Service 4400 Truck

EOS S.r.l.
Motorscan® Division
Via Monte Aquila, 2 Corcagnano
43124 PARMA – Italy
Tel. +39 0521 631411
SERVICE MANUAL
BRAKE TEST BENCH
VEHICLES OVER 3,5 t
MOD. 4400TRUCK
Rev.1 – 21/11/2013
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INDEX
1.0 INTRODUCTION ..........................................................................................................................................4
2.0 GENERAL INFORMATION ...................................................................................................................... 5

2.1 DIVIDED ROLLER SET ......................................................................................................................5
2.2 CONTROL CABINET .........................................................................................................................6
2.3 ANALOG CABINET ............................................................................................................................6
2.4 INFRARED REMOTE CONTROL ......................................................................................................7
2.5 ELECTRICAL DATA ...........................................................................................................................7
2.5.1 MOTOR DATA................................................................................................................................... 7
2.5.2 MAINS SUPPLY ................................................................................................................................ 7
2.5.3 ENVIRONMENTAL CONDITIONS .................................................................................................... 7
2.6 PEDALFORCE ...................................................................................................................................8
2.6.1 RADIO DATA..................................................................................................................................... 9
2.6.2 ACCURACY AND DISSOLUTION .................................................................................................... 9
2.6.3 AIR PRESSURE MEASUREMENT ................................................................................................... 9
3.0 MOUNTING THE 4400TRUCK STEP BY STEP ................................................................................... 10

3.1 FIRST STEP: PREPARING ACTIONS .............................................................................................10
3.2 OVERVIEW OF INSTALLATION ......................................................................................................11
3.3 NEXT STEPS: INSTALLATION AND WIRING ................................................................................ 11
3.4 MOUNTING THE ROLLER SET WITHOUT WEIGHT SYSTEM ......................................................12
3.5 MOUNTING THE ROLLER SET WITH WEIGHT SYSTEM ............................................................. 16
3.6 MOUNTING DISPLAY CABINET .....................................................................................................19
3.7 MOUNTING CONTROL CABINET ...................................................................................................20
3.8 MOUNTING 4415 ................................................................................................................................... 20
3.9 CONNECTION BETWEEN ROLLER-SET AND CONTROL-CABINET .......................................... 21
3.9.1 SENSOR CONNECTION BETWEEN GSA-0030 WITH GSA-0025 .........................................22
3.9.2 CONNECTION OF THE MOTOR CABLES IN THE CONTROL CABINET .................................... 23
3.10 CONNECTION BETWEEN CONTROL CABINET – ANALOG DISPLAY .......................................26
3.10.1 POWER CIRCUIT DIAGRAMS OF THE CONTROL CABINET..............................................27
3.11 NEXT STEPS: INSTALLING OPTIONAL COMPONENTS .................................................................. 29
3.12 SOFTWARE (VISUALISATION / DATABASE) ..................................................................................... 29
3.13 PEDALFORCE ..................................................................................................................................... 32
3.14 AIR PRESSURE SENSOR CABLE ...................................................................................................... 32
3.15 PRINTER ON 4400TRUCK .................................................................................................................. 33
3.15.1 PRINTER CONFIGURATION................................................................................................. 34
3.15.2 PRINTER OLIVETTI DM109 – IBM PROPRINTER EMULATION ......................................... 35
3.15.3 PRINTER OLIVETTI DM109 – EPSON FX 850 EMULATION ............................................... 36
3.16.4 PRINTER OPTIONS ...................................................................................................................... 37
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4.0 START UP .............................................................................................................................................. 38
4.1 CODING OF THE IR REMOTE CONTROL ............................................................................................ 38
4.2 THE SPECIAL ROUTINES ..................................................................................................................... 39
4.3 CONFIGURATIONS MODE ................................................................................................................... 43
4.3.1 CONFIGURATION-MODE V5.2E – V5.XX ..................................................................................... 43
4.3.3 SERVICE-MODE FOR REMOTE ACCESS WITHOUT CHANGING DATA ................................... 45
4.3.4 CALIBRATION MODE ..................................................................................................................... 46
4.4 CALIBRATION MODE ............................................................................................................................ 47
4.4.1 EXPLANATION OF CALIBRATION PRINCIPLE ............................................................................ 47
4.4.2 CHANGE THE CONFIGURATION LISTING by PC ........................................................................ 48
4.4.3 CHANGE, ADD AND DELETE FROM LEGALI LIMIT VALUES ..................................................... 50
4.4.4 SENSOR DETAILS & CALIBRATION PROCEDURE ..................................................................... 51
4.4.5 CALIBRATING DEVICE .................................................................................................................. 55
4.5 SERVICE MODE .................................................................................................................................... 61
4.5.1 CONFIGURATION MODE DETAILS .............................................................................................. 63
4.5.2 LANGUAGES – TRANSLATIONS .................................................................................................. 64
4.7 SENSOR CALIBRATION PEDALFORCE .............................................................................................. 65
5.0 SPECIAL OPTIONAL COMPONENTS.................................................................................................. 66

5.1 ADDITIONAL DC-POWER-BOARD FOR 2-ANALOG DISPLAYS OR LARGE CABLE LENGTH ......... 66
5.2 DISTANCE MEASUREMENT ................................................................................................................ 67
5.3 HYDRAULIC LOAD SIMULATOR .......................................................................................................... 69
6.0 APPENDIX ............................................................................................................................................. 71

6.1 APPENDIX A (COMPRESSED AIR BRAKE ASSEMBLIES).................................................................. 71
6.1.1 OPERATION OF COMPRESSED AIR BRAKES IN THE TRACTOR UNIT ................................... 73
6.1.2 OPERATION OF COMPRESSED AIR BRAKES IN THE DRAWBAR TRAILER ........................... 73
6.1.3 OPERATION OF COMPRESSED AIR BRAKES IN THE SEMI-TRAILER ..................................... 74
6.1.4 COMPUTATIONS............................................................................................................................ 74
6.1.5 TWO-POINT EXTRAPOLATION ..................................................................................................... 75
6.1.6 ONE-POINT EXTRAPOLATION (SP TEST) ................................................................................... 76
6.2 APPENDIX B – ERROR HANDLING ...................................................................................................... 78
6.3 APPENDIX C – SPARE PARTS ............................................................................................................. 79
6.4 APPENDIX D – SERVICE EQUIPMENT ................................................................................................ 80
6.5 APPENDIX E – FOUNDATION PLANS .................................................................................................. 84
6.6 APPENDIX F – ELECTRICAL PLANS .................................................................................................... 93
6.7 APPENDIX G – SCHEMATICS FOR THE SENSOR BOX GSA-0030 AND GSA-0025........................ 106
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1.0 INTRODUCTION
The 4400TRUCK is a roller brake tester with DMS sensor technology allowing the examination of
commercial motor vehicle and trailer braking systems up to axle load of 18 t.
The brake tester can be expanded into a complete truck-test-line with side-slip and joint play testers. The
4400TRUCK offers fully automatic operation, or manual operation via an infrared remote control. The triple
function display console indicates left and right brake force and side-slip. The brake force is indicated over
two automatically selected ranges: 0-8kN (0-800 kgf) for cars and 0-40kN (0 – 4000kgf) for trucks and buses.
Individual hot-dip galvanised roller sets make either cross-pit or in-floor mounting possible. Optional PC
visualisation, with customer and vehicle database systems, gives additional efficiency and flexibility of
operation.
The rollers are supplied with a plastic corundum coating. This coating is designed to provide long service life
coupled with a high friction factor, while at the same time being non aggressive to the tyre. The rollers are
driven via heavy-duty chains by two independent electric motors, with a power output of 7 to 12 kW each,
depending on model.
High precision sensors, using the latest strain gauge technology, record brake force and weight. The
integrated microprocessor system collects and analyses the data from the sensors and presents an
evaluation of the complete vehicle braking system to the user. The software includes error-checking routines
to ensure accuracy in service.
A smaller third roller fitted to each roller bed provides detection of wheel position and slip.
This prevents accidental starting of the rollers with no vehicle and minimises tyre damage due to slipping.
The micro brake 4400TRUCK switch cabinet is connected to the analog display by an RS485 based field bus
system. The user controls the test sequence by infrared remote control, by use of the keypad on the switch
cabinet or by the on-screen remote provided with the PC software.
The pointers indicate brake force and it is possible to store the results for recall after the test in the format
required by the official test organisation involved.
If a printer module is integrated into the system, it is possible to output the result data in text or graphical
format, and in varying levels of detail.
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2.0 GENERAL INFORMATION
2.1 DIVIDED ROLLER SET
With precise shear force sensors for brake testing of passenger cars, buses, heavy duty vehicles and
trailers, drive-over load up to 18 t.
 Testing load=16 t ˜ 40 KN brake force/wheel.
 Brake roller: Ø 280mm, axle distance 440mm, silicon-sand surface, elevation of rear rollers over
front rollers 50mm.
 Two speed motor 9/12,3 kW with reinforced gear box for 2,6 km/h testing speed.
Universal mounting – in-floor, cross-pit and at required track width.
Divided unit roller length W x L x D (mm)

