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Boston D401 User Manual

Atl class 4 roller brake tester
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D401
ATL Class 4 Roller Brake Tester
USER MANUAL
DOC: BOS0187 - Rev: 16.06.09
User manual D401 MOT Class 4 roller brake tester.
DOC: BOS0187
1
Boston Garage Equipment, 199 New Road, Rainham, Essex, RM13 8SJ, United Kingdom
T: +44 (0)1708 525585
F: +44 (0)1708 525408
info@boston-ge.com
www.boston-ge.com
Garage Equipment Association

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Summary of Contents for Boston D401

  • Page 1 USER MANUAL DOC: BOS0187 - Rev: 16.06.09 User manual D401 MOT Class 4 roller brake tester. DOC: BOS0187 Boston Garage Equipment, 199 New Road, Rainham, Essex, RM13 8SJ, United Kingdom T: +44 (0)1708 525585 F: +44 (0)1708 525408 info@boston-ge.com www.boston-ge.com...

  • Page 2: Table Of Contents

    Front axle brake imbalance check Parking brake Rear axle brake test Rear axle brake imbalance check Test complete Saving test results Vehicle first used before 01.01.1968 Troubleshooting & maintenance Warranty Product specifications DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 3: Introduction

    Introduction This manual describes how to safely use the D401 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.

  • Page 4: General Product Description D401

    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 D401 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.

  • Page 5: The Infra-Red Remote Control And Digital Display

    If Infra-red is selected, the PC control buttons will not be shown. Note: The activation buttons shown on the screen perform exactly the same functions as the buttons on the remote control. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.
  • Page 6 -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. User manual D401 MOT Class 4 roller brake tester. DOC: BOS0187...

  • Page 7: Optional Digital Display

    Right Imbalance Brake force left Brake force right (kgf) (kgf) • Service front Left • • 4 x 4 • Service rear • 3-wheel Right • • Parking brake DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 8: Global Control Platform (Gcp)

    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.

  • Page 9: 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.

  • Page 10: Safety Devices

    ♦ 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). DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 11: Mot Regulations

    ♦ This total weight on the Brake Data Chart includes 140 kg for the weight of the driver. ♦ On the D401 display, the vehicle weight can also be entered manually by means of the infra red remote control (see chapter 5.4).
  • Page 12 Vehicles first used before 1 January 1915. One efficient braking system require NOTE: 16% parking brake efficiency equates to a vehicle holding on a gradient of 6.25 DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 13: Brake Imbalance

    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%. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 14: Manual Mot Testing Procedure

    Manual MOT testing procedure Chapter 5 describes the testing procedure on the D401 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.

  • Page 15: Testing The Front Wheels

    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. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 16: Testing The Rear Wheels

    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. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 17: Vehicle Weight

    All brake force values are noted by the operator in the pre-described tests. The D401 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.

  • Page 18: Printing Test Results (Optional)

    % 5 times. It is a continuous cycle. Printing test results When using the D401 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.

  • Page 19: Testing 4X4 Vehicles

    Testing 4x4 vehicles The D401 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.
  • Page 20 Repeat STEP 1-4 in chapter 5 for the service brake of the rear axle. Test the parking brake as described in chapter 5.2 and 5.3. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 21: Atl Automated Procedure

    After the data has been entered, the operator must press ‘F2’ to continue. From this point on, the procedure is completely automatic and the operator must follow the on-screen prompts to carry out the test. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 22: Front Axle Brake Test

    After the 2 second delay, the operator is prompted to slowly apply the service brake to maximum. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.
  • Page 23 3 seconds. When the rollers stop, the display will change to digital format and display the test results. The LEFT and RIGHT lamps on the right of the display indicate wheel lock. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 24: Front Axle Brake Imbalance Check

    IMBALANCE’ will be shown and the rollers will re-start. When the software detects the reduced brake effort, the rollers will automatically stop and the display will change to show the test results. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 25: Parking Brake

    When the maximum effort is reached and either wheel locks, the rollers will stop and the test results are shown on the display. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 26: Rear Axle Brake Test

    8.4 Rear axle brake test The rear axle brake test is conducted in the same way as the front axle brake test. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 27: Rear Axle Brake Imbalance Check

    IMBALANCE’ will be shown and the rollers will re-start. When the software detects the reduced brake effort, the rollers will automatically stop and the display will change to show the test results. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 28: Test Complete

    The printer will also print two copies of the results automatically. One copy for the customer and the other to be retained by the testing station. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 29: Saving Test Results

    FIND and the search results will be shown as a list at the bottom of the page. Double click the search result to open the test data and re-print if necessary. User manual D401 MOT Class 4 roller brake tester. DOC: BOS0187...

  • Page 30: Vehicle First Used Before 01.01.1968

    SERVICE BRAKE = 30% from FIRST means of control PARK BRAKE = 25% from SECOND means of control The software then commences testing on the front axle as normal. DOC: BOS0187 User manual D401 MOT Class 4 roller brake tester.

  • Page 31: Troubleshooting & Maintenance

    ♦ Check the tension of the chains every four months. ♦ Lubricate the chain every 3 months when used intensively. For periodic maintenance, calibration and service contact the Boston service department or your local distributor. Warning: Do not use high pressure or steam cleaners on the RBT. The brake tester should be kept clean and dust-free.
  • Page 32 Boston Garage Equipment - 199 New Road - Rainham - Essex - RM13 8SJ - United Kingdom User manual D401 MOT Class 4 roller brake tester. DOC: BOS0187 Tel: +44 (0)1708 525585 Fax: +44 (0)1708 525408 Email: info@boston-ge.com Web: www.boston-ge.com...

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