Boston PD301 User manual

DOC: BOS0295 User Manual PD301 Play Detector
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PD301
Hydraulic Wheel Play Detector
USER MANUAL
Garage Equipment Association
Boston Garage Equipment, 199 New Road, Rainham, Essex, RM13 8SJ, nited Kingdom
T: [phone] F: [phone] [email protected] www.boston-ge.com
DOC: BOS0295

DOC: BOS0295 User Manual PD301 Play Detector
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Contents
1.0 Introduction 3
1.1 Product Description 3
2 .0 Safety 3
2.1 Special Notice 4
3.0 Operation 5
3.1 The Pedestal 5
3.2 Main Power 6
3.3 Emergency Stop 6
3.4 Mode Switching 7
3.5 Plate Operation 8
3.6 Inspection Torch 9
4.0 User Maintenance 12
5.0 Troubleshooting 14
6.0 Parts List 15
7.0 Specifications 16
8.0 Warranty 17

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1.0 Introduction
This manual describes how to safely use the PD301 for statutory Vehicle Inspection
Classes 4 and 7 vehicles.
Before operating the PD301 this user manual should be read thoroughly, and if any part is
not fully understood then please refer to the Boston technical department for clarification.
1.1 Product description
The PD301 is a hydraulically operated device used to move the position of a vehicle wheel
in different directions to detect wear and play in suspension and steering joint components.
It includes a moving plate that can move laterally by 40mm in both directions and rotate
about a centre point by 8 degrees clockwise and anti-clockwise.
The equipment comprises three items. The Pedestal, the Play Detector and the Handheld
Torch Control. Operation of the Play Detector can be achieved by using the membrane
keypad fitted to the body of the control torch, or by using the secondary keypad located on
the pedestal. There is also an optional wireless control torch.
2.0 Safety
In order to comply with your responsibilities under the Health and Safety at Work Act 1999,
it is essential that the PD301 is used, operated and maintained by a competent individual
with experience in the automotive industry.
The forces operating inside the play detector are considerable and misuse can be
dangerous. Always check that the area around the PD301 is clear and free from tools or
equipment. Be very careful during operation not to allow any part of the body, loose
clothing etc. to rest or come in to contact with the moving plate.

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2.1 Special Notice
SPECIAL NOTICE
To meet MoT testing specifications the PD301 play detector applies a very
considerable hydraulic forces to the steering components and bearings, in addition
to the play detector and it fixings. The PD301 is designed to provide long-life
performance with recommended periodic servicing.
The automatic mode should be used for several movements when required and not
run continuously. The LEFT, RIGHT and rotational manual movements should be
used only as required to provide adequate vehicle inspection. This will maintain
your play detector in excellent condition and ensures that vehicles are not affected
by applied lateral forces.
IMPORTANT: Using the PD301 on a vehicle hoist supplied by any company other
than BOSTON GARAGE EQUIPMENT, or without written certification from BOSTON
GARAGE EQUIPMENT that the PD301 is suitable for that hoist, is considered
improper use.
♦Appropriate training is required, prior to using or maintaining the PD301.
♦The PD301 has a maximum load capacity of 1500 kg.
♦If the PD301 is fitted to a vehicle hoist, it is important that the hoist is placed in
the ‘locked’ position prior to operation of the PD301, and not supported by the
steel ropes or other means. It is also important to check weekly that the floor
fixing bolts of the hoist are tight and in good condition.
♦The unit should be kept clean and well maintained to protect against wear and ensure
good operation.
♦Only a qualified technician should operate the PD301.
♦The operator should follow procedures prescribed by national standards and the
regulations of Health and Safety.
♦Keep the operating environment clean and free of oil and tools.