1000 mm 1310 x 1160 x 600
Weight ca. 710 kg
Roller diameters 280 mm
Maximum test width (pit
2900 mm
version)
Product picture Minimum test width (pit
900 mm
version)
Axle distance 440 mm
Increased height rear rollers
50 mm
to front rollers
Testing load 16.000 kg
Drive-over load 20.000 kg
Smallest test wheel size 145 R10 (ca. Ø 450 mm)
Largest test wheel size 1400 R20 (ca. Ø 1200 mm)
Basic delivery without weight sensors, Test speed 2,6-5,2 km/h
printer and LCD-display Rated output of the driving
2 x 9/12,5 kW
motors
Gear reduction i = 1 / 16,17
Measuring system DMS
Max braking force 40.000 N
Noise emission LWA <70 dB (A)
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2.2 CONTROL CABINET
Contains power electric, micro controller boards and operation keyboard, retrofitting or upgrade sets are
available for optional components:
 Cable and radio controlled air pressure sensors (PM/PX) or pedal force sensor
 Printer set
Product picture W x H x D (mm)

Dimensions
600 x 850 x 370
Weight ca. 25 kg
Voltage supply 3 x 400 V (AC)
Supply 5 x 10 mm²
Protection device 3 x 50 A
Contact rating of the main
63 A
switch
Low voltage power supply
90 to 264 V
input
Low voltage power supply
12 V / 30 VA
output
Protection rating (according
IP 54
to DIN 40 050)
Admissible air humidity
To 85 %
(relative without moisture)
Operating temperature -10 to +60 °C
Storage temperature -10 to +60 °C
2.3 ANALOG CABINET
Analog display
Measuring Smallest Character
Scaling
range division height
Internal 355 0,
300° 0- 8kN 200N=23 mm 20 mm
range
Outer 375 0, 1000N=24,5
0-40kN 32 mm
range 300° mm
Digital display
LCD – display 2 + 4 digit
Character height 76 mm
LCD Type 7 Segment display
Display values per second 5
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2.4 INFRARED REMOTE CONTROL
Product picture
To control the operation modes, printout and

evaluation methods, necessary for storing test
results.
2.5 ELECTRICAL DATA
2.5.1 MOTOR DATA
VN 230V/400V
IN 14,6 / 17,0 Ampere
Cos φ 0,80 / 0,90
N 1440 / 2860
Protection rating (according to DIN 40 050) IP 55
2.5.2 MAINS SUPPLY
Voltage 3 x 400 V (AC)

Permissible nominal voltage fluctuations ± 10 %
Protection device 3 x 50 Ampere
Supply cable 5 x 10 mm²
Motor cable 7 x 2,5 mm²
2.5.3 ENVIRONMENTAL CONDITIONS
Admissible air humidity (relative without

to 85 %
moisture)
Operating temperature -10° to +60°
Printer – Operating temperature +15° to +35°
Relative air humidity 15% to 85%
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2.6 PEDALFORCE
Base station Interface RS232

Data transmission rate 19,2 kBit/s
Transmission direction Bi-directional full duplex
System configuration With Service-Software
Voltage supply (plug power pack) 90-265 V AC
Voltage supply receiver electronics 12V DC
Charging station Material APS
Kind of charge Inductive
Enclosure (according to DIN 40,050) IP30
Supply 24 V DC / 84mA
Voltage supply (plug power pack) 90-265 V AC
Voltage supply load electronics 24V DC
Case L x W x H = 135x62x15mm
Material APS
Radio sensor (pressure) Compressed air measuring range 0-20 bar
Hydraulic measuring range 0-200 bar (planned)
Pedal pressure 0-980 N
Case M16 x 1,5 (Internal thread)
Enclosure IP65
Storage temperature - 10 to +65 °C
Operating temperature +10 to +30 °C
3x 700mAh NiMh (no Memory-
Batteries
Effect)
PEDALFORCE (complete kit)
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2.6.1 RADIO DATA
Transmitting power 10 mW
Frequency range 433-434 MHz
Complies with CE regulations - European
Permission Union wide permission (permission in further
countries on request)
Range Dependent on conditions locally. Max. 180m
Transmission direction radio Bi-directional half duplex
Working time without recharging in workshop
20 h
conditions. (Max.)
Charging time after complete discharge. (Max.) Approx. 15 h
Parallel operation of complete systems 2 Systems with max 10 radio sensors
max. Number of radio sensors 10 per system
2.6.2 ACCURACY AND DISSOLUTION
Aluminium diaphragm with resistance strain gauges (DMS), factory calibrated, on-site
calibration is not necessary. The zero point is automatically calculated on each removal of
sensor from charging base.
2.6.3 AIR PRESSURE MEASUREMENT
Maximum load 23 bar

Measuring range 0-20 bar
Measuring range receiver 0-20 bar
Accuracy 0,5% FS (type.)
Measurement resolution 0,01 bar
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3.0 MOUNTING THE 4400TRUCK STEP BY STEP
3.1 FIRST STEP: PREPARING ACTIONS
Before starting installation check the following important points first.

 Check delivered material for any
transportation damage and for
completeness.
 Clean up the mounting pits.
 Component locations, pipe locations
and cable lengths.
 Check the Voltage supply, protection
device and wiring, according to the
values in the specifications of the model
concerned.
Check the empty pipes for free passage
Check the building dimensional and level

accuracy complies with the requirements in
the foundation plans.
You will find the appropriate requirements
for the foundations in :
Appendix E (foundation plans)
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3.2 OVERVIEW OF INSTALLATION
1 Toe-tester (side slip) 6 Joint Play Tester

2 Inspection Pit 7 Analogue Display
PC-Visualisation or odometer distance unit
3 Roller Assembly 8
measurement
Control-Cabinet with connection for Pm/Pz
4 9 Mobile Display unit with Touch Screen
Cable Version
5 Printer Cabinet
3.3 NEXT STEPS: INSTALLATION AND WIRING
Now the following components will be installed and connected.

3.4 Mounting the Roller sets without weight system
3.5 Mounting the Roller sets with weight system
3.6 Mounting Display Cabinet
3.7 Mounting Control Cabinet
3.8 Mounting 4415
3.9 Connection between Roller-Set and control-cabinet
3.10 Connection between control-cabinet and display cabinet
3.11 Connection 4415 (optional)
_ _ _
Important safety notes
 When carrying out installation, maintenance and repair work, always switch off the mains power supply
at the display cabinet and secure the cabinet with a padlock to prevent it from being switched on again.
 Only approved electricians must carry out all electrical installation work.
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3.4 MOUNTING THE ROLLER SET WITHOUT WEIGHT SYSTEM
Standard mounting set for roller-bed (without weight system)
Mounting set
The roller set is fixed with 12 pieces of bumper

blocks to avoid a sliding of the roller mechanics
during extreme stressing or load. Six bumper blocks
are welded on the iron beam to fix the bearing parts
of each roller set.
Exact levelling of the rollers is done with locking

screws (M16).
Retrofitting to axle weight system is conditionally

possible.
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1. Fit support blocks 1 on the IPB 140 girder

according to assembly plan.
2. Remove the cover plates and motor cover.
3. Remove cover plates and motor cover.
4. Lift roller sets at the brackets for the cover plates,

using an appropriate webbing sling and suitable lifting
equipment, into the assembly pit.
The hoist should be rated for a carrying capacity

of min. 1,000 kg.
 Take care of sensor and motor cables!
 The elevated side is the access side!
5. Set the roller sets to 740 mm roller distance.
6. Average roller sets in direction of travel. The roller

sets must be installed precisely at right angles to the
drive-on direction. The brake rollers for the left and
right tester must be positioned along the same axis.
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7. The stops position 8 and the supports position 1

are to be attached using an initial spot weld
8. To protect the electronic parts, lift roller sets out of

the assembly pit while welding.
9. The stops position 8 and the supports position 1

can now be seam welded according to assembly
plan.
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10. Lift the roller sets back into the assembly pit.
11. Fix position-using screw M16 position 10, secure with nut position 9. Air gap between screw M16 and
weighing sensor approx. 1 mm. Level the test stand using screw position 4. Top of cover plate (for low roller)
must be flush with the floor. Lock-off screws using lock nuts.
12. Mount the cover plates, motor covers and covers again.
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3.5 MOUNTING THE ROLLER SET WITH WEIGHT SYSTEM
8-point axle weight system

The axle weighting system measures the static test load. Thus enables a calculation of the axle efficiency,
which is used for the evaluation of a truck-trailer air-brake system.
The 8-point weight system is used for dynamic weight measurement during maximum brake force
measurement giving more accurate results by allowing for weight transfer during the brake test.
In additional an automatic calculation of the total vehicle efficiency (test conditions) is possible using the axle
weight system.
Retrofitting is always possible.
 8 x shear force sensors
 mounting set for 4400TRUCK brake tester
Mounting set for axle weighting system with bearing elements

8 x bearing disc
8 x Elastomer cylinder
8 x Steel cylinder
1. Fit support blocks 1 on the IPB 140 girder

2. Remove the cover plates and motor cover.
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3. Remove cover plates and motor cover.

4. Lift roller sets at the brackets for the cover plates,
using an appropriate webbing sling and suitable
lifting equipment, into the assembly pit.
The hoist should be rated for a carrying capacity

of min. 1,000 kg.
 Take care of sensor and motor cables!
 The elevated side is the access side!
7. Set the roller sets to 740 mm roller distance.
8. Average roller sets in direction of travel. The roller

sets must be installed precisely at right angles to the
drive-on direction. The brake rollers for the left and
right tester must be positioned along the same axis.
9. The Steel cylinders position 3 with a spot welding

seam attach.
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10. To protect the electronic parts, lift roller sets out

of the assembly pit while welding.
9. Weld together the Steel cylinders.
10. Lift the roller sets back into the assembly pit.
11. With the screws position 4 the test stand positioned on a common axis. The roller sets must be installed
at an exact right angle to the direction of travel. The brake rollers of the left and right test stand must be
positioned on a common axis.
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12. Mount the cover plates, motor covers and covers again.
The Mounting plans for the Roller sets you will find on Appendix E (foundation plans)
3.6 MOUNTING DISPLAY CABINET
Install the wall bracket at the intended position.

