CryptOn EB30, EC30, EC630 Upgrade Operating Instructions Manual

EB30/EC30/630 Upgrade Page 1
Commercial Vehicle Roller Brake Tester.
OPERATING INSTRUCTIONS TES1343/A
July 2001
EB30/EC30/630 Upgrade 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, particularly paragraph 2. 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.
EB30/EC30/630 Upgrade Page 3
Index:
Safety procedures for brake testing procedures 2
Description 3
Functions and Facilities 6
PC Brake Diagnostic Program 9
The Theory of Brake Testing 12
Preparing for a Brake Test 14
Automatic Test Procedure (NOT MOT) 15
Manual Brake Test Procedure for Commercial Vehicles (MOT) 17
Manual Brake Test Procedure for Class IV and Class VII (MOT) 23
Maintenance 28
Trouble shooting 31
Terms and conditions of sale 32
After sales service 35
Notes 35
EB30/EC30/630 Upgrade Page 4
Safety procedures for brake testing
! Notice the location of the emergency stop. The switch is located in the
immediate vicinity of the brake tester.
! Read this user’s manual thoroughly before attempting to operate the brake
tester.
! Keep this user’s manual in an easily accessible place.
! Never touch the rollers when the tester is in operation.
! Do not press the third roller down with your hand, foot or any kind of tool.
! Unless authorised, do not remove or make any alteration to any part of the
tester. Contact the supplier.
! Do not use the brake tester for any other purpose than for which it is intended.
! The brake tester must not be used in environments susceptible to explosions.
! Keep unauthorised persons away from the rollers and the wheels of the vehicle
during operation of the tester.
! During service and repair of the tester: Switch the tester off and lock the switch.
! The brake tester will always stop when pressing STOP.
After having pressed STOP, the brake tester can only be restarted by pressing START or by driving a wheel set onto the roller unit.
! Pressing the emergency stop will stop the brake tester immediately. To restart:
pull the emergency stop back and press the reset key.
! For brake testers fitted with emergency light beam circuit breaker in the pit:
Braking the light beam will stop the brake tester. Reset by pressing the reset key.
EB30/EC30/630 Upgrade Page 5
Description
Main components
1. Emergency stop
2. Display console.
3. High voltage control unit.
4. Roller unit.
5. PC with brake diagnose program
6. Printer
7. Remote control
Accessories:
Base station for wireless air pressure transducers Air pressure transducers - wireless Air pressure transducers - cable connected
1. Emergency stop
Press for emergency stop.
Note: Notice the location of the emergency stop before starting the brake tester. The emergency stop is not necessarily positioned in the same place at every installation, however it will always be installed in the immediate vicinity of the brake tester.
EB30/EC30/630 Upgrade Page 6
2. Display console
1. Top digital display - air pressure, ovality and weight
2. Indicator showing type of information on top display
3. Indicator light - 4WD (accessory)
4. Indicator light - automatic operation
5. Indicator light - manual operation
6. Indicator light - scale range or 0-800 Kgf)
7. Indicator light - scale range 0-4000 Kgf)
8. Scale showing brake force
9. Pointers; red = left, black = right
10. Amber light - zeroing and fault indicator
11. Red lights - wheel locking
12. Green lights - ready for testing
13. Bottom digital display - imbalance, ovality, pressure and weight
EB30/EC30/630 Upgrade Page 7
3. High voltage control.
1. Keyboard.
2. RESET button (resetting of safety relay).
3. Main switch (power supply circuit breaker).
4. Roller unit.
1. Rollers
2. 3rd roller Fitted with: Strain gauge transducer. Speed sensor on third roller. Speed sensor on gear box Proximity sensor on third roller assembly
5. PC with diagnostic program
1. On/off switch
2. PC keyboard
3. Monitor
6. Printer
1. On/off switch
2. Paper tray
3. Cover
7. Remote control
1. Keyboard
2. Battery cover
3. Infrared transmitter window
EB30/EC30/630 Upgrade Page 8
Functions & Facilities
The functions and facilities of the brake tester in alphabetical order.
Automatic operation (not for UK MOT use) In automatic operational mode, the brake tester will start automatically when a wheel set is driven onto the rollers and stop either when the wheels lock, when stop is pressed or when driving out of the rollers.
When the brake tester is turned on it is in automatic mode. It changes to manual mode when registering a vehicle on the PC. It returns to automatic operational mode after having concluded a test or after having pressed PRINT.
If STOP has been pressed so that the AUT and MAN lights are lit.
The brake tester will not start up automatically when driving a wheel set onto the rollers. Then press STOP again before driving onto the rollers.
Imbalance In manual operational mode: Press DAFF after having started the rollers. The difference of braking effect between the left and right wheel is indicated by the positions of the pointers. The result is shown at the bottom display (as %).
In automatic operational mode: The imbalance is shown when the brake force exceeds 40 kgf. You toggle between imbalance and air pressure by pressing AIR and DAFF.
One-wheel operation (accessory). In one-wheel operation one wheel is rotating whilst the other is stationary. Press TEST and START. Choose the wheel by using UP for the left wheel and
DOWN for the right one. The display shows which one has been chosen. Press START to start the chosen wheel.
One wheel operation is used for MOT testing and to test damaged vehicles.
Four-wheel operation. (accessory). The brake tester can be fitted with a facility to test four-wheel drive vehicles. This makes it possible to test one wheel whilst the other wheel on the same axle is reversing to avoid that the torque is transmitted to other axles during the test. Brake force is measured only on the non-reversing wheel.
