Boston D701 User manual

User manual D701 MOT Class 4 roller brake tester.
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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: [phone] F: [phone] [e-mail] www.boston-ge.com

User manual D701 MOT Class 4 roller brake tester.
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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.
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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.

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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

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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’.

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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

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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

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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.

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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!

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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).

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4 MOT regulations
4.1 Brake efficiency
♦The brake efficiency of each system is calculated from the total brake force and expressed as
a percentage of the Design Gross Weight (DGW).
♦Total up the braking effort from all wheels of the vehicle when the service brake is applied.
♦Total up the braking effort recorded from the appropriate wheels when the parking brake is applied.
♦The DGW of the vehicle can be obtained from the Department of Transport Plate (commonly called
“Ministry” Plate) fitted to the vehicle. If a Ministry plate is not fitted to the vehicle then obtain the DGW
from the manufacturer’s plate fitted to the vehicle.
♦On the D701 display, the DGW can also be inputted manually by means of the infra-red
remote control (see chapter 5.4).
♦It is required to test the service brake individually, wheel by wheel.
♦Efficiency calculation
Total brake effort all wheels
Efficienc
y
% = x 100
Vehicle weight
♦The Department of Transport allows the use of an electronic calculator to perform the calculation of
brake efficiency.
♦If the separate brake measurements are assigned properly with the remote control, the display is able to
show the efficiency for both the service brake as well as the parking brake.
♦If an optional printer is connected, the brake efficiencies will be shown on the print out (only if the
separate brake measurements are assigned properly).
The MOT brake efficiency requirements are specified in the MOT inspection manual and are also shown on
the following page.

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MINIMUM BRAKE EFFICIENCIES REQUIRED
PARKINGBRAKE
CLASS OF VEHICLE SERVICE BRAKE Vehicle with a single Vehicle with a split
line braking system (dual) braking system
Vehicles with 4 or more wheels having a service brake (foot-brake)
operating on at least 4 wheels and a parking (handbrake) operating on at 50% 25% 16%
least 2 wheels.
Vehicles with 3 wheels with a service brake operating on ALL wheels and a
parking brake operating on at least one wheel which were first used:
i) before 1 January 1968 40% 25% 16%
ii) on or after 1 January 1968 50% 25% 16%
Vehicles first used before 1 January 1968 which do NOT have one means
of control operating on at least 4 wheels (or 3 for three wheeled vehicle) 30% from first 25% from second means of control
and which have one brake system with two means of control or two brake means of control
systems with separate means of control.
Vehicles first used before 1 January 1915. One efficient braking system require
NOTE: 16%
p
arkin
g
brake efficienc
y
e
q
uates to a vehicle holdin
g
on a
g
radient of 6.25
MoT Regulations

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4.2 Brake imbalance
♦The imbalance of brake force between the left and right wheels of an axle, expressed as a percentage of the
higher brake force.
♦The imbalance of the braking effort on an axle is obtained by comparing the brake efforts at each wheel
when they are tested simultaneously.
♦Imbalance calculation:
Higher brake effort – Lower brake effort
Imbalance % = x 100
Higher brake effort
♦The MOT minimum brake balance requirement as specified in the MOT inspection manual is 25%.

