Eurotek RBT 7000 ATL User manual

RBT 7000 ATL Brake Tester
Installation, Operation & Calibration Manual

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All the product specifications and information in this manual may be changed without
notice.
Operators and installers should carefully read this manual before installation and use.
Operators should strictly follow all the instructions during operation and have all
equipment maintained periodically.
Any modification, disassembly, or refit that is performed by engineers other than your
local service provider to exceed the original usage of the product is forbidden.
In the unlikely event that any damage should be caused to the equipment contract
your local service provider as soon as possible.
Although the contents of this manual have been checked with care, errors cannot be
fully eliminated. Please contact us if you find any discrepancies.

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Safety Signal Legend
Safety Signal LegendSafety Signal Legend
Safety Signal Legend
Warning Danger of Electric Shock.
Inspection area Authorized Personnel only
Danger Rotating Machinery
Read instruction Manual Before use

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Table of Contents
1. Safety Instructions ……………………..………………………………… 3
2 . R a n g e o f A p p l i c a t i o n s … … … … … … … … … … … … 4
3 . T e c h n i c a l S p e c i f i c a t i o n s … … … … … … … … … 5
4 . O p e r a t i o n P r i n c i p l e s a n d F o r m a t i o n … … … … … … 5
5 . I n s t a l l a t i o n … … … … … … … … … … … … 6
6 . O p e r a t i o n I n s t r u c t i o n s … … … … … … … … … … … … 1 8
7 . M a i n t e n a n c e … … … … … … … … … … … … … 2 5
8 . T r o u b l e s h o o t i n g … … … … … … … … … … 2 7
9 . S p a r e P a r t s l i s t … … … … … … … … … … 2 9
1 0 . T r a n s p o r t a t i o n … … … … … … … … … … … … 2 9
11 . A p p e n d i x … … … … … … … … … … … … … … … … … … 3 1

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Preface
The Vehicle Brake Tester for Axle Weight and Brake Force is a tester to inspect the vehicle axle
weight and vehicle brake performance. Firstly, the operator drives the vehicle onto the rollers. A
signal will be sent to the computer by a force sensor and will show the axle weight on a
monitor/display Board in units of kg. When this reading is complete, the rollers automatically start
to rotate; the rolling resistance force is obtained before the driver applies the brake. When driver
applies the brake, the resistive force from the vehicle’s wheels will pass to a gear unit via a Chain
connected to the rollers. This force will then pass to a Force Sensor. The force sensor will transfer
the brake force into an electronic signal and send to the computer. Once analyzed by the
computer, inspection results will be displayed on the monitor/Display Board .
1. Safety Instructions
1.1 Safety Operation Handbook
1. Do not use the equipment if any components are damaged
2. All equipments should be operated by qualified personnel only.
3. Maintenance, adjustment and calibration should be operated by qualified personnel only.
4. Do not exceed the Max capacity of the equipment.
5. Keep the equipment clean.
6. Adjust the longitudinal axle line of the equipment platform so as to parallel to the vehicle
driving direction.
7. Vehicle must pass across the equipment slowly.
8. Do not stand on the test equipment, including rollers, 3rd axles and sideslip plates.
9. Shut down the power immediately in case of an emergency.
10.Do not park or maintain vehicles on the equipment platform.
11.During the inspection, do not stand in the designated test area .
1.2 Operation Guideline for Brake Tester
Test Procedures must be carried as specified in the relevant inspection

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manual or other VOSA guidance
1. Exit Four-Wheel Drive Mode before inspection starts.
2. Vehicle should drive following the driving direction.
3. The tester starts to work only if the third axle across both sides has been pressed.
4. Keep steering still while inspecting front axle.
5. Do not apply the brake until informed by Monitor/Display Board.
6. While applying brake, do it slowly and gradually.
7. If the brake has been held for more than 10 seconds, rollers will automatically stop rolling. The
inspection will be reset.
8. If the motor fails, the system will automatically switch off the power and exit the inspection.
9. Drive slowly while exiting from the tester.
10. Check that the vehicle’s tyres conformed with safety standards
2 Range of Applications
2.1 Vehicle Axle-load Weighing
Measure static axle-load of vehicle
2.2 Vehicle Wheel Brake inspection
Wheel resistance force
Wheel brake force
Brake imbalance of two wheel on the same axle
Parking brake force

