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User manual D701 MOT Class 4 roller brake tester.
1
DOC: BOS0188
D701
ATL Class 7 Roller Brake Tester
USER MANUAL
Garage Equipment Association
Boston Garage Equipment, 199 New Road, Rainham, Essex, RM13 8SJ, United Kingdom
T: +44 (0)1708 525585 F: +44 (0)1708 525408 info@boston-ge.com www.boston-ge.com
User manual D701 MOT Class 4 roller brake tester.
2
DOC: BOS0188
Contents
1 Introduction 3
2 General product description D701 4
2.1 The infra-red remote control and digital display 5
2.1.1 Infra-red remote control 5
2.1.2 Optional digital display 6
2.1.3 Global Control Platform (GCP)
3Safety 7
3.1 Important safety rules 7
3.2 Safety devices 8
3.3Misuse 8
4MOT regulations 9
4.1 Brake efficiency 9
4.2 Brake imbalance 10
5Manual MOT testing procedure 11
5.1 Preparations before starting a brake test 11
5.2 Testing the front wheels 12
5.3 Testing the rear wheels 13
5.4 Vehicleweight 14
5.5 Calculation of brake efficiency 14
5.6 Recalling values 14
5.7 Printing test results (optional) 15
5.8 Testing procedure without remote control 15
6Testing 3-wheel vehicles 15
7Testing 4x4 vehicles 16
8Trouble shooting and Maintenance 17
9Warranty 18
Appendix A: Product specifications 18
User manual D701 MOT Class 4 roller brake tester.
3
DOC: BOS0188
1 Introduction
This manual describes how to safely use the D701 roller brake tester (further to be called the RBT) for
statutory Vehicle Inspection testing for Class 3 and 4 vehicles (further to be called MOT class 3&4). The
manual is intended for users of this equipment. Another manual for installation, service and calibration is
available.
The RBT is designed for testing commercially available class 3 & 4 vehicles for road use (including 3-wheel
vehicles and 4-wheel driven vehicles). It is important to note that the testing of 4-wheel drive vehicles is not
permitted when using the ATL automated procedure. The maximum axle load during the test is 3000 kg. The
test speed is 2.9 km/h. The RBT can be operated by one person.
This manual describes how to carry out a brake test according to the Department of Transport compulsory
scheme. The manual provides the MOT braking measurement requirements and describes a complete test
procedure.
The motor and control gear of the RBT are not flameproof and it is the responsibility of the operator to make
sure that the proposed site and the aspects of the installation comply with the Petroleum Regulations and that
they satisfy the local Petroleum Officer’s requirements.
User manual D701 MOT Class 4 roller brake tester.
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DOC: BOS0188
2 General product description D701
The RBT is a well-known method to analyse and judge the efficiency of the braking system of a vehicle.
The D701 consists of a mechanical floor unit with built in vehicle weighing system, a connection / control
panel, an infra-red remote control and the Boston Global Control Platform (GCP) for automated control
when being used for ATL one man testing.
The connection / control panel can be fitted with an optional display matrix for the display of information
and data taken from the RBT. In this format it is possible to use the D701 as a stand alone braketester
without the need for the computer platform, however in this format it is not possible to carry out the
automated one man test.
The split bed mechanical unit contains a left and a right roller bed. Each bed contains an electrical motor, a set of
three measuring rollers, a brake force transducer and additional safety sensors and an eight point vehicle
weighing system fitted to the base.
The brake forces induce reaction forces on the electric motor. An electric transducer with strain gauges measures
these reaction forces. The roller diameter is sufficiently large to keep the tyre flexing to a minimum. The special
coating of the rollers is very wear resistant and provides good friction values in both wet and dry conditions. The
third smaller roller on each side between the wheel supporting rollers has two functions: The first is to detect if a
vehicle is present in the roller bed (a built in safety device to prevent the motor to start up without a vehicle in
place). For safety purposes, the motors will not start if the left and right small rollers are not pushed down
within one second after each other (except when 3-wheel mode is selected). The second function is to detect if
tyre slippage on the rollers does not exceed the maximum value.