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5 Manual MOT testing procedure
Chapter 5 describes the testing procedure on the D701 roller brake tester according to the MOT method of
inspection. See latest MOT Inspection Manual to check for any recent changes.
♦Brake forces are indicated in kgf.
♦Weight input is indicated in kg.
♦Imbalance is indicated in %.
♦Brake efficiency is indicated in %.
♦The D700 can also be used for testing class 3 and 4 vehicles. The analogue horizontal display does not
contain a separate scale for the purpose of testing class 3 & 4 vehicles.
♦The graduations used on the analogue horizontal display for class 7 are also according to the specifications
set in the “Specification Roller Brake Testers for testing Class 3 and 4 vehicles. Issue date: 10 December
1999”.
5.1 Preparations before starting a brake test
A. Examine the tyres to ensure they are not under-inflated, if the tyre pattern is in good condition and if the
tyres are free from mud and stones.
B. Determine whether the vehicle has a single brake control system or a split (dual) brake control system. This
is important for the operator to check a PASS or FAIL on the brake efficiency.
C. Remove the (optional) covers of the roller tester and switch the power on.
NO VEHICLE SHOULD BE IN THE BRAKE TESTER WHEN THE POWER IS SWITCHED ON AS
THE WEIGHING SYSTEM WILL PERFORM AN AUTOZERO RESULTING IN WRONG
CALCULATION OF VEHICLE WEIGHTS DURING TESTING.
The machine will go through its self-test and through its warm-up stage. When the horizontal bar
diagram is going back slowly from right to left, by pressing MENU, the tester will be in its test mode.
D701 will appear in the display. The D701 is now ready for testing.
D. Drive the front axle in the roller beds and select neutral gear.
Start both rollers by pressing Key “BOTH” on the remote control to position the wheels and align the
vehicle. Make sure the tyres do not touch the sides of the chassis.
E. Press Key “BOTH” to stop the roller set. The machine is now ready to test the front wheels.
♦Pressing any KEY on the remote control can always stop the motors and abort a test.
♦In the event of an emergency, these procedures must be followed:
(1) Press any KEY on the remote control. This will stop the rollers or
(2) Press the manual start/stop buttons on the side of the cabinet or
(3) Push the red emergency stop switch, to isolate the electrical supply to the roller bed and stop
the rollers.
The described KEYS correspond with the KEYS on the both the infra-red remote control and the GCP.
To ensure accurate storage of test results, always start with the LEFT wheel of an axle.
Press “RESET” to reset the system and clear the memory from any previous results!

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5.2 Testing the front wheels
1. Press Key “LEFT” to start the left roller. If the weighing system is fitted to the braketester, there will
be a short delay and the axle weight will be shown before the roller starts. The “Left” lamp flashes as an
indication that the left rollers are running. Slowly increase the brake force on the brake pedal until
maximum effort is achieved, or until the wheel locks and slips on the rollers. The real time brake force
is displayed on the LED display in a horizontal bar diagram. At the slip limit the motor will be cut out
immediately (to avoid unnecessary wear of the tyre) and the “Left” lamp will light to indicate this
wheel lock. If slip does not occur while the maximum brake force is achieved, the left rollers can be
stopped by pressing Key “LEFT”. The “Left” lamp will not light or flash.
For an accurate measurement, the brake force has to be built up slowly!
After the rollers have stopped, on the LED display, the bar diagram for the brake force will switch into a
numerical brake force value and will remain displayed.
The operator should note the achieved brake force for the left wheel.
Press Key “FRONT” to assign the service brake left wheel for the front axle and the computer will
automatically hold the test result in its memory (only relevant for automatic brake efficiency calculation by
the computer and recalling of results per axle). The “Service front” lamp will light to confirm this
assignment.
1a. During the test, the pedal force can be held at a constant value to visually check any fluctuations on that
wheel. The operator should note and interpret the irregularities in the brake force behaviour.
2. For the right wheel press Key “RIGHT” to start the right rollers. Repeat the test procedure as
described for the left wheel in STEP 1 and note the highest brake force.
The maximum brake force value will remain displayed until the next measurement is started.
When starting the right rollers, the left wheel brake force value (and possible lock indication) will return
on the display (when correctly stored under key FRONT in step 1). After the right wheel test, both brake
force values for left and right are displayed at the same time.
The operator should note the achieved brake force for the right wheel.
Press Key “FRONT” to assign the service brake right wheel for the front axle.
The “Service front” lamp will light to confirm this assignment.
The computer has already stored the brake force measurement of the left wheel in its memory.
3. Press Key “BOTH” to start both sides and note whether a significant brake effort is recorded from any
wheel without applying the brake pedal (rolling resistance test).
4. Slowly increase the pressure on the brake pedal and aim to stop just short of the value on which
maximum brake force is achieved during the individual left and right wheel brake force measurement
(the brake forces are already noted by the operator in STEP 1 & 2).
5. Gradually release the service brake and observe how the braking effort at each wheel reduces.
6. During STEP 4, the lower reading of the two brake forces should not be less than 75% of the higher
reading.
Remark: Disregard any service brake imbalance when the brake effort from each front wheel is less
than 40 kgf.