Care must be taken to use appropriate mountings for
the wall material.
The operator supplies the appropriate mountings.
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3.7 MOUNTING CONTROL CABINET
The control cabinet is secured by two screws directly

into the floor.
3.8 MOUNTING 4415
 Release the M8 nuts on the guide rail and push the rail towards the centre of the plate.
 Take off the cover on the side slip tester plate.
 Lift the side slip tester plate into the pit and align.
 Drill out the eight locating holes with a 14 mm masonry bit.
 Lift the side slip testing plate out of the pit.
 Insert the eight S14 dowels.
 Lift the side slip testing plate into the pit, align and secure with six 12x80 mm bolts.
 Pull the sensor lead and the earth wire through the empty pipe and into the control cabinet.
 Fit the cover on the side slip testing plate and tighten the guide rail with the M8 nuts.
 Ensure that the cover engages in the leaf spring.
The cover should have up to 0.5 mm play in the longitudinal direction.
 Press the stops against the guide rail and secure with the 12x80 mm bolts.
 Move the cover completely to the left and right, to check that it can move freely and that it returns to
 the centre position.
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3.9 CONNECTION BETWEEN ROLLER-SET AND CONTROL-CABINET
Left roller-set Right roller-set

15m motor cables (4x4mm²) pull through to control 15m motor cables (4x4mm²) pull through to control
cabinet. cabinet.
15m sensor connection cable with din plug linked to 7,5m sensor connection cable with 8 wires linked to
GSA-0025 GSA-0030
Link between left roller-set and control cabinet: Link between right and left Roller-set:
 Lay the sensor cable of the left mechanics to the  Lay the sensor cable of the right roller set to the
control cabinet and connect it to the sensor left roller set and connect to the sensor
connecting cable KA-0120 connection box GSA-0025
 Lay the two motor cables through the 100mm  Lay the motor cable through the conduit DN 70 to
conduit to the control cabinet. the control cabinet.
 Lay the ground wire of the left roller set to the  Lay the grounding wire of the right roller set to
control cabinet and fasten it to the earth bus bar. the left roller set and fasten it to the earthing
screw.
Caution: Electromagnetic Brake (if fitted)

Lay the 2-wire brake cable of the right and left motor to the control cabinet.
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3.9.1 SENSOR CONNECTION BETWEEN GSA-0030 WITH GSA-0025
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Pin-table for concentric plug of GSA-0025

Pin-table for GSA-0030 connection cable:
connection cable:
ST3 – Control cabinet CABLE
1 G Pink +12V 1 Pink +12V
2 D White Detection roller left 3 Grey/pink Detection roller right
3 L Grey/pink Detection roller right 5 black Slip detector right
4 C Red Slip-detector left 6 Brown Ground
5 B Black Slip-detector right 8 Yellow Break force right
6 A Brown Ground 10 Grey Load scale right
7 F Blue Break force left 12 Red/blue Cal. – check
8 I Yellow Break force right Shielding
9 E Green Load scale left
10 K Grey Load scale right
11 H Violet n. c.
12 M Red/blue Cal. – check
Information on the connection details is shown on the connection diagrams in Appendix F

Schematics for the sensor box (GSA-0030) and (GSA-0025).
3.9.2 CONNECTION OF THE MOTOR CABLES IN THE CONTROL CABINET
 Lay the grounding wire of the right roller set to the left roller set and fasten it to the earth
screw.
 Lay the grounding wire of the left roller set to the control cabinet and fasten it to the earth
bus bar.
 Lay the two motor cables to the control cabinet and fasten them.
 The gearbox vent screws must replace the blanking plugs on the gearbox tops.
 Lay the supply cable to the control cabinet and connect it to the main switch.
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Appendix E (electrical plans)
N° N° wire motor Right N° N° wire motor Left

1 Wire 1 7 Wire 1
2 Wire 2 8 Wire 2
3 Wire 3 9 Wire 3
4 Wire 4 10 Wire 4
5 Wire 5 11 Wire 5
6 Wire 6 12 Wire 6
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K13 – Brake motor

lock-unlock relais
Important:
Use a rotating field instrument to check whether a “right-hand rotation field” exists as wiring is designed for
this.
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3.10 CONNECTION BETWEEN CONTROL CABINET – ANALOG DISPLAY
Display:
Unpack the display box, remove the back cover and

position the display box on the wall bracket and fasten it
with bolts.
Lay the connecting cable and the grounding wire from

the control cabinet to the display box (they are already
connected in the control cabinet).
Connect the grounding wire to the earth bus bar and the
connecting cable fasten both in the mounting clip.
Connecting
1 = brown 3 = white
2 = green 4 = yellow
Control cabinet:
Lay the connecting cable and the grounding wire from

the control cabinet to the display box (they are already
connected in the control cabinet).
Connect the grounding wire to the earth bus bar and the
connecting cable and fasten both in the mounting clip.
Connecting
1 = brown 4 = yellow
2 = green 5 = blue
3 = white
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3.10.1 POWER CIRCUIT DIAGRAMS OF THE CONTROL CABINET
Dahlander Motors 400 V / 3Ph with reverse turning mode and electromagnetic brake.
Each motor type and power board of the control cabinet is described in four steps: just principal
examples.
3-Phase Power circuit diagram with contactors and transformer unit for 230V/1Ph voltage
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Power circuit diagram for contactor / relays controlling
Switch mode
power supply for
12VDC
electronics
I2C-Relay board
Mounted on
electronic panel
Circuit diagrams for additional features “electromagnetic brake”
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3.11 NEXT STEPS: INSTALLING OPTIONAL COMPONENTS
Installing optional Components
3.12 Software (Visualisation / Database)

3.13 Pedalforce
3.14 Air pressure cable sensors
3.15 Printer on 4400TRUCK
Note:
If none of the optional components for the system are required, continue the installation from the
NEXT STEP !
3.12 SOFTWARE (VISUALISATION / DATABASE)
The software enables a synchronised visualisation of the testing procedure and control via an on-screen
remote control.
The input of order data records all customer details and several printouts (graphic / tabular form) are
possible with all WINDOWS standard printers.
A database module stores test results and customer and vehicle data. It is then possible to recall stored
data at a later date.
Professional user: Before starting the brake testing sequence of a vehicle, the customer and vehicle data
(calculation pressure & total gross weight) should be loaded to avoid a complicated input with the remote
control.
Delivery set:
- Communications board with RS232-interface and mounting set
- Diskettes or CD with Software
- Serial connection cable 10 m length
- Minimum requirements for the PC-System:
Pentium PC (>500 MHz) with CD-ROM, Mouse, keyboard.
 128 MB RAM
 20 GB hard disc
 Operating system WINDOWS 95/98/2000/XP/Millennium or NT4.0 (Service Pack 6)
Screen shot Connection cable for RS232 link

between PC and control cabinet
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Connect the Laptop / PC-Station to the RS232-port of PC-board (CPU)
Start the installation:

 Put the Setup-CD into your CD-ROM drive and start
the file "setup.exe ".
 Select LANGUAGE
 Choose destinations directory and Interface.

 To install the software to a different drive and folder.
Default is = C:\44TRUCK
 To continue the installation click on "OK"
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 Wait the message “Installation is complete.”
 Start the software program
INITIAL IMAGING
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3.13 PEDALFORCE
L’installazione dell’optional PEDALFORCE è descritta dettagliatamente nel relativo manuale di service

codice 13SMPEDALFORCE.
3.14 AIR PRESSURE SENSOR CABLE
Principle of Operation
The air pressure sensors CFD-0103/v are two sensors to

obtain pneumatic pressure values in the braking system of
commercial vehicles or trailers.
In addition there is a sensor, which determines the pedal or

hand force when the service brake or the parking brake is
operated.
The measured values are recorded in CFD-0103/v and

transferred via a 20m-connection cable online to the receiver
unit in the control cabinet.
In addition, the CFD-0103/v sensors can also be used for

ALB setting work and tension alignment. The software test
programs offer the required functions.
Basically, both CFD-0103/v can be used universally. It is important that the user connects the appropriate
sensor for the right measuring task shown by the letters PM / PX on the control cabinet.
The measurement range (0-20 bar) is the same for all the pressure sensors.
Intended Use
The sensors must under no circumstances be subject to higher pressures than those specified in their
measurement range. If the overload exceeds 15% there is a risk of destroying the sensors.
Measured Values Display

The results of the measurement are displayed on the following modules:
 Analogue display - during the brake test or in the special ALB test program
 Print-out - maximum values of the PM/PX in the tabular test printout, list printout
  PC visualisation - during the brake test or in the special ALB test program
The compressed-air sensors are connected to the analogue input of the DS computer and must be
calibrated.
Important:
The compressed-air sensors should not be interchanged after calibration. If necessary, they
should be marked (with the letters Pm and Px since they are mechanically identical but have
different calibration values.
Connect up the compressed-air sensors before the start-up procedure of the brake tester. Otherwise they
will not be recognised during initialisation.
After the start-up routine, the pressure display 0.0 _ _ 0.0 on the LCD display will indicate that the
compressed air sensors have been connected up.
If no compressed air sensor has been connected up, the LCD will show the standard display: 00 _ _ 00
(braking and brake force difference).
With the compressed-air sensors connected, it is possible to toggle between the two displays by pressing the
button Pm Z.
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3.15 PRINTER ON 4400TRUCK
Connect the printer interface with the DS Board (without PC software).
Connect the printer and the printer connection board in the control cabinet with the Centronics
Cable.
Install Printer on P.C.
Connect the printer and the

