Sun Microsystems SBA 1200 GB User manual

SBA 1200 GB
SUN BRAKE ANALYSER
Operating Manual
HIGH TECH SECURES YOUR FUTURE

Operating Manual SBA 1200 GB
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Operating Manual SBA 1200 GB
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Operating Manual
SBA 1200 GB
SUN BRAKE ANALYSER
Copyright December 2009 Snap-on Equipment GmbH
All rights reserved
Part number: 2000618380 Rev: 3

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DISCLAIMER OF WARRANTIES
AND LIMITATIONS OF LIABILITIES
Whilst the authors have taken due care in the preparation of this manual, nothing
contained herein:
modifies or alters in any way the standard terms and conditions of the purchase,
lease or rental agreement under the terms of which the equipment to which this
manual relates was acquired,
increases in any way the liability to the customer or to third parties.
TO THE READER
Whilst every effort has been made to ensure that the information contained in this
manual is correct, complete and up-to date, the right to change any part of this
document at any time without prior notice is reserved.
Before installing, maintaining or operating this unit,
please read this manual carefully, paying extra
attention to the safety warnings and precautions.
Snap-on Diagnostics
Unit 17 Denney Road
PE30 4HG Kings Lynn
Great Britain
Tel: +44 / (0) 1553-697296
Fax: +44 / (0) 1553-767992

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Table of Contents
1. Introduction........................................................................................................... 8
1.1 About this Manual...................................................................................................... 8
1.2 Short Description of the SBA 1200 GB..................................................................... 8
2. Operational Safety and Accident Prevention..................................................... 9
3. Display Cabinet................................................................................................... 11
4. IR Remote Control (Option) ............................................................................... 13
5. Test procedure.................................................................................................... 16
5.1 Testing the front wheel.............................................................................................17
5.2 Testing the rear wheel...............................................................................................19
5.3 Delete function..........................................................................................................20
5.4 Enter a weight............................................................................................................21
5.5 Measuring ovality......................................................................................................21
5.6 Stopping a test ..........................................................................................................21
6. Pedal Force Transducers (Optional)................................................................. 22
7. Printout (Optional).............................................................................................. 23
8. Service-Routine .................................................................................................. 24
8.1 Calibration routine ....................................................................................................26
8.2 Clock setting..............................................................................................................29

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1. Introduction
1.1 About this Manual
Congratulations for buying a Brake Tester SUN SBA 1200 GB.
In the present Operating Manual, you will find detailed information on the routine
work with your brake tester. SUN products speak for themselves by a steady ad-
vancement implying, however, that the Operating Manual may not always be up-
dated.
1.2 Short Description of the SBA 1200 GB
Brake Testers of the series SUN SBA 1200 GB allow easy and quick brake testing
for motorcycles. The test stand is particularly designed for the quick diagnosis in
workshops.
Easy operation connected with a quick test run allows time-saving and efficient brake
tests one after the other after a short training period. The standard version of the
brake tester SUN SBA 1200 GB is equipped with the following components:
roller set
display cabinet with electronic control system
The following options are additionally available:
printer
7-digit display
IR remote control
cable operated pedal force transducer, for hand and foot respectively
wireless pedal force transducer for hand and foot respectively