Chassis LEFT c/w
-cover plate
-electric motor
-force transducer
Main switch
Emergency switch
Manual start/stop buttons
Infra-red
remote control
S
Measuring roller
Measuring roller
Slip detection roller
Chassis RIGHT c/w
-cover plate
-electric motor
-force transducer
520
715
BSS2000
Side-Slip Meter
The BSS2000 Side-Slip Meter is sold as a separate
device and can easily be added to the D401 / D701
roller braketesters
Control cabinet with digital display
User manual D701 MOT Class 4 roller brake tester.
5
DOC: BOS0188
During the test, the computer measures the brake force values. The system will calculate the imbalance
between the left wheel brake force and the right wheel brake force of an axle, as well as the brake efficiency
of the service brake and the parking brake.
2.1 General control
The equipment can be switched on by means of the mains switch on the side of the control cabinet. The unit
can be operated through the infra-red remote control or by the keyboard on the GCP. The system however
can also be operated manually using the manual buttons located on the side of the control cabinet (see
chapter 5.8). The system can be switched off at any time by pressing the emergency stop button, also located
on the side of control cabinet. The functions of the remote control and the control cabinet are explained in
the two following paragraphs 2.1.1 and 2.1.2.
2.1.1 Infra-red remote control / PC control
The system can be manually controlled by means of an infra-red remote control or the keyboard on the GCP.
For safety purposes, it is not possible for both methods of control to be active at the same time. As the user
only requires the remote control for manual testing, the option to select which control to use can be found
from within the manual test procedure on the GCP. Selecting the type of control can be done in the
following way.
Note: The activation buttons shown on the screen perform exactly the same functions as the buttons on the
remote control.
If the control panel shown here is displayed
on the screen then keyboard control only is
selected and the infra-red remote control is
de-activated.
Select the desired type of control and click
ok. If Infra-red is selected, the PC control
b
uttons will not be shown.
To change the type of control press ‘F6’.
User manual D701 MOT Class 4 roller brake tester.
6
DOC: BOS0188
Start /Stop
-Start / stop left motor
-Start / stop right motor
-Start /stop both motors
Assign
-Results front axle
-Results rear axle
-Results parking brake
Vehicle DGW
-Manually entered DGW
Show efficiency results
-Service brake
Show efficiency results
-Parking brake
Recalling values
-Service brake front axle
-Service brake rear axle
-Parking brake
-Print test results
Small numbers in right top corner
(1,2,3,4,5,6,7,8,9,0) are for manual
DGW input purposes.
See chapter 5.4.
2.1.2 Optional digital display
The optional display contains a horizontal LED digital matrix display (for showing measurements both in bar
graph as well as in numerical values), seven indication lamps, a main switch, three manual start/stop buttons
and an emergency stop switch. The display is shown in exactly the same format on the GCP screen when
using manual mode. For ATL one man testing the screen will only show the approved automated test
procedure.
Digital LED display Displays the brake force in a bar diagram in kgf for:
-The left wheel of an axle.
-The right wheel of an axle.
-The manual weight input.
-The brake efficiency in %for the service brake.
-The brake efficiency in % for the parking brake.
Digital LED display left Displays the brake force in numerical values in kgf for:
-The left wheel of an axle.
Special functions
-Select manual mode
-Select 3-wheel mode
-Select 4x4 mode
ATL Automated Test
Mode
-Select ATL mode
User manual D701 MOT Class 4 roller brake tester.
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DOC: BOS0188
Digital LED display right Displays the brake force in numerical values in kgf for:
-The right wheel of an axle.
Digital LED display centre Displays in numerical values:
-The imbalance left/right of an axle.
Seven lamps -3x to indicate the assigned axle: front, rear, parking brake.
-2x to indicate wheel lock (slip) left and right wheel.
-1x to indicate when the 3-wheel mode is selected.
-1x to indicate when the 4 x 4 mode is selected.
Emergency switch -To be used to stop the rollers in case of an emergency.
Manual start buttons -For testing without the infra red remote control.
D701
•
•
•
(kgf)
Brake force left
300
kgf
200 400 500 700
100
0
250 20 200
Left
3-wheel
Imbalance
(
%
)
Right
kgf
Brake force right
•
(kgf)
•
•
•
Left
Right
4 x 4
800
600
300
200 400
100
0 800
600
500 700
Service front
Service rear
Parking brake
User manual D701 MOT Class 4 roller brake tester.
8
DOC: BOS0188
2.1.3 Global Control Platform (GCP)
The GCP is the main control unit for the automated brake test. It consists of a computer system with Boston
ATL software, and is also able to operate other products in the Boston range such as emissions testers,
engine diagnostic testers and more. For further details on other functions please contact Boston or your local
distributor.
