Sherpa BPS-Kompakt 3.0 Manual de usuario

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 1

Operating Manual for

Roller Brake Tester

BPS-Kompakt- 3.0 to 6.0

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 2

Despite careful content verification e cannot guarantee that this edition is free of errors.

This manual is intended for users ith previous technical kno ledge in the field of vehicle testing technology.

version BA-BPS-K-3.0-6.0-D-120225

language: English

Date: 25.02.2012

Am Industriepark 11

D-84453 M hldorf

Telephone: +49 (0) 8631 3766 -0

Telefax : +49 (0) 8631 161650

Internet: http://www.sherpa.de

E-Mail: inf[email protected]

Technical modifications and all content contained herein are subject to change.

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 3

.Contents

1. Important Basic Information.................................................. 7

1.1 Scope of Delivery............................................................................................... 7

1.2 Additional Equipment........................................................................................ 7

1. Responsibilities of the Manufacturer in accordance with .............................. 7

1.4 Responsibilities of the Operator ...................................................................... 7

1.5 External Interfaces ............................................................................................ 7

1.6 Legal Information .............................................................................................. 8

1.7 Documentation .................................................................................................. 8

1.8 Conventions....................................................................................................... 8

2. Safety .................................................................................... 10

2.1 Safety guidelines ............................................................................................. 10

2.2 Behaviour in the case of an emergency......................................................... 10

2. Purpose and Use ............................................................................................. 10

2.4 Requirements for the Personnel .................................................................... 10

2.5 Health and Safety at Work............................................................................... 10

2.6 Safety-relevant environmental conditions..................................................... 11

2.7 Assembly and Disassembly............................................................................ 11

2.8 Disposal ........................................................................................................... 11

2.9 Compliance with the Operating Manual......................................................... 11

2.10 Safety markings on the machine .................................................................... 11

2.11 Remaining risks and safety precautions ....................................................... 11

. Technical Information .......................................................... 12

.1 Identification .................................................................................................... 12

4. Description of the system.................................................. 12

4.1 Range of Application....................................................................................... 1

4.2 Main Component ............................................................................................. 14

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 4

4.3 Modes of Operation ......................................................................................... 16

5. Installation Requirements.................................................... 17

5.1 Installation........................................................................................................ 17

5.2 Fun tional Des ription.................................................................................... 17

5.3 Des ription of the Pro ess ............................................................................. 17

5.4 Display Units.................................................................................................... 17

5.5 Assembly Site .................................................................................................. 18

5.6 Delivery and Installation Requirements of the Test Stand ........................... 18

5.7 Installation Plan ............................................................................................... 18

5.8 Entire Spa e Requirement .............................................................................. 18

5.9 Dimensions and Weights ................................................................................ 18

6. Assembly and Installation, Initial Commissioning............. 19

6.1 Assembly Requirements ................................................................................. 19

6.2 Safety................................................................................................................ 19

6.3 Assembly and Installation............................................................................... 19

6.4 Calibration devi e in a ordan e with ISO 17025......................................... 19

6.5 Initial Commissioning ..................................................................................... 19

6.6 Option lifting and lowering devi e ................................................................. 20

6.7 Option Remote Control ................................................................................... 20

7. Operation ............................................................................ 212

7.1 Safety................................................................................................................ 22

7.2 Operating Elements......................................................................................... 22

7.3 Display Units.................................................................................................... 23

7.4 Operation of the Test Stand............................................................................ 24

7.5 Modes of Operation ....................................................................................... 234

7.6 Remote Control................................................................................................ 25

7.7 Motor y le brake test (option)........................................................................ 25

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 5

7.8 „Automatic all-wheel drive detection“ (option) ............................................. 25

7.9 Electronic ontrol Box - General View .......................................................... 26

7.10 Test procedure automatic all-wheel drive detection................................... 267

8. Brief Operating Instructions................................................ 28

8.1 Start up the test stand..................................................................................... 28

8.2 Entering the test stand.................................................................................... 28

8.3 Brake Test ........................................................................................................ 28

8.4 Leaving the test stand.................................................................................... 28

8.5 losing-down................................................................................................... 28

9. Trouble Shooting.................................................................. 29

9.1 Safety................................................................................................................ 29

9.2 Service Address............................................................................................... 29

9.3 Location and marking of fuses....................................................................... 29

9.4 Error type detection......................................................................................... 29

9.5 Error checklist ................................................................................................. 29

10. Maintenance and Repair ...................................................... 32

10.1 Safety................................................................................................................ 32

10.2 Proof of Maintenance ...................................................................................... 32

10.3 ontrol Process and Testing Devices............................................................ 32