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2. Operational Safety and Accident Prevention
Conscientiously follow the regulations in the Operating Manual in order to
avoid injury to persons and damage to the equipment.
Please mind that during the brake test no one is staying at close
range to the turning rollers.
If possible, secure the test stand area by means of railings and
colour markings on the floor or by danger signs with warning
lamps. CAUTION! BRAKE TEST!
The tester must remain seated on the vehicle during the test
prior to the testing procedure after having checked that no one is
close to the roller set!
If the Brake Tester is installed at the traffic zone of the workshop
or at an area accessible to the public, it is important that the test
stand is covered or equipped with railings if not in use.
Lock the main switch if the brake tester is not in use in order to ex-
clude any unallowable usage.
Safety regulations in operation:
-No adjustment work with turning rollers!
-No motor start via the test stand drive!
—No parking on roller brake testers, especially neither with the drive axle, nor with
engaged gear or with turned-on ignition since the engine of the vehicle could start
up on initiating the rollers thus risking that the driverless vehicle gets out of con-
trol.
—The „emergency operation mode“ (key-operated switch) should only be applied
in order to be able to drive a vehicle off the roller set in case of any test stand op-
erating failure.
—Withdraw the key for emergency operation from the display cabinet and put it in
safekeeping to prevent any unauthorized use.
—On actuating the „automatic operation mode“, the rollers start up as soon as a
vehicle is driven onto the test stand. For this reason, the driver should take the IR
transmitter with him to be able to switch the test stand off in case of emergency.
test stand
in
operation

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The Brake Tester may only be operated within the rated power and the maximum
speed stated in the Technical Data Sheet. Shift period for the rated power is 20%
meaning a two minutes´ operating time is followed by a rest period of 8 minutes.
Slowly drive the vehicle onto the test stand thus avoiding unnecessary strain to
both the vehicle and the test stand.
From time to time check the fastening screws of the cover plates
on their tight fit in order to avoid any tyre damage when driving
onto and off the test stand.
The access to electrical control devices, such as the exchange of
safety fuses not controllable from outside, is only allowed to
skilled workers.
Prior to opening the switch cabinet, disconnect the system from
the mains supply.
Keep dry all parts of the electric system!
Check the safety devices of the brake tester, in particular the
initiators and safety rollers, in regular intervals on their perfect
functioning. Step-in safety devices between the test rollers are
obligatory.

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3. Display Cabinet
Actual measured brake force Information rear wheel Information front
wheel
Weight / PD
Switch on indication Measuring direction Automatic mode Manuel mode
Ready indication

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Meaning of the individual operating elements:
Lamps:
ON
Indicates that the test stand is switched on
and ready to use
Measuring direction
Indicates the measuring direction
Automatic
Indicates that the test stand is working in automatic
mode
Manual
Indicates that the test stand is working in manual
mode
Buttons:
Auto off
Deletes automatic mode if no vehicle is in the roller
set
Switches off a test
Auto on
Activates the automatic mode.
Starts a test one time
Cal.
Only required for service / fault finding

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4. IR Remote Control (Option)
The use of the IR remote control allows you comfortable test stand control.
Key 1 Start the input of the test weight
In case of weight input or figure input, this key stands for „7“.
End the input by key 12.
Key 2 Start the input of the total weight.
In case of weight input or figure input, this key stands for „8“.
End the input by key 12.
Key 3 Delete data.
For this purpose, it is important to actuate this key twice within 5 seconds.
Only then all data are deleted and the automatic operation mode set on axle 1
and front axle respectively.
In case of weight input or figure input, this key stands for „9.
keys 1 –3
keys 4 –6
keys 7 –9
keys 10 –12

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Key 4 Switch between front and rear wheel.
In case of weight input or figure input, this key stands for „4“.
Key 5 Switching between front –rear wheel.
In case of weight input or figure input, this key stands for „5“.
Key 6 Print out.
The stored data are printed.
In case of weight input or figure input, this key stands for „6“.
Key 7 Stopping the roller set
STOP a running measurement.
Switch OFF automatic operation mode if the two starting switches are in UP
position.
In case of weight input or figure input, this key stands for „1“.
Key 8 Switch on automatic mode, start and store a measurement.
Test of one wheel as a service brake with automatic storing of actual axle
number after ending the test.
Switch ON automatic operation mode if the two starting switches are in UP
position.
In case of weight input or figure input, this key stands for „2“.
Key 9 Stopping the roller set
STOP a running measurement.
Switch OFF automatic operation mode if the two starting switches are in UP
position.
In case of weight input or figure input, this key stands for „1“.
Key 10 Start a measurement without store a measurement.
In case of weight input or figure input, this key stands for „0“.