PC with the Centronic-Cable
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3.15.1 PRINTER CONFIGURATION
Seikosha SP-2400 DIP switch adjustment:
Note:
Switch the printer off, before changes of the
DIP switching positions to be made.
Attention:
If the printer were in operation, the print head
before contact cooling leave.
DIP switch adjustment:

1. Open the Printer cover
2. Take out the ribbon cartridge Push the print
head by hand to the right
3. Push the cover of the DIP switches at the
mechanical block to the left and remove the
cover.
Remount the cover after adjustment of the DIP

switches, refit the printer ribbon and the printer
covers.
Reading the DIP-switch changes takes place only during the printer initialisation routine after
switching on the printer and/or after receipt of the ‘INITIAL’ signal on the parallel interface.
DIP Switch 1 DIP Switch 2
Switch Description Value Switch Description Value
1 –3 International Character set USA 1 –3 Serial transmission rate 9600 BPS
4 Mode Epson 4 Serial expression Ready/online
5 Character set Graphic 5 Parity no parity
6 Page length 12 Inch 6 Serial data length 8 Bits
7 DC1 / DC3 Code No 7 Interface choice parallel
8 CR Code choice Auto feed 8 Single sheet off
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3.15.2 PRINTER OLIVETTI DM109 – IBM PROPRINTER EMULATION
The following diagram shows the structure of the menus for the "initial set up" in IBM proprinter
emulation and or Oliprinter code.
These printer defaults of the SET UP are the factory programmed.
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3.15.3 PRINTER OLIVETTI DM109 – EPSON FX 850 EMULATION
The following diagram shows the structure of the menus for the "initial set UP" in the Epson FX
850 emulation mode.
These printer defaults of the SET UP are factory programmed.
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3.16.4 PRINTER OPTIONS
If Printer is selected from the Options submenu, the

following window opens:
Notes on printer selection:

If the None option is chosen, the software will not be able
to print out the results.
The Olivetti DM109 and Seikosha SP-2400 options are
the default settings for the dot matrix printers supplied as
standard by Motorscan.
The driver for the EPSON FX-850 must be installed as a
WINDOWS standard printer.
If any other printer is used, the Other option should be
selected.
Selecting this option will open another window, in which settings for commercially available
printers can be entered.
Notes on the Options window:
The black/white button must be

clicked if the standard printer
connected is not a colour printer.
Deactivate this button to print out
results and graphics in colour using
a colour dot matrix or inkjet printer.
Editing is only possible when using
a dot matrix printer:
A significant reduction in printing time can be achieved with most printers by selecting Text
mode.
It is possible to input a value in the Paper feed field for special types of printer.
Paper feed values: -99 mm...99 mm
These settings apply both when printing in the visualisation mode and from the database of the
software program.
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4.0 START UP
4.1 CODING IR REMOTE CONTROL

4.2 THE SPECIAL ROUTINES
4.3 CONFIGURATIONS MODE
4.4 CALIBRATION MODE
4.5 SERVICE MODE
4.1 CODING OF THE IR REMOTE CONTROL
If several test lines or individual test stands are to be used in one hall it is necessary to code the remote
controls differently in order to avoid cross talk between the test lanes.
Setting of the Remote Control Address

11 variations can be set (default is 0). The coding can be changed as follows:
Remove battery from the remote control.
Insert battery again.
Press the STOP key 5x consecutively.
Enter the desired address within 5 seconds.

e.g.: Address 4
If the battery is changed again later, addressing has to be carried out again if the desired address is not 0.
Address table
Address 1 Address 2 Address 3 Address 4
Select step 17 in the configuration routine. The set or entered value is shown in the centered 4-digit LCD at
the right side. On the left side, the code of the remote control is shown for a short time.
As usual for other configuration steps, the desired value is entered and confirmed with “ENTER”.
Note:
During standard operation, the test stand reacts only to the remote control commands with the configured
address. During special routines, however, the address setting is not taken into account.
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4.2 THE SPECIAL ROUTINES
How to get in the service, calibration or configuration mode
 Switch ON the system by main-switch.
 After switch on, the left LCD the word displays "INIT" during the
initialisation phase of the system.
 On the right LCD the firmware release number is shown.
 The service staff have to activate the service mode while the
message ‘tool’ is displayed by the LCD’s.
 The control cabinet keyboard or the software service routine

window, which appears for 6 seconds, can be used for selection.
 Press the keypad button on the control cabinet while the

LCD message shows ‘tool’.
Configuration mode (code required)
Calibration mode (code required)
Service mode
1 Automatic key Caution:
2 Run left side key If no LCD’s are fitted the following can be used:
 Connect a Laptop with RS232-Communication board and
3 Run right side key
software
4 Stop key  Connect the Service kit LCDs
5 Power On control lamp  It is not possible to use only the step motor pointers.
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 Alternative: Click on the software special routine

window and select the required mode:
 Configuration mode (code required)
 Calibration mode (code required)
 Service mode
Standard code sequence to enter the configuration and

calibration mode:
Clear code input in case of mistakes.
Code Input Dialog
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Extended accesses to the special routines starting from version 5.3 (eprom)
Service mode
Confirm with Enter to go in the Service-Routine
Change the Mode with the Arrow keys
Calibration mode (code)
Press Enter to start the Calibration-Routine
Standard code sequence to enter the configuration and

calibration mode:
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General operating and input procedure

Analogue Display:
Value Step-n. The analogue display for the right-hand side (red
pointer) shows the stage currently in progress.
The analogue display for the left-hand side

(green pointer) shows the current value.
- The red pointer shows the Step Numbers

- The green pointer shows the Values
Working window on software screen: Please note, that the software On-Screen
Value step-n. remote control should be used to send the
commands to the brake tester electronics.
Choose the desired step by pressing the Stop

key and Automatic-key on the PC-window
“remote control”
Alternative: Press the button on the display
Enter the desired value
Confirm or store the desired value by pressing ENTER key
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4.3 CONFIGURATIONS MODE
4.3.1 CONFIGURATION-MODE V5.2E – V5.XX
Step Description - configuration-mode V5.0x value default

1 Type of the motors 0 = Star-Delta motor 0
rated frequency of the slip rollers 1 = Dahlander motor
2 end value inside analog scale (input in kN) 8
3 end value outside analog scale (input in kN) 40
4 printer selection 0 = Olivetti DM109 1
1 = Seikosha
5 slip limit If the slip limit is set to the default value of 25 %
25%, the test rig will shut down, if the sensing
roller’s speed drops below the roller set’s
speed by 25%.
6 selection of the language (standard: German) 0
7 Mechanical setting of the green pointer left – green 0
8 Mechanical setting of the red pointer right – red 0
9 Not used -
10 special version The system loads all legal default values of the 0
selected country after pressing the ENTER key
1= CH 2= NL 3= I 4= PL 5= F 6= USA
7= N 8=UK 9=UK MOT 10=Malaysia
11 wheel weights in the printout 1= Wheel weights in the result printout 1
0= no
12 printout axle graphics 1= Axle-graphics and listing printout 1
0= only listing printout
13 Registration MESRA PY (hydraulics) 1 = MESRA sensor available 0
0 = MESRA sensor not available
14 Registration MESRA PD (pedal 1 = MESRA sensor available 0
pressure) 0 = MESRA sensor not available
15 Duration of peak value display Example: 1000 = 1000 ms = 1,0 s 4000
500 = 500 ms = 0.5 s
16 Automatic mode activated on start 0 = normal mode 0

1 = automatic mode (only allowed for official
testers)
17 Entry of infra-red address (0 - 10) 0
18 Delivery type 2= Motorscan Logo 2
19 Reset roller start counter 0 = no function 1 = RESET on zero -
20 Bi-directional testing mode 0=Normal mode (only one test-direction) 0
1=Bi-directional mode (two test directions)
21 Brake type pre-selection permit Selection of the brake type during the roll 0
recondition measurement permit (Special
version PL&I)
0=no 1=yes
22 MESRA duration of the error display Range of values 0..9999s 30
control pit All inputs in seconds the number keys 1000,
100, 10 serve the input of the seconds.
23 Safety device controlled by slip-roller 0=no 0
1=yes
24 Controlling of weight simulation device 0=no * not yet available * 0
with IR-Remote-Control 1=yes
25 End of Green range Range of values 0-9.9 mm, 3,0
* Start of the yellow range * all inputs in mm
26 End of Yellow range 6,0
* Start of the red range *
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Step Description - configuration-mode V5.0x value default

27 Analog display with two parallel brake 0=standard display 0
force scales 1=special display with two brake force clocks
28 Definition calculated pressure Range of values 0. .9,9 bar 6,5
all inputs in bar
29 Definition permissible total weight Range of values 0. .9999 kg * 10 all inputs in 0
kg * 10 the number keys 10000, 1000, 100, 10
are used for input.
Example: 4500 = 45000 kg = 45 t
0500 = 5000 kg = 5 t
30 slip range 1 LED-Arrows on – 0..27 % (Norwegian 9
software)
31 slip range 1 LED-Arrows are blinking – 0..27 % (Norwegian 18
software)
32 Controlling of the MESRA warnings yes = 1 0
over slip-rollers no = 0
33 Limit of brake force imbalance green- Adjustment of the threshold for the difference 15
yellow display – green / yellow. (0..99; 15 [%])
34-39 Dummy - not in use Reserved configuration steps
40 Legal values and limit values - Before starting the brake test procedure, the user has
to select a testing program (P1-P15) to load vehicle
- specific limits for online visualisation and total
evaluation in the printout.
180 - The software uses the limit values of the service,
x0 Brake force difference Service brake parking and secondary brake-system:
 brake force difference
x1 Difference Parking brake  efficiency / brake performance
- Each testing program (P1, P2, P3, P4…) has a special
x2 Difference Secondary setting, which could be defined in the following
brake configuration steps.
x3 Efficiency brake force Service brake - The testing program tachocontrol (P6) and Air-
pressure on-line measurement (P7) do not use limit
values.
x4 Efficiency brake force Parking brake
- The default values in the special version N. 0 respects
the German TÜV/DEKRA.
x5 Efficiency brake force Secondary - Country specific default/limit values are loaded, if the
brake service staff select the correct special version in
x6 PD Service brake configuration step N.10
- P1: step 40-49
x7 PD Feet Parking brake - P2: step 50-59
- P3: step 60-69
x8 PD Hand Parking brake - P4: step 70-79
- P5: step 80-89
x9 Ovality global - P6-7: tachocontrol / air-pressure on-line
- P8: step 90-99
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4.3.3 SERVICE-MODE FOR REMOTE ACCESS WITHOUT CHANGING DATA.
Step Description Value range