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7. Press Key “BOTH” to stop both rollers. After the rollers have stopped, on the LED display, the bar
diagrams for brake forces left and right will switch into numerical brake force values.
The maximum imbalance in brake forces for the left and right wheel is also displayed numerically.
The operator should note the imbalance and determine a PASS or FAIL according to the MOT regulations
(see chapter 4.2 Brake imbalance). The operator can also store the results in the computer’s memory.
Press Key “FRONT” to assign the service brake imbalance result for the front axle.
The “Service front” lamp will light to confirm this assignment (the assignments of the independent left and
right wheel brake force measurements will also be displayed numerically).
8. If the vehicle has a parking brake on the front wheels, press Key “LEFT’ to start the left roller and
apply the parking brake. Follow the procedure as described in STEP 1.
Keep the hold on button or trigger in the disengaged position at all time.
Press Key “PARK” to assign the parking brake measurement for the left wheel.
The “Parking Brake” lamp will light to confirm this assignment.
Repeat the test of the parking brake for the right wheel as described in STEP 2.
Press Key “PARK” to assign the parking brake measurement for the right wheel.
The “Parking Brake” lamp will light to confirm this assignment.
Repeat the imbalance test for the parking brake as described in STEP 3-7.
Press Key “PARK” to assign the parking brake imbalance result.
The “Parking Brake” lamp will light to confirm this assignment. (the assignments of the independent
left and right wheel brake force measurements will also be displayed numerically).
Remove the vehicle from the roller bed.
It can be helpful to start both roller sides of the brake tester when driving out of the rollers.
5.3 Testing the rear wheels
9. Release the brakes and drive the rear wheel into the rollers. Follow instructions A, D, E as described in
paragraph 5.1 to prepare the vehicle for testing the rear wheels.
10. Repeat STEPS 1-7 for testing the rear wheels of the service brake individually and for the imbalance as
described for the front wheels.
The operator should note the maximum brake forces as well as the imbalance.
The only differences is the storage of the measurements:
Press Key “REAR” to assign the service brake left wheel for the rear axle.
Press Key “REAR” to assign the service brake right wheel for the rear axle.
Press Key “REAR” to assign the service brake imbalance result for the rear axle. (the assignments of the
Independent left and right wheel brake force measurements will also be displayed numerically).
The “Service rear” lamp will light to confirm all three assignments.
11. If the parking brake is operated by the rear wheels, follow the procedure described in STEP 8.
12. Remove the vehicle from the roller bed.
It can be helpful to start both roller sides of the brake tester when driving out of the rollers.

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5. 4 Vehicle weight
12a. If the D701 is fitted with a weighing system, then weight measurement is automatic and would have been
shown on the display at the beginning of the test (see 5.2 above). However, the vehicle weight can also be
entered manually using the remote control or GCP keyboard.
The DGW of the vehicle can be obtained from the Department of Transport Plate (commonly called
“Ministry” Plate) fitted to the vehicle. If a Ministry plate is not fitted to the vehicle then obtain the DGW
from the manufacturer’s plate fitted to the vehicle.
Weight input procedure:
Press Key “KG”. The digital display will mention “ KG: ”. The operator should always enter 4 digits (if
the vehicle weighs under 1,000 kg, the first digit should be a 0 (zero)). Each key on the remote control
mentions a number, which can be used for vehicle weight input. The display will present each digit
(example: KG: 0985). The computer will use the last entered weight until a new weight is entered or
“RESET” is pressed. After entering the 4 digits, the total weight is displayed for a few seconds.
5.5 Calculation of brake efficiency
13. Manually calculate the brake efficiency for both the service brake and parking brake as described in
chapter 4.1 by means of a calculator. Determine if the vehicle PASSES or FAILS on brake efficiency and
imbalance. All brake force values are noted by the operator in the pre-described tests.
The D701 is capable of displaying the efficiency for the service brake and the parking brake when all
separate tests are assigned properly and the vehicle weight has been manually entered.
When pressing key %once, the service brake efficiency is displayed.
The display will show “EFF. SB ….%” (SB = Service brake).
When pressing key %again, the parking brake efficiency is displayed.
The display will show “EFF. PB ….%” (PB = Parking brake).
5.6 Recalling values
14. When required by the operator, the test results of the service brake and the parking brake can be recalled
on the display by means of the remote control. The results can all be recalled by pressing Key %.
Press once : Shows the last results of the service brake front axle and imbalance result left/right
wheel, as well as possible wheel locks.
Press again : Shows the last results of the service brake rear axle and imbalance result left/right
wheel as well as possible wheel locks.
Press again : Shows the last results of the parking brake and imbalance result left/right wheel,
as well as possible wheel locks.

