,Rad,re) [N] Fi,Rad,li = braking force of all left wheels

Zges = ------------------------------------------- Fi,rad,re = braking force of all right wheels
2
MGes [kg] * 9,81 [m/s ] MGes = weight of the vehicle
ZGes = total deceleration
I1–0 27
Ovality
Fmess,ovality max – Fmess,ovality min Fmess,ovality,max = maximum brake force per wheel
Fovality = ------------------------------------ *100 % with one rotation
Fmess ovality max Fmess,ovality min = minimum brake force per wheel
with one rotation
Extrapolation Service Brake

An extrapolation of the brake forces will only be carried out if the following sizes are measured or
stated:
• Axle pressure PX
• Computational pressure
The calculation of the total deceleration for a loaded towing vehicle or a trailer/semi-trailer will be only
effected, if the following entry is made :
Selection of Extrapolation Method

Activation of selection function
+
Control selection backwards / for-
wards
or "C a l c 2 P" "C a l c 1 P"

Two-point extrapolation = One-point extrapolation
(SP)
Save
28 I1–0
Two-point Extrapolation
Procedure for the two-point extrapolation of a loaded vehicle for the service brake:
Calculation of the extrapolated braking forces for each axle:

This calculation is made for the left and right brake forces of an axle.
Fmax - F1
m = ----------------------- PXmax: measured max. axle brake pressure [bar]
PXmax - PX1 Fmax: measured max. brake force [N]
PX1: first measured axle brake pressure [bar]
F1: first measured brake force [N]
Pcalc.: calculated pressure entered [bar]
Fneu: extrapolated brake force for left
or right side of an axle [N]
Fneu = Fmax + m *( Pberech - PXmax)
Addition of extrapolated total brake forces:

The left and right brake forces of the stored axles are added.
Fneu(total)= ∑ Fnew(axles) Fneu(total): Sum of all axle brake forces [N]

Weight(total): Total weight of the vehicle [kg]
Zneu(Gesamt) : Total deceleration [%]
Calculation of the total deceleration in %:

Fnew(total):
Znew(total)= ----------------------------------------- * 100%
2
Weight(total) * 9,81 m/s
The total deceleration can only be calculated if the “loaded total weight” is entered via the remote con-
trol.
Diagram of the braking process of a wheel and following extrapolation of the brake force:
F[N]
Fneu
Fmax
F1
PX1 PXmax Pberech P[bar]
Two-point extrapolation
I1–0 29
Printout of the values:
The force and brake force values for the two point extrapolation are printed for each axle in lists.
Print with MICRO-BRAKE 8000:
Axle graphics of service brake with EC spectrum

of complete train.
plus list print out
Print with SCREEN-TEST-LINE 9000:

Menu displays: 6-axles graphics with EWG-
7-axles graphics without EWG-
Note:
In step 12 of the configuration the print of the axles graphics may be prevented.
Example: MICRO BRAKE 8000
list print out
towing vehicle axle 1 Axle weight 2620 kg

Pedal DIFF. Pedal PM[bar] PX[bar] z
pressure pressure
[N] [N]
160 11 180 0 0 1 roller resistance
690 8 630 0.5 0.6 5 opening pressure with
... accompanying force
...
...
5687 8 6400 3.0 2.9 47 maximum values
Structure of the lists:

st
The 1 line always represents the data that are registered when the roller resistance is measured.
nd
The 2 line always contains the opening pressure PX1 with the accompanying brake force F1. The
opening pressure PX1 is stored when LH and RH brake forces are higher than the double roller resis-
tance.
nd
The 2 line always contains the maximum axle brake pressure PXmax with the accompanying brake
force Fmax.
30 I1–0
One-point Extrapolation (SP Test)
Procedure for the BSU/SP extrapolation of a loaded vehicle for the service brake:
Calculation of the extrapolated braking forces for each axle:

This calculation is made for the left and right brake forces of an axle.
Pcalc. - 0,4 bar

m = ----------------------- PXmax: measured max. axle brake pressure [bar]
PXmax - 0,4bar Fmax: measured max. brake force [N]
Pcalc.: calculated pressure entered [bar]
Fneu: extrapolated brake force for left
or right side of an axle [N]
Fnew = Fmax * m 0,4 bar: minimum pressure to make mechanical brake cylinders
workable.
Addition of extrapolated total brake forces:

The left and right brake forces of the stored axles are added.
Fneu(total)= ∑ Fnew(axles) Fneu(total): Sum of all axle brake forces [N]

Zneu(Gesamt) : Total deceleration [%]
Calculation of the total deceleration in %:
Fnew(total):
Znew(total)= ----------------------------------------- * 100%
2
The total deceleration can only be calculated if the “loaded total weight” is entered via the remote con-
trol.
Diagram of the braking process of a wheel and following extrapolation of the brake force:
F[N]
Fneu
Fmax
0,4 bar
PXmax Pberech P[bar]
BSU extrapolation
I1–0 31
Extrapolation – parking brake
An extrapolation of the parking brake will only be carried out if the following sizes are entered:
F(total)= ∑ F(axles) F(total): Sum of all axle brake forces [N]

Zneu(total) : Total deceleration [%]]
F(total):
Znew(total)= ----------------------------------------- * 100%
2
Parking brake slipped?

Empty towing vehicles resp. trailer/semi-trailers tend during the test of the parking brake to slip early
when low brake forces are applied. According to the extrapolation of the admissible total weight the
vehicle often does not reach the legal value for decelerations.
In order to make clear this fact to the examiner, the following function is integrated:
If during a check of the parking brakes the vehicle has been switched off due to slip and also the ad-
missible total weight of the towing vehicle resp. the trailer has been inserted, on the print the following
symbol appears in the category “final valuation of the parking brake”:
„>>„
In case of connection between the STL9000 visualisation and the test bench, the sign “>>” may also
appear on the screen.
32 I1–0
Test Sequence Special Programs
Test Program 6
TachoControl
In the test program 6, it is possible to switch on the roller sets of the brake test stand via remote control
and/or keyboard if no Semmler software is linked to the test stand.
Otherwise the control of the test stand is implemented by the Semmler program.
The safety functions (e.g.: slip shutoff) are always active.
The Semmler TachoControl or the procedures for other tachometer control programs is described in
more details in the following points:
The left and/or the right LCD display show the weight and the number of the test program. On operat-
ing the motors, the slip arrows blink.
LCD display variations in the Test Program 6:
left LCD right LCD

Weight: P6 state of rest
- - - - P6 measuring operation
(blink)
The pointers of the stepper motors are in zero position.
Semmler Program
General
If no STL9000 visualisation is connected to the test stand, a serial communication with the Semmler
PC is set up via the computer board in the control cabinet of the MB8000.
Otherwise the program STL9000 and the Semmler software can be installed on a PC.
On the installation of the Semmler software, the interface (e.g. COM1, COM2,..) which is connected to
the control of the MB8000 must be stated.
Caution: The IR remote control can no longer fully operate the test stand.
The „STOP“-key switches off the test stand in case of an error.
The „STOP“-key functions on the remote control and the keyboard.
Using the „Test program selection“-key the user can directly select another program.
I1–0 33
Operation
The operation itself and the safety instructions of this program must be taken from the SEMMLER op-
erating instructions.
With the following remote control commands, the menu control of the TachoControl system is effected.
With these keys, the individual menu options are

selected in the Semmler program.
Corresponds to PC keyboard: Cursor up/down
The action is started by pressing the enter key.

Corresponds to PC keyboard: [ENTER]
By pressing the CL key, the current menu is

closed.
Corresponds to PC keyboard: [ESC]
Using the STOP key, the Semmler program

TachoControl is ended.
Other Tachometer Control Programs

If the vehicle is positioned in the test stand, the roller set can be switched on/operated via the key-
board or the following remote control commands.

variable)
Vehicle is positioned on the test stand:

The keys „Left on“ and „Right on“ are simulated.
The motors are switched off using the STOP

key.
In addition to the above keys and the program selection key, all other remote control keys are blocked.
Note:
If within 5 minutes no change in the brake force occurs, the test stand control switches off the motors.
Caution:
On operation of the motor, both slip arrows blink.
The test program 6 is ended by the selection of another test program
34 I1–0
Test Program 7
Air pressure checking of the pressures applied / ALB measurement
With the test program 7, all MESRA remote sensors can be depicted.
When measuring, the measured values are shown digitally and in the form of a bar chart for each re-
mote sensor connected.
In this manner, the ALB controls can be simply checked.
The tester has the possibility to see and if necessary print the summarised measured values in the
print view.
During the air pressure test, the lorry does not have to be positioned in the test stand and/or the roller
set does not need to be switched on.
Note:
The depiction of all MESRA remote sensors is only possible in connection with a PC and STL 9000.
Cable sensors connected cannot be depicted.
I1–0 35
MESRA System Messages:
f a remote sensor has an error (battery defect) or if it is outside its transmitting area, instead of the
measured value, an error message is shown. If a remote sensor (during measuring) is in a zero condi-
tion, its readiness for operation is signalised after one minute.
If the remote sensor is positioned again in the charging station after measuring, a corresponding mes-
sage is shown at the screen. By default, the MESRA Sensor PY (hydraulics is switched off in the con-
figuration routine. If the PY exists in the system, the value 1 must be set in the step 13.
The remote sender is defect or outside its transmitting range.
The remote sensor is ready for operation.
The remote sensor is again in the charging station after measuring.
Optionally, the MESRA error message can be output via an external warning device (horn, warning
light etc.) when using an additional relay card.
Start of Air Pressure Test
By pressing the remote “Manometer” keys, the message is started.
The pressures measured appear

on the screen of the test program 7
The measurement is interrupted by pressing the

STOP key.
Print View and Printing of the Results
By pressing the key the print view is opened. Measured values can be viewed and printing
stared by pressing the printer symbol.
36 I1–0
I1–0 37
Printer Configuration
Printer Seikosha SP – 2400 (standard printer)
DIP switch setting:
Note:
Switch off the printer before carrying out any modifications to the DIP switch-positions.
Caution:
If the printer was in operation allow the printer head to cool before attempting to touch it.
DIP switch setting:
1. Open printer cover
2. Remove the colour cassette tape
3. Manually push the printer head to the right.
4. Push the DIP switch cover on the mechanical block to the left and remove the cover.
After setting the DIP switches replace the cover, reinsert the colour cassette tape and replace the
printer cover.
The reading of the DIP switch setting is carried out after the printer has initialised upon restarting the
printer and/or after receiving the "INITIAL" signal to the parallel interface.
38 I1–0
Printer Seikosha SP – 2400
Drucker SEIKOSHA SP - 2400

DIP - Schalter - Einstellung
DIP - Schalter 1:
DIP -Schalter1
On
1 2 3 4 5 6 7 8
Schalter 1 - 3: Internationaler Zeichensatz USA

Schalter 4: Moduswahl EPSON
Schalter 5: Zeichensatzwahl Grafik
Schalter 6: Seitenlänge 12 Zoll
Schalter 7: DC1/DC3 - Codewahl nein
Schalter 8: CR - Codewahl AUTOFEED
DIP - Schalter 2:
On
DIP - Schalter 2
1 2 3 4 5 6 7 8
Schalter 1 - 2: serielle Übertragungsgeschwindigkeit 9600BPS
Schalter 3: serielle Ausdruckswahl BEREIT/ BETRIEB
Schalter 4 - 5: Paritätswahl KEINE PARITÄT
Schalter 6: serielle Datenlänge 8 Bits
Schalter 7: Schnittstellenwahl Parallele Schnittstelle
Schalter 8: Einzelblattzuführung AUS
Note:
These DIP switch settings have already been factory-preset.
I1–0 39
Error Handling
In case of errors all LED-symbols will blink on the screen. In case of the existence of LCD displays
(optionally) the corresponding error code is shown there. All errors are automatically printed.
In case of missing or defect components which do not have any influence on the functional safety or
are no options, a message (e.g. ...46) is shown on the LCDs for a short time. The test stand, however,
returns to the basic status quite in contrast to the error messages.
An error message appears on a display

The error conditions can be removed by a repair of the test
units.
Partially reduced operation is possible.
The user has to confirm the error/alarm messages.
IR remote control – key <Stop>
Button at the control display
No. Designation Remark

