CryptOn 660-R Operating Instructions Manual

OPERATING INSTRUCTIONS

TES1489/A

Dec 2005

BRAKE TESTER 660-R

660-R OPERATING INSTRUCTIONS Page 2

IMPORTANT

Every reasonable effort has been made to ensure that information within
these Operating Instructions is correct at the time of release, but Crypton
cannot accept-responsibility for any errors that may occur.

The information in these Operating Instructions is subject to change
without notice, and does not represent a commitment on the part of
Crypton.

Service & Warranty

The reliability of this equipment is fully supported by our service agent.
Please refer to the page at the end of this manual for full details.

Note:
Your attention is drawn to our Terms & Conditions of Sale. If a service
engineer is called out. under service warranty where, upon inspection and
test the equipment is found to be in full working order and no fault found,
the user is liable to be charged the cost incurred for this call out. Before
calling out an engineer, ensure your equipment is faulty by checking its
operation, particularly mains supply and fault codes/self test if applicable.

WARNING:

Do not attempt to operate this equipment unless you have read

and understood these

instructions.

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CONTENTS

Safety precautions 4
Hints and Tips 5
INTRODUCTION 6
Description of system components 6

Emergency switch 6
Pit unit 6
Control unit 8
Motor control 8
Alternative display 8
Printer 8

Remote control 9
Guide to testing 11
Test description 12
MOT Test Procedure – Class IV 12
Enter car on PC 12
Reset system 12
Front Axle 12
Centre 12
Left brake test 12
Right brake test 12
Bind, ovality and imbalance test 12
Rear Axle 13
Centre 13
Left brake test 13
Right brake test 13
Bind, ovality and imbalance test 13
Parking Brake 14
Left brake test 14
Right brake test 14
Printing results 14
Manual Testing 15
Class IV 15
Class III - Testing one wheel only 16
Prompt sheet 17
Calculations 18
Maintenance 19
Technical Specification 21
After Sales Service 22
Notes 23

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SAFETY PRECAUTIONS

Read these operating instructions carefully and thoroughly before
attempting to operate the equipment.

This operating manual should be available at the testing site at all times.

Always follow the procedures and actions defined in this manual, failure to
do so may result in personal injury or other damage. The manufacturer
cannot be held liable for personal injuries or vehicle damage that occur as
a result of misuse of the equipment.

All the national and international safety guidelines and legal regulations
are to be followed when operating testing equipment.

The operator is obliged to adhere to all the regulations applying to the
workplace and to ensure his knowledge of such regulations is up to date.

Do not allow other personnel near the test vehicle or rollers while a test is
in progress. Check that the area is clear before the rollers are started or
the vehicle moved EACH TIME this action is taken.

Testing often takes place with the engine running, to provide a vacuum
supply to the brake servo. Ensure exhaust extraction or adequate
ventilation is used to clear the poisonous exhaust gasses.

Do not modify the equipment or change any internal settings – this could
result in a very dangerous condition where the rollers could be started
WITHOUT a vehicle in the rollers!

TESTING STANDARD

When performing statutory MOT tests it is vital to follow the brake
test procedure detailed in the latest version of the relevant MOT
Inspection Manual

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HINTS & TIPS

The brake tester must only be used for its intended purpose.

All the performance limits are to be followed, do not drive excessively
heavy vehicles over the pit unit or otherwise abuse the equipment as
damage may occur and test result accuracy may be affected.

Only authorised and well-trained personnel should perform the testing.

The work area should be kept clean and dry.

Always keep a safe distance from moving parts. The area must be marked
so that vehicle owners are aware of the danger associated with brake
testing.

Note the location of the emergency stop switch before starting to use the
equipment.

When driving off the brake tester, the roller motors should be switched on
so that the rollers are driven. This limits the speed of the rollers to a safe
value. If the vehicle is driven off the rollers without them being powered
damage may occur.

Do NOT use the brake tester to start the engine of a vehicle as this may
damage the electric motors.

Drive on and off the tester slowly and in a controlled manner.

Always check the ground clearance of the vehicle is adequate before
performing the test.

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INTRODUCTION

The 660-R is a roller brake tester designed to perform VOSA MOT tests on
Class III and Class IV vehicles.

Control can be performed using the remote handset at the vehicle so one
man operation is possible and a printer is available to produce a record of
results if fitted.

Description of system components

The roller brake tester consists essentially two parts: one above ground,
the control and display console and one below ground, the road simulation
rollers. A brief description of the various features follows:

Emergency switch

The brake tester is equipped with an emergency stop switch. Note the
location of the emergency stop before starting to use the equipment. The
emergency switch is not necessary positioned in the same place at every
installation, check the location before using the equipment.

Pit unit

The rolling road consists of two sets of free roller pairs connected by a
chain and indirectly driven by two electric motors through gearboxes. The
gearbox is joined to the roller tester frame by a force transducer. During
the motor operation when the car is braking, the resultant force is
transmitted from the rollers to the brake force transducer. The outputs of
the transducers are monitored by the internal circuits and eventually
shown on the display as brake effort.

A small third roller is fitted between each pair of main rollers. These
perform two vital functions. Firstly to monitor the presence of a wheel in
the rollers so that motors can only be energised when a vehicle is present
and secondly to measure speed of the wheel that is being braked. This
ensures that the motors are automatically switched off when the tyre
starts to slip on the roller surface.

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660-R MOT Class III and IV Roller Brake Tester

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Control unit

The control unit contains front panel with:

Green indicator light : Car on rollers / Rollers drive direction / 4WD

(Arrows Lup, LDn, Rup, RDn)

Red indicator lights: Wheel locks (Lock left & Right)

Green indicator light : Ready for test (Ready)

Scale showing brake force:

Pointers: Green for left, red for right

Digital display (DDsp): Imbalance, ovality, pressure, weight

Amber indicator lights: Showing type of information on digital display

(Oval, Pres, Wght)

Inside: Power supply board for control computer, front panel,
amplifiers and motor control

Outside: Main switch, Emergency switch

Alternative display

A twin dial display can be specified when ordering a 660-R and this has
two separate dials mounted side by side rather than the co-axial
arrangement. All scales and other indicators are identical as shown:

Printer

The printer is an optional device that can be specified at the time of
purchase or fitted later. Follow the instructions in the printer handbook
for loading paper and fitting ink cartridges (if applicable).