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REMARK: Key % is for the use of the brake efficiency and the recalling of values. All 5
requested values are displayed by pressing key % 5 times. It is a continuous cycle.
5.7 Printing test results
When using the D701 for statutory MoT testing, the printing of results is automatic. At the end of the test, the
printer will produce two copies, one marked GARAGE COPY and the other CUSTOMERCOPY. When using
the manual mode, the operator can obtain a single print of results by pressing KEY.
5.8 Testing procedure without remote control
It is possible to perform a test without remote control or GCP keyboard input. This test procedure requires
two persons. One person to perform a test, while the other person pushes the start/stop buttons on the display.
The brake force will be displayed, however, these values can not be stored in the computer memory and
therefore automatic calculation of the brake efficiency is not possible.
On the control cabinet there are three push buttons mounted on the side casing. If you want to start the left,
right or both rollers, press the related button. Press the button again, to stop the rollers. The test starts up and
the procedure is the same as described in paragraph 5.2 and 5.3. The manual buttons function as Keys
“LEFT”, “RIGHT”, “BOTH” on the remote control.
6 Testing 3-wheel vehicles
The D701 is capable of testing 3-wheel vehicles, as classified under MOT class 3 and 4 vehicles. This mode
allows the operator to start the left side of the roller bed, if the smaller middle roller of this one side only is
pressed down.
NOTE: The testing of 3-wheel vehicles is not permitted when using the ATL automated
procedure and the MANUAL procedure should be applied in this instance.
When the 3-wheel mode is selected, as a safety precaution, the right rollers will not start when the middle roller
of the right side is pressed down as well.
♦The motor can always be stopped by pressing any KEY and the test will be aborted.
♦In the event of an emergency, these procedures must be followed:
(1) Press any KEY on the remote control or GCP keyboard. This will stop the rollers or
(2) Press the manual start/stop buttons on the side of the cabinet or
(3) Push the red emergency stop switch, to isolate the electrical supply to the roller bed and stop
the rollers.
Preparations
A. Examine the tyres to ensure they are not under-inflated, if the tyre pattern is in good condition and if the
tyres are free from mud and stones.
B. Remove only the left optional cover of the roller tester and switch the power of the tester on.
C. Drive the front axle (front wheel) in the roller bed and select neutral gear.
D. Start the left roller by pressing Keys “3-WH” and “LEFT” to position the wheel and align the vehicle.
Make sure the tyre does not touch the side of the chassis.
The “3-wheel” lamp on the display will constantly light as a warning and to confirm this function and will
stay on during the test of the single wheel axle.
E. Press Key “LEFT” to stop the roller set. The “3-wheel” lamp is still on.
F. The machine is now ready to test the front wheel.
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User manual D701 MOT Class 4 roller brake tester.
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DOC: BOS0188
Test procedure
1. While the 3-wheel mode is already selected, press “LEFT” to start the left roller.
This is for 3-wheel mode only and therefore not the same as Key “LEFT” as described in
chapter 5.2. The “3-wheel” lamp on the display will constantly light as a warning.
The “Left” lamp flashes as an indication that the left rollers are running.
2. Slowly increase the brake force on the brake pedal until maximum effort is achieved, or until the wheel
locks and slips on the rollers. At the slip limit the motor will be cut out directly and the left lamp will
light to indicate this wheel lock. If slip does not occur while the maximum brake force is achieved, the
left roller can be stopped by pressing Key “LEFT”. The wheel lock lamp will not light or flash.
For an accurate measurement, the brake force has to be built up slowly!
After the rollers have stopped, the maximum brake force is displayed in a numerical value and will remain
displayed until the next measurement is started.
The operator should note the achieved brake force.
Press Key “FRONT” to assign the service brake of the single wheel for a single wheel-front axle.
The “Service front” lamp will light to confirm this assignment
Press Key REAR to assign the service brake of the single wheel for a single wheel-rear axle.
The “Service rear” lamp will light to confirm this assignment
3. During the test, the pedal force can be held at a constant value to visually check any fluctuations on that
wheel. The operator should note the irregularities in the brake force behaviour.
4. Follow the procedure described in chapter 5 for testing the service brake and parking brake on the dual
wheel axle (can be front or rear axle) for brake force as well as imbalance. Assigning results of the
measurements is according to the same principle.
To exit the 3-wheel mode, press key “3-WH”. The 3-wheel lamp will go out as a confirmation that
the 3-wheel mode is de-activated.
7 Testing 4x4 vehicles
The D701 is capable of testing 4 wheel drive vehicles, however this function can only be used in the MANUAL
test mode. The brakes of each wheel of an axle are tested separately one after the other. On one side the rollers
turn in the normal direction, while on the other side the rollers turn in the reverse direction.
NOTE: The testing of 4 wheel drive vehicles is not permitted when using the brake tester for statutory
MoT testing.
Always refer to the car manufacturer’s specification before testing these types of vehicles.
Always ensure that the correct buttons on the remote control are used.
Press Key “4x4” to select the 4-wheel drive mode and Key “LEFT” to start the left roller. The right
rollers will turn in the reverse direction. This key is for the 4x4-mode only and is therefore not the same
as Key “LEFT” as described in chapter 5.2. The “Left” and “Right” lamp will flash and the “4x4”
lamp will light to indicate that the tester is in the 4x4 mode.
1Slowly increase the brake force on the brake pedal until maximum effort is achieved, or until the wheel