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3. Technical Specifications
Max Wheel Load
2000 kg
Max. measurement of weigh load
1500 kg
Axle-load Measurement Range
0～3000 kg
Measurement Range
0～12500 N
Brake force calibration ratio
1 N : 2.0 N
Wheel Diameter
500～800 mm
Minimum wheel Distance(Inner)
850 mm
Maximum wheel Distance(Outer)
2600 mm
Roller Diameter
Ф245 mm
Roller Length
900 mm
Roller friction Coefficient (Dry/Wet)
> 0.85/0.6
Roller Axle Separation
432 mm
Roller testing Speed
2.5 km/h
Electric Motor Power
4.0 kW × 2
Equipment Dimensions (L×W×H)
2970×830×440 mm
Equipment Weight
840 kg
Power Supply
3 phase 415V + PE/50Hz
Working Temperature
0～40℃
Application Humidity
≤90%

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4. Brake tester Construction
Roller brake tester with weighing unit is composed by follows parts:
•Tester: Roller Bed
Load cell unit, Roller, Gearbox, Motor, transmission chain, Force sensor 7 Roller cover
plates
•Control Station:
Cabinet, Monitor, Computer, Keyboard, Mouse, Printer, Main Switch, Control Board,
Circuit Board, etc.
5. Installation
The pit should be constructed with C25 concrete. Follow the instructions of the pit construction
map drawing provided by your service provider. Make sure the pit dimensions are correct and the
concrete has completely set.
To install the equipment, follow the guidance of the engineers from your service provider. Please
carefully check the delivery items against the packing list before installation.
5.1 Equipment Installation
• Check the quality of pit construction; dimension tolerances should respect the requirement
of the pit construction map drawing .
• Place the two support bars inside the pit. Adjust the distance between 2 bars (of 2790 mm);
make sure the bars are well located in the pit and are also able to match the relative
positions of the 4 sensors on the test bench. Then use a gradient meter to adjust the
horizontal level of the support bars. Fix the support bars with expandable bolts .

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•Check and lock the four load-cells (2 load-cell per side) in the test bench.
•Place the test bench in the pit according to the vehicle driving direction, and make sure the
equable distance between the test bench and the pit wall.
2
7
0mm

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•Remove the Side-Cover Plates and Middle-cover of the bench; check the 4 load-cell
sensors are exactly located on the relative support bars
•Butt the Distance Control bolt on the bench against the pit wall; maintenance the distance
between Bolt and pit 1 mm, then lock the nuts of the Distance Control bolt.
•Connect the electrical cable and signal cable to the relative connection port in the control
cabinet. Bolt back down the Side-Cover Plates & Middle-cover.

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5.2 Electrical
Layout map
Electric Arrangement Plan
3T201 2009 01 - -
Rev. ApprovedDateRemarks
DRAWN
DESIGNED
CHECKED
APPROVED SCALE
NO
TI TLE
DRAWI NGNO .
I SSUEDDATE
Connector
Relay Board
RB 1 .
RB 2 .
COMM
RL1
RL2 RL3 RL4
Left Right
3Ph 18A/ 3Ph 18A/
L Brake. RBrake.
A1 A1
A2 A2
Breaker
3Ph 415V
25A
ON ON ON
1Ph 220V
10A
ON ON
DC12V
AC230V
Switching Power
Supply
Electric Board
Filter
220V10A
In
Out
ACContactor
Wiring Duct
Signal Cable Connector
PowerRS 232 -
MainControl
Board
Left Switch Sig .
Right Switch Sig .
Weight Sig .
Brake Sig .

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(3). Circuit Wring Diagram ：
：：
：
Circuit Wiring Diagram
3T201 2009 01 - -
Rev. Approved Dat eRemar ks
DRAWN
DESI GNED
CHECKED
APPROVED SCALE
NO
TI TLE
DRAWI NGNO .
I SSUEDDATE
Left Right
3Ph 18A/ 3Ph 18A/
L Br ake. R Br ake.
A1 A1
A2 A2
Breaker
3Ph 415V
25A
ON ON ON
1Ph 220V
10A
ON ON
DC 12V
AC 230V
Switching Power
Supply
Electric Board
Filter
220V 10A
In
Out
AC Contactor
Control
Switch
BL1
BL2
BL3
BR1
BR2
BR3
KM2
KM1
L1
N1
GND
L1
Connector
LB 1
LB 2 LB 3
N
N1
LB2
L1
N1 L1T1 T2 T3
N2
L2
N2 L2
N1 N1
BL1 BL2 BL3 BR1 BR2 BR3
KM2 KM1
T1 T2 T3 T1 T2 T3
T1 T2 T3
L1 L2 L3
N N

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Circuit Diagram
Circuit Principle Diagram
3T201 5 2 - -
Rev. Approved Dat eRemar ks
DRAWN
DESI GNED
CHECKED
APPROVED SCALE
NO
TI TLE
DRAWI NGNO .
I SSUEDDATE
K1 K2
M1 M2
3～ 3～
K1 K2
A1 A1
A2 A2
Main Swtich
Breaker Breaker
Connector
Brake Motor
Left Right
Connector
N L GND
BL
BR
CM

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5.3 Installation of control Panel
The control Panel can be sited on the left or right hand side of the test bench at a distance of
approx 2-3 meters.
Connect the Test bed power cables and the signal cables to din type connector in the Control
Panel
Connect the mains supply cable to a suitable power supply
Warning
Isolate electrical power before any electrical installation!