10.4 Inspection and Maintenance Plan .................................................................. 32

10.5 Specification of the Inspection and Maintenance Plan................................. 32

11. Disassembly and Disposal .................................................. 33

11.1 Safety................................................................................................................ 33

11.2 Disassembly................................................................................................... 323

11.3 Description of Disoposal Work....................................................................... 33

12. omplementary Documentsränzende Unterlagen ............. 34

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 6

12.1 Drawings and Layouts..................................................................................... 34

12.2 Foundation and Installation Plans.................................................................. 34

12.3 Spare Parts and Consumables ....................................................................... 34

12.4 lectronic Documentation .............................................................................. 34

12.5 Operating Manuals for the options................................................................. 34

12.6 Test Reports..................................................................................................... 34

12.7 Service Address............................................................................................... 34

13. C Declaration of Conformity.............................................. 35

14. Notes ..................................................................................... 36

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 7

1. Important Basic Information

1.1 Scope of Delivery

1.1.1 Basic Equipment:

- set of rollers

- electric control bo

- display

- manual for operating instructions

1.2 Additional Equipment:

- remote control (infrared)

- pedal force meter

- simultaneous display (analog), several simultaneous displays possible via bus system

- digital display “Sherlane“

- printer

- weighing unit with four dynamometers per set of rolls

- heater of control bo

- heater of set of rolls

- PC converter bo with software „SharlanePC“

- radio pressure converter

- automatic all-wheel drive detection

- ASA-Livestream Set

1.3 esponsibilities of the Manufacturer in accordance with:

- Machinery Directive 2006/42/EC of May 17, 2006

- EMC Directive 2004/108/EC of December 15, 2004

- Low Voltage Directive 2006/95/EC of December 12, 2006

- Directive Vkbl. (official gazette of the Federal Ministry of Transport, Building and Housing in

Germany) 2003 / p. 303 for the operation, condition and testing of brake testers

- EC Directive CE marking

- DIN EN 60204-1 electronic equipment of the machines

- GS-EM I 04 - 01 and BGR (the German Federal Institute for Geosciences and Natural

Resources) 157 auditing standards for machines and devices responsible for vehicle

maintenance and for testing vehicles

- EC-declaration of conformity

1.4 esponsibilities of the Operator

- The machine may only be installed by competent and qualified personnel.

- The machine may only be used in accordance with its intended purpose.

- This operating manual must be read carefully in its entirety before commissioning the machine.

Keep these instructions within reach at all times.

- Personal injuries which are a result of the non-compliance with this operating manual are not

covered by the Product Liability Act.

- Sherpa does not assume liability for any damage to the test unit or the vehicle that was caused

due to non-compliance with this operating manual.

- Safety guidelines warn of potential risks and help to avoid personal injuries and damage to

properties. For your own safety, it is imperative that you adhere to the safety guidelines set out in

this manual.

- The national and international safety regulations applicable in the respective country of operation

must be adhered to at all times. Every operator himself/herself is responsible for complying with

the regulations applicable to him/her and for obtaining independently the respective current

regulations.

- The operating manual is part of the machine.

- The operating manual must be maintained and updated throughout the entire service life of the

machine.

- The operating manual must be forwarded to any subsequent owner of the machine.

1.5 External Interfaces

- Interfaces for computer connection

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 8

1.6 Legal Information

1.6.1 Limitation of Liability

- Our liability is li ited to the foreseeable da ages typically occurring under the contract. We shall

only be held liable for da age caused deliberately or due to gross negligence.

- The above li itation on liability does not apply in the event of injury to body or health.

- Any entitle ent to da ages expires regularly, two years after the ti e that it beca e justifiably

clear that da age had occurred, or at the latest ten years after the da age occurred.

1.6.2 Warranty

- We warrant that our products are free fro defects for a period of 12 onths fro the date of

delivery to the purchaser. This does not apply for the delivery of used products. Any warranty is

excluded here.

- Within the scope of the warranty, we are entitled to li it our responsibilities to provide a re edy

and/or a replace ent delivery at our own discretion.

- We accept no liability for any consequential da age or lost profits.

- All parties to the contract reserve the right to rescind the contract in the case of any unsuccessful

atte pt to re edy defects and/or any i possible replace ent delivery.