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Key 11 Start ovality measurement.
The ovality measurement is activated by pressing this key during a running
brake test
Key 12 Confirm the input.
In case of weight input or figure input: finish and store input

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5. Test procedure
In order to ensure a smooth test sequence, please proceed as follows:
Switch on the test stand using the main switch. Make sure that no vehicle is in the
test stand.
The test stand is ready for operation after the lamps have ceased flashing.
There are two possibilities of starting the brake test.
Using the remote control (primary control).
Using the buttons on the side if the unit (secondary controls).
Automatic mode is not to be used in the UK.
When performing a brake test as part of a MOT procedure, always refer to the
MOT operator manual for specific requirements, a copy of the manual can be
found at www.motinfo.gov.uk.
When performing a brake test it is recommended that unless using the printer op-
tion, results are manually recored after each brake is completed.
When testing a motorcycle with linked brakes or a sidecar with brakes, the overall
brake efficiency should be calculated by the operator.
The brake efficiency for each system is the total of the brake forces achieved by
operating the brake control divided by the total weight of the motorcycle, rider
and sidecar if fitted.
The following description of the test procedure is for manual mode via remote
control.

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5.1 Testing the front wheel
Before entering the roller set the display for the front wheel is flashing and is ready
for a test.
Rear wheel Front wheel
Drive onto the test stand with the front wheel.
Provided a weighing unit is installed, the wheel weight is now indicated.
Wheel weight front wheel
After pressing the key the rollers start up after a short waiting period. Do not
brake as long as the lamps are flashing at the display cabinet.
If the lamps have ceased flashing and no brake is applied, the rolling resistance is
shown on the needle. Now it is possible to brake slowly and regularly up to wheel
block. If a pedal sensor is used the measured value is shown on the display instead
of the wheel weight.
Efficiency front wheel
Wheel weight and /or
pedal force when a sensor is used

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Directly after the roller set has stopped the kind of stop is shown on the display.
There are 3 different kinds of stop:
LL = wheel has locked, FF = brake force reduction, PP = wheel was lifted out
Kind of stop front wheel
5 seconds after the roller set has stopped the efficiency of the wheel is shown on the display.
This efficiency is calculated after the wheel weight.
Efficiency front wheel
Wheel weight
ATTENTION:
If the test time is too short the display shows
And the test should be repeated.
Now the test for the front wheel is finished and the rear wheel can be tested.

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5.2 Testing the rear wheel
Before entering the roller set the display for the rear wheel is flashing and is ready for
a test.
Rear wheel Efficiency front wheel
Drive onto the test stand with the rear wheel.
Provided a weighing unit is installed, the wheel weight is now indicated.
Efficiency front wheel
Wheel weight rear axle
After pressing the key the rollers start up after a short waiting period. Do not brake
as long as the lamps are flashing at the display cabinet.
If the lamps have ceased flashing and no brake is applied, the rolling resistance is
shown. Now it is possible to brake slowly and regularly up to wheel block. If a pedal
sensor is used the measured value is shown on the display instead of the wheel
weight.
Efficiency front wheel
Wheel weight and /or
pedal force when a sensor is used

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Directly after the roller set has stopped the kind of stop is shown on the display.
There are 3 different kinds of stop:
LL = wheel has locked, FF = brake force reduction, PP = wheel was lifted out
Kind of stop rear wheel
5 seconds after the roller set has stopped the efficiencies of the wheels are shown on the
display. These efficiencies are calculated after the total weight.
Efficiency rear wheel Efficiency front wheel
Total weight
This result is shown on the display as long as the memory is deleted.
5.3 Delete function
The memory should be deleted before a new test is started.
After the delete key is pressed the display is showing “ccc” and the needle for the
brake force is going to half of scale.
Now the delete key must be pressed again within 3 seconds. Only then the dele-
tion is performed. As a confirmation the display shows “CCC” and the needle for the
brake force is going to end of scale.