1 Date (dd.mm)
2 Date (yyyy)
3 Time (hh.mm)
4 Slip sensor, left (displayed value changes as slip roller turns) Lower value
25 – 250 [digits]
5 Slip sensor, right (displayed value changes as slip roller turns)
Upper value:
6 Sensing roller, left (displayed value changes when sensing roller depressed) 251-1000 [digits]
7 Sensing roller, right (displayed value changes when sensing roller depressed)
8 Zero point, brake force sensor, left [digit] 25-250
9 Calibration check, brake force sensor, left [digit] 750-980
10 Physical value for brake force, left [N] Manual input
11 Physical value for brake force, left, with calibration check [N] 40000
12 Zero point, brake force sensor, right [digit] 25-250
13 Calibration check, brake force sensor, right [digit] 750-980
14 Physical value for brake force, right [N] Manual input
15 Physical value for brake force, right, with calibration check [N] 40000
16 Zero point, weight sensor, left [digit] 25-250
17 Calibration check, weight sensor , left [digit] 750-980
18 Physical value, weight sensor, left [kg] Manual input
19 Physical value, weight sensor, left, with calibration check [kg] 8 Point 6600
20 Zero point, weight sensor, right [digit] 25-250
21 Calibration check, weight sensor, right [digit] 750-980
22 Physical value, weight sensor, right [kg] Manual input
23 Physical value, weight sensor, right, with calibration check [kg] 8 Point 6600
Additional sensor (PM/PX cable version) for air/hydraulic-pressure and pedal force
24 Zero point air-pressure PM [digit] 25-250
25 Calibration check PM [digit] 750-980
26 Physical value PM [bar] Manual input
27 Physical value PM with calibration check [bar] 99
28 Zero point air-pressure PX [digit] 25-250
29 Calibration check PX [digit] 750-980
30 Physical value PX [bar] Manual input
31 Physical value PX with calibration check [bar] 99
32 Zero point pedal force sensor PD [digit] 25-250
33 Calibration check PD [digit] 750-980
34 Physical value PD [daN] Manual input
35 Physical value PD with calibration check [daN] 981
36 Zero point hydraulic sensor PY [digit] 25-250
37 Calibration check PY [digit] 750-980
38 Physical value PY [bar] Manual input
39 Physical value PY with calibration check [bar] 200
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4.3.4 CALIBRATION MODE
Step Description Value range

8 Zero point, brake force sensor, left [digit] 25-250
9 Calibration check, brake force sensor, left [digit] 750-980
10 Physical value for brake force, left [N] Manual input
11 Physical value for brake force, left, with calibration check [N] 40000
12 Zero point, brake force sensor, right [digit] 25-250
13 Calibration check, brake force sensor, right [digit] 750-980
14 Physical value for brake force, right [N] Manual input
15 Physical value for brake force, right, with calibration check [N] 40000
16 Zero point, weight sensor, left [digit] 25-250
17 Calibration check, weight sensor , left [digit] 750-980
18 Physical value, weight sensor, left [kg] Manual input
19 Physical value, weight sensor, left, with calibration check [kg] 8 Point 6600
20 Zero point, weight sensor, right [digit] 25-250
21 Calibration check, weight sensor, right [digit] 750-980
22 Physical value, weight sensor, right [kg] Manual input
23 Physical value, weight sensor, right, with calibration check [kg] 8 Point 6600
Additional sensor (PM/PX cable version) for air/hydraulic-pressure and pedal force
24 Zero point air-pressure PM [digit] 25-250
25 Calibration check PM [digit] 750-980
26 Physical value PM [bar] Manual input
27 Physical value PM with calibration check [bar] 99
28 Zero point air-pressure PX [digit] 25-250
29 Calibration check PX [digit] 750-980
30 Physical value PX [bar] Manual input
31 Physical value PX with calibration check [bar] 99
32 Zero point pedal force sensor PD [digit] 25-250
33 Calibration check PD [digit] 750-980
34 Physical value PD [daN] Manual input
35 Physical value PD with calibration check [daN] 981
36 Zero point hydraulic sensor PY [digit] 25-250
37 Calibration check PY [digit] 750-980
38 Physical value PY [bar] Manual input
39 Physical value PY with calibration check [bar] 200
40 Pedalforce Net scan 1
41 Type of the motors and rated frequency of the slip rollers 0
You will find a description of the steps in the section “Sensor details & calibration procedure”
Refer to Appendix I (Older Configuration modes) for older Configurations-listings!
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4.4 CALIBRATION MODE
4.4.1 EXPLANATION OF CALIBRATION PRINCIPLE
During the calibration process, the software is used to relate a physical value to the digital
values, which were generated through the A/D conversion of the sensor signals.
Each sensor has 4 calibration stages (Stages 1-4 ) assigned to it, which are described under
the following points.
Important:
The force sensors must be calibrated to 6,600 kg per side.
Changing over from 4400TRUCK to 4415

After the calibrating routine has started, the test rig enters the first calibrating stage for the brake
test rig. Use the following commands to switch between the individual testing units.
or Changeover between testing units
Step N. Description Value range

04 Zero point side-slip potentiometer (side-slip tester) [digit] 25-250
05 -
06 Physical value side-slip potentiometer [mm] Manual input
07 -
When switching over to a toe-tester plate, the following appears briefly on the LCDs: “¦----¦“.
When changing to the brake test rig the following appears: “----“.
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4.4.2 CHANGE THE CONFIGURATION LISTING by PC
Click on the ‘options’ menu select the “configuration” option.

After input of the code a list window opens where all the configuration steps are listed. The
appropriate configuration can now be changed and a restart of the truck brake tester machine is
not necessary.
Standard code sequence to enter the configuration Clear code input in case of mistakes.
and calibration mode:
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The default values are located in the description line as last value before the units.
Changes are made in the right column. Using the "defaults" button loads the default values into
the configuration list. The previous setting are shown in the left column. Changes made are
stored after clicking the OK button, and choosing Yes in the confirmation dialogue.
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4.4.3 CHANGE, ADD AND DELETE FROM LEGALI LIMIT VALUES
Start the program and choose the "options" - "password“ menu.

In the following dialogue window choose " limits ".
Now the limit value dialogue is shown. All current limit values are listed, and can be modified,
added or deleted.
Changes made are stored after clicking the OK button and choosing Yes in the confirmation
dialogue.
The button "default" returns the limit values to the default values.
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4.4.4 SENSOR DETAILS & CALIBRATION PROCEDURE
The measuring systems processor card (e.g. NC2055) analogue/digital converter has a
resolution of 10 Bit, i.e. 210 = 1024 steps.
The sensors output a signal of 0-10 mA, proportional to the load. After the A/D conversion it is
possible to display this measuring range by means of the 1024 steps in the digital values of 0 -
1023 required for the calibration.
The zero point and the measuring range’s accumulated value are each increased or lowered by
app. 10 % of the measuring range. This permits a drift of the measuring range (temperature
drift...) of +/-10 % without reducing measuring accuracy.
Graphical display:
There are two methods of calibration:

Mechanical calibration (Stage 3)
Calibration by calibration check (Stage 4)
A zero point reset (Stage 1) must always be carried out!

Example: Calibration by calibration check (Stage 4)
Stage 1: Zero point reset: Zero point = app. 100 digits

Stage 2: Calibrations check OK? Calibration check = app. 900 digits -> OK!
Stage 3: Mechanical calibration (not used)
Conduct calibration check: Allocation of physical value = 40000 N
100 digits = 0 N
Stage 4: 900 digits = 40000 N (==> 800 digits stroke)
Measuring range resolution = 40000 N / 800 digits
= 50 N/digit
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Zero point - Stage 1

In a non-load state the sensor transmits an output current of app. 1mA.
After the A/D conversion of the sensor signal the processor card outputs a digital value of app.
100 digits.
The technician should use the limit value (page 10) table to verify, whether the sensor signal in
non-load status is within the prescribed limits.
Apart from this pushing/pulling the sensor should show whether the selected sensor reacts to
force or pressure changes. Here the displayed value should change on the display cabinet’s
left-hand LCD.
Adjustment procedure:
- Select sensor test stage.
The zero point can be stored by pressing the ENTER key.
Sensor must be not be loaded at this point!
Calibration check - Stage 2

In this stage, the sensor, which is not under any mechanical load, transmits a current, which
corresponds to the output signal of a sensor under maximum load.
The corresponding digital value is shown on the display cabinet’s LCD.
This is a test value and cannot be altered by making an entry.
The technician should use the limit value (page 10) table to verify, whether the sensor signal in
non-load status is within the prescribed limits.
1. Select sensor test stage.
2. Checking digital value:
 If the digital value lies within the permissible limits, it is possible to carry out a calibration
by using a calibration check (Stage 4).
 If the digital value lies outside the permissible limits, any calibration done with a
calibration check (Stage 4) will lead to errors. The analogue section of the system has
malfunctioned.
Physical value - Stage 3

In this stage the sensor’s physical measured value can be measured and adjusted by means of
a mechanical device.
The physical value which corresponds to the mechanically loaded sensor or sensor signal can
be entered using the remote control.
The physical value is shown in the display cabinet’s left-hand LCD and alters as the sensor load
alters.
Example: Weight sensor – suspension tester
Weight sensor in non-load status: 0
Weight sensor with person on test plate: weight per person in kg / enter with remote control.
- Select sensor test stage.
- Place calibration force on sensor.
Enter desired physical value.
Confirm entered value.