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Electrical Panel Dimensions

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5.4 Equipment Adjustment
The Control Software should be installed in the MS Windows 2000 Professional or higher grade
version.
Use the attached installation CD to install the software by execute the “SETUP.exe” file, and then
follow the indication of installation guide.
Test bench Adjustment
turn to main switch, and then individually the Left and Right AC contractors to check the rotation
of Electrical Motors. In case of the wrong turning direction of Motor, please turn off the main
power supply and then exchange the 2 connection poles of fire cables inside the Motor cable
box.
Test of the signal voltage
Item Sensor signal
voltage(V)
Signal voltage
of control
board(V)
Prox. sensor(V)
(main control
board)
Axle-load 7.4
～ 7.6 0.3 ～ 0.8 —
Brake
tester 7.4
～ 7.6 1.15 ～ 1.35 Close
： 0.30 ～ 0.35
Open ： 3.70 ～ 3.90
Note:
Close
The speed sensor does not face the hole; The Axle of the position sensor is released
Open:
The 3rd Axle is pressed for position sensor and The speed sensor is facing hole.
Control software Adjustment:
Launch and start the control software, then press “F8-Configuration” to monitor the
communication port data and relative parameters.

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6.1 Auto Operation Flow Chat
Clean the wheels of the vehicle.
Launch the software, click “Start” then type in the customer
information. Select test items, and then click “GO”.
Drive the Vehicle onto the Brake Tester slowly, make sure the
front wheels are parking on the rollers. Shift the gear into
Neutral.
After weighing and display of Axle-load value on screen. Do not
apply brake. Rollers will run automatically to measure the
Resistance Force of each wheel.
Follow the instruction, complete apply the brake in 2-3 seconds
after informed. And the Brake Force will be measured.
Drive the rear wheels onto the Brake Tester slowly, make sure
the rear wheels are parking on the rollers. Shift the gear into
Neutral. Apply brake or handbrake.
After weighing and display of Axle-load value on screen. Do not
apply brake. Rollers will run automatically to measure the
Resistance Force.
Follow the instruction, complete apply the brake in 2-3 seconds
after informed. And the Brake Force will be measured.
Apply Handbrake when informed by Control Station.
Drive the vehicle out of the test line and parks on a suitable
space. Operators should then give the test result to the driver.
Preparation for Test
Start Test
Measure the front
axle load of vehicle
Inspect the Front
Wheel Brake
Measure the rear
axle load of vehicle
Inspect the rear
Wheel Brake
Inspect the Parking
Force
Inspect the
Roller
Resistance
Force of
Front wheels
Inspect the
Roller
Resistance
Force of
rear wheels
Inspection Complete

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6.2 Operation Process
Switch on the equipment power supply.Check the tyres pressure and look out for any
abnormalities.
Any problems should be rectified before entering the brake Tester.
Launch the software, click “ F2-Vehicle ” to enter the login interface, input the vehicle
Registration manufacturer and Model these fields are mandatory next enter the owner’s
information, and then select the class of vehicle and fuel type etc
The system will automatically save the all inspection data after a completed inspection
process. If the vehicle information or data has been previously entered then, use
F5-Query to search the exist data will be loaded
Press F10-Continue” begin the Test

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Drive slowly the front wheel on the brake tester bench, until the 2 wheels of vehicle are well
located on the rollers set, the system will indicate to measure axle weight on the screen the
weight of Axle will be measured.
The rollers will now spin to centralize the vehicle in the roller test bed

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After axle Centralising the vehicle the system will indicate to inspect the brake force. Do not apply
any brake movement (neither pedal brake nor hand brake) and shift gear to Neutral position
when the rollers start to rotate, it is in the operation of Wheel resistance measurement. The tester
should examine for Judder & Bind After the wheel resistance measurement is completed, the
System will indicate the driver to apply brake force slowly to the limit or until lock out is achieved.
Then the front wheels brake force will be measure and displayed. The rollers will automatically
shut-off.
The sytem will then begin brake effiency test and the tester will be asked to
slowly depress the service brake