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3.0 Operation
The PD301 may be used in conjunction with MoT Automated Test Lanes (ATLs). The
operation of the PD301 for MoT testing must be carried out with reference to, and in
accordance with the MoT Tester’s Manual. (copy available from VOSA on request) During
testing, it is necessary to apply the parking brake so that underside inspection can be
safely carried out when using the Play Detector.
On every power-up, the play detector will perform an auto-centre. The plate will first move
right and then left until it comes to rest in the centre position. It will only return back to this
position after each button press in “Continuous Mode” or when the unit is re-started.
To preserve energy and reduce pump / motor wear, the software will de-activate the motor
approximately 2 seconds after each operation.
Note: Ensure the plate is free to move and there is no weight on the plate during the
auto-centre procedure. The plate must be at the centre point before testing a
vehicle.
3.1 The Pedestal
The control pedestal houses the hydraulics and main control system for the Play Detector.
From the pedestal, the operator can switch between Torch or Pedestal mode, and Manual or
Continuous mode. Also there are individual control buttons to manoeuvre the moving plate in
any of four individual directions and an Emergency Stop button that stops the plate
immediately.
Mode
and plate
operation
buttons
Emergency
Stop button
Main power
switch

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3.2 Main Power
The Main Power switch disconnects all power to all parts of the console when switched off.
There is also a safety power isolator inside the pedestal which disconnects all power in the
event of a fault. This can only be accessed by removing the top panel and front cover of the
pedestal, and can be reset by depressing the START switch.
It is recommended that the console be switched off every evening.
3.3 Emergency Stop
The Emergency Stop button can be pressed at any time to immediately stop the plate from
moving. Its function is to stop the motor and associated operational buttons. The button is
spring loaded and once it has been pressed it will remain depressed until released.
To release the button, rotate the button in the clockwise direction until it springs back to its
original position.
Note: Always ensure that the plate is free to move and clear before de-activating the
Emergency Button. Once re-activated, the motor will restart and the system will
perform the auto-centre procedure.
Main START
switch

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3.4 Mode Switching
a) Torch / Pedestal
When the Torch mode is selected, the Torch LED will show and the play detector
can only be operated from the remote torch. The plate operation and mode change
buttons on the Pedestal are disabled as a safety precaution against accidental
operation from another operator.
When the Pedestal mode is selected, the Pedestal LED will show and the play
detector can only be operated from the Pedestal console. The plate operation
buttons on the Torch are disabled as a safety precaution against accidental
operation from another operator. The inspection lamp at the front of the torch can
still be operated as normal.
b) Manual / Continuous
The Manual and Continuous modes allow the operator to change the way in which
the plate moves under the vehicle wheel.
When using the Manual mode, the plate will move in the direction corresponding to
the pressed button. This allows incremental movement of the top plate when
diagnosing problems.
When Continuous mode is selected, the plate will move in one direction and then
the opposite direction continuously until the button is released. This allows the
operator to look for play in both directions, without having to use another button to
move the plate in another direction. Whenever a plate operation button is released,
the plate will return to the centre position.

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3.5 Plate Operation
When the Manual mode is selected, the Manual LED will show and the play
detector will operate in the following way.
BUTTON DEPRESSED PLATE MOVEMENT
LEFT Moves LEFT
RIGHT Moves RIGHT
ROTATE LEFT Rotates LEFT
ROTATE RIGHT Rotates RIGHT
When the Continuous mode is selected, the Continuous LED will show and the
play detector will operate in the following way.
BUTTON DEPRESSED PLATE MOVEMENT
LEFT Moves LEFT first and then RIGHT repeatedly until button release
RIGHT Moves RIGHT first and then LEFT repeatedly until button release
ROTATE LEFT Rotates LEFT first and then RIGHT repeatedly until button release
ROTATE RIGHT Rotates RIGHT first and then LEFT repeatedly until button release
The above tables also refer to button operation on the handheld torch control.
LEFT ROTATE RIGHTRIGHT ROTATE LEFT