Sensor must be mechanically loaded!
Caution:
Any calibration conducted during stage 4 will be deleted.
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New Steps 40 And 41

With existing Pedalforce radio system a net scan
Step 40: Pedalforce Net scan must be accomplished with the start-up of the
test-line. For this, the sensors may not be in the
charging stations and must be ready for use (see
Pedalforce service manual). Net scan examines
the system and determines all existing sensors.
If a sensor, during the Net scans, is in the loading
station or a sensor is not ready for use, it cannot
be recognised by the radio system and air
pressure checking cannot be carried out. A Net
scan must be carried out at start-up if a sensor is
renewed, added or removed.
Using:
Step 40 – Default = 0
Note:
Net scan can be repeated at each time – because
that is generally not necessary!
Start the net scan with ENTER.
With successful net scan, show the number of sensors which are found in the radio
system.
A further confirmation does not have to take place - net scan is final.
Step 41 – Type of the motors and rated frequency of the slip rollers
Using:
Using Value Adjustment The select the motor type first.
0 Star Delta Motor
1 Dahlander Motor
Confirm with ENTER .
The announcement changes into the frequency display.

Now the idling speed is measured:
Drive vehicle into the rollers. Keep both buttons

pressed on the control cabinet (dead man circuit).
The test-line starts after few seconds and switches

off again after about. 10 seconds.
Caution:
 Do not operate Vehicle brakes!
 No persons may be in the vicinity of the roller set
during this test.
Press ENTER to store the measured idling speed.

Alternatively the value (for example: 19 cycles per second) can be entered also manually.
For this the number buttons are used.
Enter desired value.
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Physical value with calibration check - Stage 4 (Electronic Calibration)

In this stage the maximum physical value of the measuring range or sensor can be adjusted by
simulation with the aid of the “calibration check” signal and entered by remote control.
Caution:
Any calibration conducted during stage 3 will be deleted.
Example: Sensors must be in non-load status!
Weighted sensor: 7.5 t (weight entry by remote control)
Brake-force sensor: 40000 N (enter force by remote control)
Adjustment procedure: - Select sensor test stage.

- Calibration check automatically simulates a
maximum sensor load.
Enter desired physical maximum value by

remote control.
Confirm entered value.

Sensor must not be mechanically loaded!
Limit values
Zero point brake force, weighted, PM, PZ, PD and PH 25 - 250 digits (100 digits)
Zero point toe tester plate 300 - 700 digits (600 digits)
Calibration check 750 - 980 digits (850 digits)
Calibration value brake force (maximum value) 40000 N
Calibration value weight (maximum value) (4-point) 7500 kg (per page)
Calibration value PM (maximum value) 9.9 bar
Calibration value PZ (maximum value) 9.9 bar
Calibration value PD (maximum value) 981 N
Calibration value PH (maximum value) 200 bar
Calibration value toe tester plate Actual deflection [mm]
The values in brackets () serve as a guideline for standard settings.
Printing out configuration and calibration data
Press one of the three buttons
The data can be printed out at the printer at any stage of the calibration routine!
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4.4.5 CALIBRATING DEVICE
General
 The dynamometer (Figure 1), which is part of the calibration unit, is a sensitive measuring
unit which has to be treated with care and to be stored in the original packing if not used.
 The dynamometer must be calibrated once a year.
 Caution: The dynamometer (ring power sensor) must not be overloaded. Max. load = 10 kN
(please observe attached instructions for use Figure 3)
 For each dynamometer, a conversion table (Figure 2) is attached with which the load of the
pointer traveling can be converted according to the type of load (tension/pressure).
 The general safety instructions of 4400truck have to be observed.
Figure 1 Figure 3
CONVERSION TABLE (6E77)

LOAD (kN) TRACTION PRESSION
0 0 0
1 21,1 24,8
2 42,1 49,8
3 63,2 74,9
4 84,2 100,3
5 105,2 125,8
6 126,2 152,6
7 147,1 177,6
8 167,9 203,9
9 188,6 230,4
10 209,2 257,1
Figure 2
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Calibrate 4400TRUCK
Mount hanger
 Remove cover of roller set.
 Screw in eyebolt M12x80 into the calibration
borehole.
 Attach round steel chain with screw shackle to
eyebolt.
1= Eyebolt
2= Calibration borehole
Installation of the dynamometer:

 Mount adapter mb30 on calibration unit.
 Position calibration system on test stand.
 Screw on adapter.
 Fasten dynamometer with hexagon bolt M8X40
to adapter.
 Use elevating spindle until threaded shackle
can be screwed to the dynamometer.
1= Adapter
2= Dynamometer
3= Screw shackle with chain
4= Adapter
Adjusting of calibration equipment:

 Align calibration unit vertically to calibration
borehole.
1= Align vertically to calibration borehole
Pretensioning of the dynamometer:

 Turn the hand wheel of the calibration unit
clockwise until the pointer has moved two scale
lines on the dynamometer scale.
 Set the display to zero using the setting ring at
the dynamometer.
1= Handwheel
2= Setting Ring of Dynamometer
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Calibration (mechanic):
 Confirm zero point of sensor (see Sensor details & calibration procedure).
 Set a load of 8 kN according to the conversion table (Fig. 2) of the dynamometer using a hand wheel (if
necessary readjust until the display of the dynamometer is stable). 8kN on the dynamometer correspond
to 40 kN on the display.
 Enter and confirm the final value of the sensor 40 kN using the remote control (see calibration routine mb
8100).
 During a check test, the unit has to be tensioned again using the hand wheel and a load of 30 % of the
final value must be set (= 2.4 kN at Dynamometer). The test rig must have a value of approx. 12 kN (+3
% of the scale final value).
Conversion of table value
Example of tension calculation (only valid for the figure 2):
2kN = 42,1 scale lines

2,4kN = X (100%)
Calculation of Force on Dynamometer

Example
Given: Roller radius r1 = 139 mm
Lever arm from the middle of motor shaft to middle
of calibration bore hole r2 = 360,5 mm
Transmission i = 15/29
Max. force on roller circumference F1 = 40 kN
Required: Max. force on dynamometer F2
Solution:
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Calibration table
Brake force Force at Dynamometer
40000 N 8000 N
25000 N 5000 N
12000 N 2400 N
7500 N 1700 N
Calibrating device with reference sensor

General
 The dynamometer (Figure 1), which is part of the calibration unit, is a sensitive measuring unit which has
to be treated with care and to be stored in the original packing if not used.
 The dynamometer must be calibrated once a year.
 Caution: The dynamometer (ring power sensor) must not be overloaded. Max. load = 10 kN (please
observe attached instructions for use Fig. 3).
 For each dynamometer, a conversion table (Fig. 2) is attached with which the load of the pointer
travelling can be converted according to the type of load (tension/pressure).
 The general safety instructions of 4400TRUCK have to be observed.
Figure: 1: Control terminal with reference sensor Figure: 2: reference sensor
Overview over the Parts for 4400TRUCK
A = Universal calibration unit

B = Adapter
C = Screw shackle
D = Round steel chain, 3 links
E = Eye bolt M12X280
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Calibrate 4400TRUCK
Mount hanger:
 Remove cover of roller set.
 Screw in eyebolt M12x80 into the calibration bore
hole.
 Attach round steel chain with screw shackle to
eyebolt.
1= Eyebolt
2= Calibration bore hole
Installation of the reference sensor:

 Position calibration system on test stand.
 Screw on adapter.
 Fasten reference sensor with hexagon bolt M12X50
to adapter.
 Use elevating spindle until threaded shackle can be
screwed to the reference sensor.
1= Adapter
2= Reference sensor
3= Screw shackle with chain
Calibration (mechanic): The hand wheel of the calibration plant so for a long time
in the clockwise direction turn to a change of approx. 2
kg (corresponds approx. 100 N braking force) on the
display of the reference sensor is reached.
The announcement of the reference sensor in zero
position bring <enter key >.
The zero point of the braking force sensor (= lower base)
confirm.
At the reference sensor stop a load of 819 kg by means
of hand wheel (If necessary place behind, until the
announcement on the display of the reference sensor
stably stands).
819 kg at the reference sensor correspond to 40 kN on
the announcement.
The final value of the braking force sensor 40 kN (=
upper base) confirm.
During a routine check be stopped a load must be again
eased of 30% of the final value (= 245.7 kg at the
reference sensor) by means of hand wheel and.
1= Hand wheel At the test stand it self then a value of approx. must. 12
2= Control terminal kN (?3% of the full scale) results in.
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Calculation of Force on reference sensor
Given: Roller radius r1 = 140 mm

Lever arm from the middle of motor shaft to
middle of calibration bore hole r2 = 360,5 mm
Transmission i = 15/29
Max. force on roller circumference F1 = 40 kN
Required: Max. force on reference sensor F2
Solution:
Calibration value in kg at the reference sensor
Brake force [N] Calibration value on reference sensor [kg]