Error 1 Vehicle on roller set when switching on the unit
Error 2 Line break, slip roller left
Error 3 Line break, slip roller right
Error 4 Line break, sensing roller left
Error 5 Line break, sensing roller right
Error 6 Line break, brake force sensor left
Error 7 Line break, brake force sensor right
Error 8 Line break, weigher sensor left
Error 9 Line break, weigher sensor right
Error 10 Zero point too high – left brake force sensor
Error 11 Zero point too high – right brake force sensor
Error 12 Zero point too high – left weigher sensor
Error 13 Zero point too high – right weigher sensor
Error 14 Amplifier defect – sensing roller left
Error 15 Amplifier defect – sensing roller right
Error 16 Amplifier defect – slip roller left
Error 17 Amplifier defect – slip roller right
Error 31 No communication with battery RAM
Error 32 Checksum error ==> Configuration value
Error 33 Communication with relay card faulty
Error 34 Checksum error ==> Calibration value
Error 35 No communication with EEPROM
Error 37 Error XDATA test
40 I1–0

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EDV 905 082 132 Operating Instructions

Test Unit Roller Brake Tester

BA micro brake mb 813/Eng/Rev.03/02.07

First edition: 11.02

Beissbarth GmbH Automobil-Servicegeräte

Model tag data

Brake Test Stand

Side Slip Plate

Startup completed on ___________________________

Startup completed by (Name) ___________________________

Customer Service Department +49 – 89 – 14901 – 233

Germany +49 – 89 – 14901 – 211

Safety Instructions - Lorry A1

Control Cabinet Type 1 B1

Infrared Remote Control JLS-0180 C1

Air Pressure Sensor Cable Version D2

Air Pressure Remote Sensors D3

Test Unit Roller Brake Tester micro brake 813 G2

Test Unit Track Plate micro side slip 8400 G4

Test Procedure Roller Brake Test Stands

micro brake 8000/8100/813 I1

Por la presente, declaramos que la máquina/equipo descrito a continuación, como resultado de su

Bezeichnung der Maschine/Ausrüstung: Machine/Equipment description: Description de la

Typ:. micro-brake 8000/8100/813 (mb 8000/8100/813)

In conformance with the requirements of the following EC Guidelines:

En concordance avec les exigences des directives CE:

In conformita con le seguenti normative CE:

Conforme con los requerimientos de las siguientes Guias de la CE:

Em conformidade com os seguintes Regulamentos CE:

Conform de Bepaligen van de EG-Richtlijnen:

I enlighet med EC följande väglednings föreskrifter:

Angewandte harmonisierte Normen, insbesondere: Applied harmonious norms, in particular: Application de

EN 60204-1; EN ISO 12100-1; EN ISO 12100-2, EN 294;

First edition: 07.01

Archiv: \\muefs01\data\5-Prüfen\80\905.802.052-03- Safety-Instructions-Lorry -ENG\Originale\

Beissbarth GmbH Automobil-Servicegeräte

Operator's Duty of Care 4

§§ these measures and to ensure that they are carried out.

The operator must particularly ensure that

This symbol indicates particular danger to people.

This symbol indicates particular danger to machine, materials and the

This symbol does not indicate safety instructions, but information

Basic Safety Measures During Repair and Maintenance

Before carrying out maintenance or repair work, do not permit any

Dispose any environmentally harmful lubricants, coolants or cleaning

Follow Environmental Regulations

Laws, Guidelines and Standards

• Guideline for the use, assembly and testing of brake testers.

BA Control Cabinet Type 1/Eng/Rev.03/03.08

First edition: 07.01

Archive: Tech.Redaktion_bbmuc001_(H) \ Papier_Dokumentation \

Beissbarth GmbH Automobil-Servicegeräte

Left ON /Right ON key

RS 485 driver card Drawing EDV-915804001 S 485 driver card

Item Quantit Unit Designation Item number / standard abb. Remarks:

2 1 pc Sensor connecting cable KA-0170 Item No 935803027

3 1 pc Key board PT-2010 Item No 935603026

4 1 pc Flat cable KV-1080 Item No 935603024

5 1 pc Central computer NC-2051 Item No 935603004

7 1 pc Central computer NC-2050 Item No 935603005

9 1 pc Power supply VP-3020 Item No 935603009

10 1 pc Power supply cable KA-0082 Item No 935603010

11 1 pc Relay card QR-2010 Item No 935603008

12 1 pc Flat cable KV-1047 Item No 935803023