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Torch lamp ON / OFF
Battery Low LED
Move plate LEFT
Move plate RIGHT
Rotate plate LEFT
Rotate plate RIGHT
Deactivate SAFETY
PD activated
Power ON
3.6 Inspection Torch
The inspection torch provides a remote means of operating the Play Detector with the ability
to light the area of inspection. The torch is hard-wired to the pedestal by means of a heavy-
duty coiled data cable. The button operations are the same as described in section 3.6
above with the addition of an extra LAMP ON / LAMP OFF button. It is not possible to switch
between MANUAL and CONTINUOUS modes using the torch, this can only be done from
the pedestal, and only when PEDESTAL mode is selected. The torch keypad is laid out as
below.
Keypad Functionality – Hardwired Torch
The torch is programmed with a standard safety feature to prevent accidental operation of
the Play Detector should the buttons be pressed. The operation of the four lower buttons
(control buttons for the moving plate) are disabled until the SAFETY button is depressed
first. When the SAFETY button is pressed, the LED under the PD symbol will light. This
signifies that the four control buttons are now ‘active’. After six seconds of inactivity, the
PD LED will automatically switch off and hence the safety is engaged. Only when the PD
LED is lit can the Play Detector be operated.
The green power LED will remain lit all the time that power is supplied to the torch, and the
lamp ON / OFF will work at all times irrespective of safety status and pedestal / torch
modes.
The BATT light has no function on the hardwired torch.

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Keypad Functionality – Wireless Torch
The wireless torch is programmed with the same standard safety feature as the hardwired
torch to prevent accidental operation of the Play Detector. But in addition, to save power,
the torch will automatically switch off completely after eight minutes of inactivity. In this
condition, the green power LED will not be lit.
To reactivate the torch, the lamp ON/OFF button must be pressed. The green power LED
will now show and the lamp will switch on. To activate the control buttons, the SAFETY
button must also be pressed to illuminate the PD LED as before. The operation is now the
same as the hardwired version above.
The BATT LED will show when the torch battery requires charging. In this case, the torch
should be placed in the charging cradle and allowed to charge. Charging is signified the
flashing of the BATT LED and when fully charged, the BATT LED is switched off.
The optional wireless torch operates using radio frequency on the FM band. It has a
maximum operating distance of 50m when fully charged and a charging time of
approximately eight hours. Under constant use the operating time is approximately 1.5 hours
without charge.
To ensure the wireless control is always ready for use, place it on the charger when not in
use.
Lamp ON / OFF
Move LEFTMove RIGHTRotate LEFTRotate RIGHT
Remote Control Torch
Charge Pin
SAFETY release

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Torch Connectivity – Hardwired Torch
The hardwired torch is connected to the main control pedestal using a corrosive and lubricant
resistant, 6m high quality coiled cable. At rest, the cable measures 1.4m and approximately
6m at full stretch. This allows for extra flexibility when using the torch for underside
inspection of long wheelbase vehicles.
The cable is attached at the torch end by means of a 6.25mm lockable jack plug socket. The
socket is designed to unlatch at maximum pull to prevent damage to either the torch or
pedestal connectors. In the event of having to replace the cable, the connection can be
unplugged from the torch by simply pulling the connection from the torch body using
adequate force. To unplug the cable from the pedestal, pull back the latch, rotate the
connector anti-clockwise and remove.
The part numbers for the replacement items can be found at the rear of this manual.
See below.-

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4.0 User Maintenance
The PD301 requires little maintenance but should be checked every month as below.-
Note: Ensure the main power switch it turned OFF before removing the top plate and
the EMERGENCY STOP has been activated.
Remove the four counter-sunk screws that attach the moving top plate to the internal cross
beam.
Underneath the top plate, there are twenty Nylatron load bearing discs. Using PTFE spray,
apply one spray to each disc in turn. Underneath the main cross beam, there are two more
load bearing Nylatron supports. Also apply a single spray to each support. Finally, in the
centre of Play Detector underneath the main cross beam, there is a sliding block in which the
pin of the moving plate locates. Using multi-purpose industrial / automotive grease, apply
lubrication to the block and channel in which it slides. Also apply grease to the main pin in
the centre of the moving plate.
Remove screws
and lift off moving
plate
Apply PTFE lubrication
to the top surface of all
discs.