40000 819
30000 614,3
20000 409,5
12000 245,7
10000 204,8
5000 102,4
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4.5 SERVICE MODE
Special measurement mode for brake force accuracy check

Do not drive into the roller-set, to activate the special
measurement mode for:
- Brake force accuracy check (reading by the
pointers on the analog display)
- Service functions
!!!! All security functions are disabled!!!!
Press the key to activate the input mode for
the empty weight.
Press again the key to activate the special
measurement mode for the brake force accuracy

check.
Caution:
- The security functions slip sensors are disabled
- The slip bar sensors of the left and right roller-set
(vehicle in roller-set) are disabled!
After the test mode is selected, enter the service
code the message “code” disappears.
Standard code sequence to enter the Configuration

and calibration mode:
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Special measurement mode is active, if the

message “test” is blinking on the left LCD.
Practical usage:
- Install the calibration unit and apply the load/force
to check the readings of the analogy display
(accuracy test)
- Start the rollers to check the measurement
tolerance (Ovality) of the mechanical unit and
measurement system.
- Useful for power test without security switch off
1. Left and right brake force measurement without functions for approval procedures and service
turning rollers. demands.
The brake forces of the left and right roller-set are

shown by pointers and PC-visualisation.
Brake force difference or air-pressure is displayed on

the LCD.
brake force shown by Pointers and PC

-----------------------------------------------------------------------
2. Left and right brake force measurement with
running motors/rollers.
Caution: “ Danger to Life”

General information:
- Measurement will be stopped, if the brake force
values remain on a certain level for more than 60
seconds.
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4.5.1 CONFIGURATION MODE DETAILS
01 = Selection of motors and idling speed

Select the correct motor/engine type
0 = Star-delta motor
Step N.1a 1 = Dahlander motor
Confirm the motor type
Step N.1b The nominal idling speed should be between 18-19 Hz

(50Hz net frequency).
Solution with manual input of the idling speed:

Please input idling speed manually with the key “10” and
“1” and confirm with enter.
Solution with automatic measurement of the idling speed:

Hold both keys down on the display cabinet (dead-man
circuit); the test rig start up after a few seconds if a vehicle
is on the roller set and shuts down again after app. 10
seconds.
Caution:
 Do not apply vehicle brakes!
 No-one should be in the immediate vicinity of the
roller set during the test period!
Confirm measured idling speed
05 = Slip control
Slip is understood to refer to the difference in the sensing roller’s speed to the nominal speed of the braking
roller.
If the slip limit is set to the default value of 25%, the test rig will shut down, if the sensing roller’s speed drops
below the roller set’s speed by 25%.
High braking forces or wet tyres can cause the tyres to “spin” when braking.
A drop in value to (<25%) may cause the system to shut down.
An increase in the value to (>25%) may lead to greater wear on the tyre tread.
06 = Select language
The following languages are integrated into the printer server:
0 = German 8 = Italian
1 = English 9 = Croat
2 = French 10 = Polish
3 = Spanish 11 = Portuguese
4 = Greek 12 = Finnish
5 = Norwegian 13 = Estonian
6 = Czech 14 = Brazilian
7 = Dutch
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07/08 = Compensation of tolerance for pointers

As a result of the mechanical stop device and the stepping motors' gearing, the analogue display is subject
to a tolerance that can be equalised with the aid of configuration stages 7 and 8. This makes it possible to
boost the accuracy of the reading.
The tolerance compensation is carried out as follows:
Press key until the corresponding pointer moves away

from stop.
Confirm entry
These inputs are made by the manufacturer and therefore do not usually need to be altered!
4.5.2 LANGUAGES – TRANSLATIONS
Current overview of the integrated languages

TRUCK Software Software Software
N. Language
4400 (Print out) (Visualisation) (Database)
0 German Ok Ok Ok Ok
1 English Ok Ok Ok Ok
2 French Ok Ok Ok Ok
3 Spanish 50% All further languages are only partly missing or !
4 Greek Ok Ok
5 Norway Ok Ok Ok Ok
6 Czech 50%
7 Dutch Ok
8 Italian Ok Ok Ok Ok
9 Croatian 50%
10 Polish Ok
11 Portuguese Ok Ok Ok
12 Finnish ---
13 Estonia Ok
14 Brazilian Ok Ok Ok Ok
15 Hungarian
16 Russian
17 Slovenian Ok
18 Vietnam -- Ok Ok Ok
19 Bulgarian Ok Ok Ok
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4.7 SENSOR CALIBRATION PEDALFORCE
Operating Instructions MRS-Tool
Starting Pedalforce configurations-tool on the Software

Start the program and select the menu "options" - "password".
In the following dialogue window "select MRS-Tool".
After the test mode is selected, enter the service code the message “code” disappears.
Standard code sequence to enter the

Configuration and calibration mode:
After the code input the MRS Calib/Config Tool for the
configuration of the MRS Basis station and the sensors
started. A successful connection with the test line is
shown by the word "CONF" flashing in the LCD
display.
Individual adjustments to the radio system can now be

made with the MRS433 Calib/Config Tool.
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5.0 SPECIAL OPTIONAL COMPONENTS
5.1 ADDITIONAL DC-POWER-BOARD FOR 2-ANALOG DISPLAYS OR LARGE CABLE LENGTH
Install a 2nd DC-power-supply for the

electronics in the Control cabinet:
1. If the cable length between
control cabinet and analogue
display is > 30 m
2. If two analogue displays are used.
Note: Please measure the DC
voltage in the analogue display and
decide whether retrofitting is
required:
 recommended: >10V
 LED are bright enough
 step-motors are working fast
 IR- commands are recognised
easily
RS232-connection
cable ZR-board
Mount the DC-power-board

above the existing with
distance screws.
230V/N
power board
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5.2 DISTANCE MEASUREMENT
Setup software
To start the Semmler software the path to the Semmler program must be provided in the software.
In the following dialogue the path to the Semmler software is entered.
Mounting mechanical components
The high resolution slip roller for the Semmler-

Tachocontrol measurement (Ø80mm) is mounted as
a special slip detection roller unit.
A low-pressure gas damper allow a spring deflection

of the rocker by approx. 25 kg load.
The cover plate for the chain wheels has a window to

permit the installation of an optical counter.
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Kienzle-mounting-set A special mounting unit has to be installed in the

roller set to fix the Kienzle-frequency sensor. These
sensors measure the speed of the driven brake roller.
The mounting unit is fixed at the slip roller unit with

two hexagon screws.
Provided by Motorscan:
- sheet metal mounting unit for the left or right side
Provided by Kienzle:
- frequency sensor Kienzle NBN2-8GM50-E0
- mounting set
Rollerset heating system Ribbed radiator for the left and right roller set. The
heating systems are installed below the front
brake roller and it’s protected against dust and
stone damage.
2 x ribbed radiator stainless steel (750mm)

230 V /50 Hz, 750 Watt
IP65, connection with PG11 gland threads
Power supply and isolator are to be provided

by the customer.
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5.3 HYDRAULIC LOAD SIMULATOR
The hydraulic load simulator is used to reach a larger

individual axle load during brake testing. This permits
larger brake forces and prevents an early slip switch-
off especially on the rear axle of an artic tractor unit
or semi-trailer with small wheels and twin or triple
axle construction.
A control box with two keys (pull/push) operates a

hydraulic power pack. This supplies two hydraulic
cylinders with belts to pull the axle assembly down.
Maximum pulling force: 10 t
The load simulator can only be used for cross-pit

installation and is mounted with special floor anchors
directly between left and right roller set.
Technical data:
- power supply: 3x400 V, (5x1,5mm2)
- fuse = 16 A slow-blow
- Power: 1,5 kW, rpm 1450 1/s
- Working pressure 120 bar, pump capacity 6 cm2
- Max. force 2 x 50 kN
Ground rails for hydraulic cylinders
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6.0 APPENDIX
6.1 APPENDIX A (COMPRESSED AIR BRAKE ASSEMBLIES)
Compressed air brake assemblies

Bases
Compressed air pumped by the compressor arrives via the pressure regulator valve air dryers at the four-
circuit protection valve.
The four-circuit protection valve has the task, to supply the four independent circuits with compressed air. In
case of failure of one circuit this is switched off automatically, while the others continue to be supplied with
air.
Air reservoir I and II supplies:

- brake valve of the vehicle (foot pedal disk brake valve = PM)
- supply pressure for ALB control device rear axle
air reservoir III supplies:
- parking brake valve
- trailer control valve and supply pressure for trailer
air reservoir IV supplies:
- ASR Differential brake valve
- Other loads
Service brake assembly: (BBA)

With the service brake assembly (foot brake) both the vehicle speed can be reduced and the vehicle brought
to a stop. It has step-less operation and affects all wheels.
The dual circuit foot brake valve has to proportionally increase the
actuating pressure, PM. At full braking: PM = air reservoir pressure
Rest position: 0,0 bar

Start gradates: 0,4 bar
Gradation: 0,3 bar
Finally, the actuating pressure PM is controlled variably by the ALB

control device. The ALB control device is for the regulation of the
brake pressure PX in the brake cylinder.
That is, in the fully loaded condition the pressure PX is increased

equally with the actuating pressure PM by the ALB control device, in
order to work against the larger inertia of the vehicle (thrust) during
the brake applications.
Diaphragm brake cylinders are connected to mechanical brake

actuators (disks -, S-cam -, spreading wedge brakes) to generate the
necessary braking force for the service brake.
Tri-stop brake cylinders are connected to mechanical brake actuators