1.7 Documentation

1.7.1 Operating Instructions – in accor ance with DIN EN 62079

- The following docu ents, if not already included in the operating anual, are at your disposal:

- Operating Manual: option „auto atic all-wheel drive detection“

- Re ote control Mechoscreen – brief instructions

- SherlanePC oparating anual

- ounting and installation instructions

- electrical circuit diagra

- aintenance and service instructions (including the Calibration Manual and the test report of the

routine test)

- list of spare parts

1.8 Conventions

1.8.1 Illustration

front axle parking brake rear axle entire weight printout

left right confir select device

- direction of rotation and

easure ent reversal of the rollers

auto atic button

toggle function for „auto atic ON or

OFF“ and STOP

1.8.2 Abbreviations

BPS brake tester e- otor electric otor

L / R left / right kW kilowatt

kN kilo Newton kg kilogra

k /h kilo etres per hour

LED digital indicator light

1.8.3 Technical Terms

SB service break FSB parking brake

PM pneu atic charge pressure PX pneu atic brake cylinder pressure

DMS strain gauge

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 9

2. Safety

2.1 Safety guidelines

- According to the manufacturer s declaration the "PRINCIPLES about testing the safety of roller

brake testers and roller dynamometers" (GS-EM I 04-01), as well as the auditing standards for

machines and devices responsible for vehicle maintenance and for testing vehicles (BGR 157)

were taken as a basis during the production of the brake tester.

- This operating manual must be read carefully in its entirety before commissioning the machine.

Keep these instructions within reach at all times.

- Personal injuries which are a result of the non-compliance with this operating manual are not

covered by the Product Liability Act.

- Sherpa does not assume liability for any damage to the test unit or the vehicle that was caused

due to non-compliance with this operating manual.

- Safety guidelines warn of potential risks and help to avoid personal injuries and damage to

properties. For your own safety, it is imperative that you adhere to the safety guidelines set out in

this manual.

- The national and international safety regulations applicable in the respective country of operation

must be adhered to at all times. Every operator himself/herself is responsible for complying with

the regulations applicable to him/her and for obtaining independently the respective current

regulations.

Danger: If instructions are not followed carefully or not complied with, the personal safety

can be put at risk.

Warning: If these instructions are not followed carefully or not complied with, the device

might be damaged.

Please note: Additional information will be provided.

2.2 Behaviour in the case of an emergency

- In the case of a dangerous situation or an emergency, the test stand must be shut down by

means of the main switch (emergency stop function) at the electric control box.

2.3 Purpose and Use

- The roller brake tester can be used to test the brake systems of two-track vehicles.

- The test stand may only be used in accordance with its designated purpose and within its

performance limits.

- The measured brake force is indicated separately for each wheel.

- The test stand is not designed for testing all-wheel drive or multi-axle vehicles. However, all-

wheel drive vehicles can be tested on some conditions.

2.4 Requirements for the Personnel

- The test stand may only be operated by authorized qualified personnel.

- The test stand may only be operated by trained qualified personnel.

2. Health and Safety at Work

- main switch: A lockable main switch (emergency switch) is available.

- sensor rolls: The test unit only starts if both sensor rolls are pushed down within 2

seconds .

- step protection: protection sheets are installed beneath the sensor rolls.

BPS – K – 3.0 – 6.0 Sherpa Autodiagnostik page: 10

2.6 Safety-relevant environmental conditions

- The V-shaped slot bet een the rollers must be secured by a cover or an elevated step

protection.

- If the repair pit is under construction and the test unit in operation, no person is allo ed to stay in

the area belo the vehicle.

- Depending on the national regulations, the repair pit must be covered or secured by other means

for access.

2.7 Assembly and Disassembly

- see "assembly, installation, initial commissioning"

2.8 Disposal

- The transmissions of the driving engines are filled ith oil hich must be disposed of separately.

- Electronic circuit boards must be disposed of separately.

- This also applies for remote controls and printers.

- Sheet metal and iron parts are scrap metal.

2.9 Compliance with the perating Manual

- The operating manual must be complied ith at all times.

- The operating manual must al ays be kept close to the machine and be available to the entire

personnel of the machine at all times.

- If applicable, the operating manual must be for arded to any subsequent o ner of the machine.

2.10 Safety markings on the machine

- The roller sets of the testing facility must be marked ith circumferential arning markings on the

floor or be secured by a barrier.

- The option "automatic all- heel drive detection" is indicated on the control box.

2.11 Remaining risks and safety precautions

- Bet een the drive rollers is a V-shaped slot in hich the sensor roll moves. Depending on the

set-up area of the test unit, the test unit must be covered or fenced off to prevent access.

- If the drive rollers are elevated, there is a risk of tripping over.

- The test unit is equipped ith rollers hich are independently driven by electric motors. While the

rollers are spinning nobody is allo ed to be in the direct vicinity of the rotating rollers.

- After the vehicle has been driven onto the test stand, shift into neutral to disconnect the po er

flo to the drive axles.

- No parts or heels must be parked on or bet een the test rollers.

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