The GCP contains a high specification PC with a laser printer and large display monitor. The ATL one man
test braketester operating software is pre-installed and activated during installation. Connection to the main
control cabinet is via hard-wired serial link or wireless Bluetooth depending on customer requirements. The
GCP should be positioned within clear viewing distance of the RBT so that the operator inside the vehicle
can easily follow the automated commands on the display. A second wall mounted PC display can also be
connected to the GCP to enable better viewing as well as a LED matrix display fitted to the control cabinet.
User manual D701 MOT Class 4 roller brake tester.
9
DOC: BOS0188
3 Safety
In order to comply with your responsibilities under the Health and Safety at Work Act 1974, it is essential
that this brake tester and any optional accessories are sited, installed, operated, and maintained by Boston
Garage Equipment or your authorised / approved local distributor.
3.1 Important safety rules
♦All persons installing, operating or maintaining this brake tester and any optional accessories must be
familiar with the layout of the equipment, the safety precautions, the emergency shutdown procedures
and vehicle braking systems.
♦Appropriate training is required, prior to installing, using or maintaining this roller brake tester.
♦In case of an emergency, all electric power can be disconnected by pushing the emergency button on the
side of the display, or turn the main power switch off.
♦The instructions in this manual must be strictly adhered to, to avoid injuries to personnel and damage to
machine and vehicle.
♦The equipment may be operated only within its rated capacity. The equipment is designed for MOT class
3 & 4 vehicles.
♦During the test no person should stand close to the mechanical units.
♦The testing area should be clear of personnel, tools and equipment before starting each stage of the test.
♦Do not stand on, or walk over the rollers at any time.
♦The unit should be placed inside a rigid, flat and clean surface, protected against water, humidity and
weather influences.
♦Only a qualified technician should carry out any work on the electrical system.
♦He should follow procedures pre-described by national standards and the regulations of the local Power
Company.
♦It is not allowed to make the safety features inoperative or to remove them.
♦Do not park a vehicle on any part of the tester.
♦It should only be used where the operator has a good view of the whole machine.
♦Don’t leave the RBT switched on and unattended.
♦Keep the operating environment clean and free of oil. Never leave loose objects around the RBT.
♦When the RBT is not working correctly, switch off the RBT immediately and refer to the user manual or
contact Boston Garage Equipment.
♦Isolate the RBT from the power supply before maintenance, by switching off the main power and to
secure it with a lock.
♦Make sure the remote control is stored safely when not in use.
♦Always use the original tools to adjust the RBT.
♦Follow the maintenance specifications accurately.
♦Avoid any direct- or indirect electrical contact.
♦Avoid any electrostatic influences.
♦Do not test a vehicle when there is insufficient light.
♦Take precautions to extract exhaust in the workplace properly while testing.
♦Special attention is required for testing 3-wheel and 4WD-vehicles!
User manual D701 MOT Class 4 roller brake tester.
10
DOC: BOS0188
3.2 Safety devices
With the design of the RBT the following safety devices have been installed, to reduce risks as much as
possible.
♦The RBT is provided with an emergency stop button on the side of the control cabinet by which the
machine can be stopped immediately in case of an emergency. To release the emergency stop button
after operation, rotate the button.
The RBT can only be switched on if the centre rotating measuring rollers are pressed down, i.e. when
there is a vehicle axle in the roller brake tester (except when 3-wheel mode is selected).
♦By applying the brake force and locking any wheels under test, the rollers will stop immediately.
♦Closed covers for the chain and electrical components.
♦The electrical circuits are built in the display cabinet, to reduce any direct danger.
♦The RBT is ground wired to earth.
♦Optional roller cover plates can be provided to close the mechanical unit when the brake tester is not in
use.
3.3 Misuse
The RBT is designed for use as a brake tester for statutory testing of MOT class 3 & 4 vehicles and for brake
diagnostic purposes only.
It must NOT be used for any other purpose e.g.
♦‘Running in’ of brake linings.
♦Brake adjustments.
♦Diagnosis of vehicle faults e.g., tyre examination etc.
♦Any purpose requiring the operator to be in the danger zone, other than to conduct a brake test and/or
maintenance and calibration purposes (authorised personnel only).