Press 4WD. Drive the first set of wheels onto the rollers and press START. The green light lights up on the side of the wheel to be tested and the relevant pointer shows the brake force. Press OK to store the result. Press START to test the other wheel and press OK to store the result.
EB30/EC30/630 Upgrade Page 9
Choose which wheel to be tested first before starting the test: Press 4WD once to choose the left wheel (indicated by the left light). Press 4WD again to choose the right wheel to be tested first. Press a third time to return to normal operation.
Parking brake. The parking brake is tested in the same way as the foot brake. It is therefore not necessary to make special concessions for testing the parking brake.
However in manual mode it is necessary to indicate when the parking brake is to be tested. The reason is that special calculations are used for the parking brakes. With a wheel set on the rollers press START and choose the transducer using the UP and DOWN keys. Press START again to start the rollers. Press PARK to indicate the test of the parking brake. The bottom display shows momentarily the number of the relevant parking brake, for example P1. Then the bottom display shows the pressure P
The top display
M.
shows the chosen pressure Pc.
Printed report. A report can be printed after a test in manual operational mode. Press the PRINT key after the last axle has been tested and accepted. The report shows all relevant calculations both of each individual axle and of the whole vehicle. The report can also contain relevant graphs. The content and layout of the report is set up in the program on the PC.
Holding the result on the display.
In both manual and automatic mode the pointers and the LED displays will remain showing the results after locking the wheels until either restarting the tester, pressing OK or after 5 minutes have elapsed.
EB30/EC30/630 Upgrade Page 10
Symbols.
The following symbols will appear on the LED display:
Parking brake and number.
Accept of signal from remote control
Emergency stop activated
The brake tester is locked and does not communicate with PC
The brake tester transmits signal to printer
Imbalance in %
Ovality in %
Testing left secondary brake.
Testing right secondary brake
Testing left parking brake.
Testing right parking brake
EB30/EC30/630 Upgrade Page 11
PC Brake Diagnostic Program
With diagnostic program, the performance of the brakes of a vehicle can be analysed in details. The results can be analysed graphically in many ways and stored for later comparison. The program is very user friendly and supported by a comprehensive help system. Pressing F1 will provide the answers to most questions. The text in the help program is dependent upon the content on the screen and provides clear and relevant answers.
The program is easy to use. Choose menu items and buttons on the screen with the arrow keys and press ENTER. Fill in the cell on the screen with the specifications you are asked for by the program (You will find the instructions on the bottom line of the screen). This insures correct and easy use.
Registration of a vehicle. For manual testing of a vehicle it must be registered on the PC. If the vehicle has not been tested on the brake tester before, it is necessary to key in some specifications. If it has been tested before a lot of the specifications are stored in the program and can easily be transferred to the new test.
Choose BRAKE TEST on the menu. If the vehicle has been registered before on the tester, choose OPEN VEHICLE DATA and find the registration number on the list. If the vehicle has not been registered before:
Choose “ENTER VEHICLE DATA” and fill in the form on the window:
Name: (name of owner of vehicle) optional Address: (address of owner) optional Address: (address of owner) optional Zip Code: (postal code) optional City: (town) optional Telephone no.: (Customers phone no.) optional Job no.: (Internal job no.) optional Tested by: (Initial/name of operator) optional
When the key-in data are satisfactory, choose OK.
Choose the relevant type of vehicle. Choose “Other brake type” Choose whether or not a trailer is hitched.
A new window appears:
EB30/EC30/630 Upgrade Page 12
Make: (Make of vehicle) Obligatory Reg. No. (Registration no) Obligatory Man. year (Year of manufacture) Obligatory Gross vehicle weight (maximum allowed weight) Obligatory
Actual vehicle weight (Weight at time of test) Optional No. of axles: (Number of axles to be tested) Obligatory Mileage: (Mileage at day of testing) Optional Remarks (Any relevant remark) Optional
When the data of the vehicle has been opened or keyed in they must be transferred to the brake tester. Choose START BRAKE TESTING from the main menu. Perform the brake test as described in the chapter "Brake testing, manual mode" After the completion of the test, the results can be printed out on a colour printer and/or processed graphically on the PC - see below.
Printouts A series of printouts can be performed on the colour printer. You can choose between a:
Graphical processing of the results. The results can be studied in details by using the graphical facilities in the PC program. The results can be analysed immediately after the test, or data from an earlier test can be called from the memory of the PC.
After the completion of the test you can choose between the before mentioned user designed standard printout set-up or a specially designed printout. The user designed printout is described in menu point CONFIGURATION - STANDARD PRINTOUT. The special designed printout is described in a similar menu. Choose the desired specifications by marking them with " " using the space key for setting or removing the tick. You can choose from different types of graphs, tables and calculations in the PC program:
Brake force - PC graph -when air pressure has been measured For each axle the brake force is shown as PC . The graph shows the relation between the brake force and the pressure in the cylinder on each axle. This will for example detect defective valves.
Time graph -when air pressure has been measured. For each axle the graph shows the brake force and air pressure as they are developing with time elapsed. If the brake pedal was released whilst the display showed "U" the thick line shows increasing brake force whereas the thin line shows the brake force when releasing the brake pedal.
PC - PM graph -when air pressure has been measured. The graph shows the development of the air pressure in the cylinder in comparison with the pressure in the main line. The pressure in the cylinder is shown on the Y-
Loading...
+ 25 hidden pages