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After the monthly maintenance is complete, replace the moving plate and ensure that it is
tightly secured. On a regular basis the oil reservoir inside the pedestal should also be
checked. The level should always remain the same, but in the event of any leaks this may
change. For service and repair always contact your local distributor.
If the PD301 is being used for statutory MoT testing, VOSA stipulate that the equipment is
subject to annual service and calibration. This must be done by an APPROVED Boston
engineer and a contract should be in place with Boston or an approved agent for this work.
Apply PTFE lubrication
to the top surface of
the beam supports.
Apply GREASE
lubrication to the
sliding block and
channel, and main pin
on the underside of the
moving plate.

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5.0 Troubleshooting
TROUBLE POSSIBLE CAUSES SOLUTION
Play Detector does not operate
- No electric supply.
- Cable connections.
- Internal fuse burnt out.
- Main power switch is off
- Emergency stop activated
- Circuit protector activated
- Check three phase supply
- Check all connections.
- Replace
- Switch on
- Deactivate emergency stop
- Deactivate circuit protector
Power is on but no plate movement - Emergency stop activated - Deactivate emergency stop
- Wrong control selected - Select desired control
Torch does not switch on - LED cluster damaged or faulty - Check / replace cluster
Torch does not operate plates - Data cable or keypad damaged
- Wrong control selected
- Check / replace
- Select desired control
Motor operates but no plate
movement
- Oil level too low
- Bad connection on solenoid actuator
- Software error
- Add oil
- Check internal connections
- Contact service agent

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6.0 Parts list
Orders for spare parts should be forwarded to BOSTON GARAGE EQUIPMENT or your
APPROVED distributor and must contain the following information:
• Model number and serial number
• Part number of the required part
• Item description and quantity required
• If the PD301 is installed on a vehicle hoist, the Hoist Model number is required
• Required delivery date
Part No. Description
B3033 Nylatron load bearing discs (set of 20)
B3034 Stainless moving top plate
B3035 Countersunk screws for moving / cover plate (set of 4)
PD301TH Handheld torch complete (hardwired)
B3079 Handheld torch flexible coiled data cable
PD301TWK Wireless handheld torch upgrade kit
B3008 Handheld torch white LED lamp cluster
B3010 Handheld torch membrane keypad
B3085 Protective rubber casing for torch
B3040 Pedestal membrane keypad
B3067 Hydraulic hose flexible trunking
B3038 PTFE lubricant spray (200ml)

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7.0 Specifications
Electric motor 220/380 V -3 PH -50 Hz
Electric motor power 0.75 kW
Inspection torch and control circuit voltage 24 V
Inspection torch LED cluster power 2.25 W
Hydraulic working pressure 200 bar
Maximum force applied to moving plate 12.8 kN
Admissible load on moving plate 1500 kg
Minimum lateral travel of moving plate 40mm
Minimum plate rotation 8°
Dimensions – Play Detector (L x W x H) 600 x 605 x 42 mm
Dimensions – Pedestal (L x W x H) 220 x 420 x 1200 mm
Hydraulic oil and capacity ISO 32 / 3 Ltr
Hydraulic oil replacement schedule Annually
Noise level during operation <70dB
Wireless inspection torch operating distance Max 50m
Wireless inspection torch charging time 4 Hours (Approx)
Wireless inspection torch battery voltage 7.2 V
Wireless inspection torch operating time (without charge) 1.5 hours (Approx)

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8.0 Warranty
The PD301 is covered by Boston’s standard 2 year warranty. Terms and Conditions are
available on request.
It should be noted that fair wear and tear and the following parts are EXCLUDED from the
warranty.
•The flexible coiled data cable from pedestal to torch
•The flexible hose carrier from pedestal to play detector
•The LED cluster inside the torch assembly
•All Nylatron load bearing parts

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Boston Garage Equipment – 199 New Road – Rainham – Essex – RM1 8SJ – United Kingdom
Tel: [phone] Fax: [phone]
Email: [e-mail] Web: www.boston-ge.com