User manual D701 MOT Class 4 roller brake tester.
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DOC: BOS0188
locks and slips on the rollers. At the slip limit the motor will be cut out directly and the “Left” lamp will
light to indicate this wheel lock. If slip does not occur the left roller can be manually stopped by
pressing Key “LEFT”. The lock lamp will not light or flash.
The tester is still in the 4x4 mode.
For an accurate measurement, the brake force has to be built up slowly!
2. After the rollers have stopped, on the LED display, the bar diagram for brake force will switch into a
numerical brake force value and will remain displayed until the tester is manually reset.
The operator should note the achieved brake force for the left wheel or assign the results according to the
same KEYS as described in chapter 5.2.
2a During the test, the pedal force can be held at a constant value to visually check any fluctuations on that
wheel. The operator should note and interpret the irregularities in the brake force behaviour.
3 Press Key “RIGHT” on the remote control to start the right roller.
REMEMBER: The tester is still in the 4x4 mode. The 4x4 lamp still lights.
WARNING: Do NOT press the LEFT key when the 4x4 mode is NOT selected.
The left rollers will turn in the reverse direction. Follow the procedure as described for the left wheel.
4 During STEP 1 and 2 of a 4x4-vehicle, the lower reading of the two brake forces should not be less
than 75% of the higher reading.
Both wheels cannot run in the same direction at the same time. A measurement as described in STEP 3 in
chapter 5.2 is therefore not possible. The brake force for the left wheel and the brake force for the right
wheel have to be compared by the operator and the imbalance should be calculated manually.
5Repeat STEP 1-4 in chapter 5 for the service brake of the rear axle.
6Test the parking brake as described in chapter 5.2 and 5.3.