Air bellows are used for the determination of
(disks -, S-cam -, spreading wedge brakes) to generate the the loaded weight and can be used therefore
necessary braking force for the service and parking brake. as the control variable for ALB devices. Also
the level of the loading point can be adjusted.
Parking Brake: (FBA)

The parking brake (FBA) has to hold the vehicle while stationary, even on an incline and in the absence of
the operator. It must be able to work also in case of total failure of the pneumatic or hydraulic systems.
Therefore mechanical operation on the brakes is required. This can by push pull cables, linkages or by
spring actuators.
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The parking brake valve has the task, to vent connected tri stop
brake cylinders or spring accumulator cylinders gradually, so that the
full braking effect occurs.
Rest position: full air reservoir

Start gradates: 2,2 bar
Gradation: 0,3 bar
Full breaking: 0,0 bar
Secondary brake assembly: (HBA)

The secondary brake assembly must fulfill permit braking, with decreased efficiency, if a failure of the service
brake occurs. It may be a third independent brake assembly with separate operation, separate operation of
two circuits of the service brake, or the parking brake (if it can be gradually applied) can be used.
Two-line brake assembly:

The power supply and control of the trailer brake assembly take place from the towing vehicle.
 Supply line
 Control line (= dependant on increase of pressure with operation of the brake)
Compressed air is supplied through the coupling heads of both lines to the trailer during braking.
ALB describing regulates the braking force in dependence of the loading:
ALB sign of the front axle ALB sign of the rear axle
Indicated the cylinder brake pressures PX of the respective axle in the condition "are loaded" "empty" and.
With some vehicles also various weight gradations are possible.
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6.1.1 OPERATION OF COMPRESSED AIR BRAKES IN THE TRACTOR UNIT
6.1.2 OPERATION OF COMPRESSED AIR BRAKES IN THE DRAWBAR TRAILER
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6.1.3 OPERATION OF COMPRESSED AIR BRAKES IN THE SEMI-TRAILER
6.1.4 COMPUTATIONS
Braking force difference

Measured with maximum brake force:
Fli/re,max = maximum brake force of left or right wheel
Fli/re,min = maximum brake force of left or right wheel
Fdiff, = Brake force difference with Fli/re,max
Deceleration
Fli = brake force left wheel
Fre = brake force left wheel
MAchse = axle weight – static
Z = axle deceleration
Fi,Rad,li = braking force of all left wheels

Fi,rad,re = braking force of all right wheels
MGes = weight of the vehicle
ZGes = total deceleration
Ovality
Fmess,ovality,max = maximum brake force per wheel
with one rotation
Fmess,ovality min = minimum brake force per wheel
with one rotation
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6.1.5 TWO-POINT EXTRAPOLATION
Procedure for the two-point extrapolation of a loaded vehicle for the service brake:
Calculation of the extrapolated braking forces for each axle:
This calculation is made for the left and right brake forces of an axle.
PXmax: measured max. axle brake pressure [bar]

Fmax: measured max. brake force [N]
PX1: first measured axle brake pressure [bar]
F1: first measured brake force [N]
Pcalc.: calculated pressure entered [bar]
Fneu: extrapolated brake force for left
Fneu = Fmax + m *( Pberech - PXmax) or right side of an axle [N]
Addition of extrapolated total brake

forces:
The left and right brake forces of the
stored axles are added.
Fneu (total): Sum of all axle brake forces [N]
Weight (total): Total weight of the vehicle [kg]
Fneu(total)=  Fnew(axles)
Zneu(Gesamt): Total deceleration [%]
Calculation of the total deceleration in %:
The total deceleration can only be calculated if the “loaded total weight” is entered via the remote control.
Diagram of the braking process of a wheel and following extrapolation of the brake force:
Two-point extrapolation
Printout of the values:

The force and brake force values for the two point
extrapolation are printed for each axle in lists.
Axle graphics of service brake with EC spectrum

of complete train.
plus list print out
Print with SCREEN-TEST-LINE 9000:

Menu displays: 6-axles graphics with EWG-
7-axles graphics without EWG-
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Note:
In step 12 of the configuration the print of the axles graphics may be prevented.
Example: MICRO BRAKE 8000
Structure of the lists:

The 1st line always represents the data that are registered when the rolling resistance is measured.
The 2nd line always contains the opening pressure PX1 with the accompanying brake force F1. The opening
pressure PX1 is stored when LH and RH brake forces are higher than the double rolling resistance.
The 2nd line always contains the maximum axle brake pressure PX max with the accompanying brake force
Fmax.
6.1.6 ONE-POINT EXTRAPOLATION (SP TEST)
Procedure for the BSU/SP extrapolation of a loaded vehicle for the service brake:
Calculation of the extrapolated braking forces for each axle:

This calculation is made for the left and right brake forces of an axle.
PXmax: measured max. axle brake pressure [bar]

Fmax: measured max. brake force [N]
Pcalc.: calculated pressure entered [bar]
Fneu: extrapolated brake force for left
or right side of an axle [N]
Fnew = Fmax * m 0,4 bar: minimum pressure to make mechanical brake

cylinders operate.
Addition of extrapolated total brake forces:

The left and right brake forces of the stored axles are added.
Fneu(total)=  Fnew(axles) Fneu(total): Sum of all axle brake forces [N]
Weight(total): Total weight of the vehicle [kg]
Zneu(Gesamt) : Total deceleration [%]
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Calculation of the total deceleration in %:
The total deceleration can only be calculated if the “loaded total weight” is entered via the
remote control.
Diagram of the braking process of a wheel and following extrapolation of the brake force:
BSU extrapolation
Extrapolation – parking brake

An extrapolation of the parking brake will only be carried out if the following sizes are entered:
 Total weight for towing vehicle and/or trailer/semi-trailer loaded
F(total)=  F(axles) F(total): Sum of all axle brake forces [N]

Weight(total): Total weight of the vehicle [kg]
Zneu(total) : Total deceleration [%]
Parking brake slipped

Empty towing vehicles especially trailer/semi-trailers tend to slip early during the test of the
parking brake even when low brake forces are applied. According to the extrapolation of the
admissible total weight the vehicle often does not reach the legal value for decelerations.
In order to make clear this fact to the examiner, the following function is provided:
If during a check of the parking brakes the vehicle has been switched off due to slip and also
the admissible total weight of the towing vehicle and the trailer has been inserted, on the print
the following symbol will appear in the “final valuation of the parking brake”:
„>>„
In case of connection between the software visualisation and the test bench, the sign “>>” may
also appear on the screen.
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6.2 APPENDIX B – ERROR HANDLING
If an error occurs this is showed on the display by flashing all the LED’s. If LCD displays are present (option),
they will show an appropriate error code. The errors codes are sent automatically to the printer.
With missing or defective components, which do not have influence on the safety of operation or options to
represent, a message (z. becomes B. ...50) is shown briefly on the LCD's. The test stand changes however
into the difference to the error messages into the normal initial state.
An error message appears on an indicator
If the error conditions is not serious it may be
possible to continue limited operation.
The error/warnings must be reset by the user:
IR remote control key < stop >.
Button on the control cabinet.
Error states
Error 1 Vehicle on rollers when rig switched on
Error 2 Line break, left slip roller
Error 3 Line break, right slip roller
Error 4 Line break, left position sensing roller
Error 5 Line break, right position sensing roller
Error 6 Line break, left brake force sensor
Error 7 Line break, right brake force sensor
Error 8 Line break, left weight sensor
Error 9 Line break, right weight sensor
Error 10 Zero point too high - left brake force sensor
Error 11 Zero point too high – right brake force sensor
Error 12 Zero point too high - left weight sensor
Error 13 Zero point too high – right weight sensor
Error 14 Amplifier faulty - left position sensing roller
Error 15 Amplifier faulty - right position sensing roller
Error 16 Amplifier faulty - left slip roller
Error 17 Amplifier faulty - right slip roller
Error 31 No communication with battery RAM
Error 32 Check sum error ==> default values Config
Error 33 Communication with relay board faulty
Error 34 Check sum error ==> default values Calib
Error 35 No communication with EEPROM
Error 37 Error, XDATA test
13SM4400*A 78 13SM4400_A
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Message states
Message 36 No communication with keypad
Message 50 No communication with printer server
Message 47 No communication with LCDs
Message 48 No communication with LEDs
6.3 APPENDIX C – SPARE PARTS
Name Part Number

remote control without battery 2601T4400
RS-232-Converter 33C232ROL
Printer console 33CONSPRN
Command box 33BOX4400
A/D display 33DPY4400
Kit for A/D display 33DPY4400 30KFM4400
signal cable extension 33CPS2200
Pedalforce (old)
Transmitter BFB-2411 33PFTRASM
pedal force sensor wireless BFB-106 2700PFMS
Antenna 33PFANT
Cable for antenna 33PFCA
connection cable battery/BFB-2411 33PFCB
connection cable BFB-106/BFB-2411 33PFCC
Flat cable for receiver board 33PFCR
battery USN-1000 2108PFBAT
charging station USL-0010 33PFBRB
power supply charging stat. USN-0040 2303PFAL
Receiver board for box 33PFSR
Pedalforce (new)
Transmitter 33PFTRASM*A
pedal force sensor wireless BFB-108 2700PFMS*A
Antenna 33PFANT
cable for Antenna 33PFCA*A
connection cable BFB-108/ Transmitter 33PFCC*A
Flat cable for receiver board 33PFCR
charging station 33PFBRB*A
power supply charging stat. 2303PFAL*A
Receiver board for box 33PFSR*A
Support board (4 pcs.) 07RSPF
Support for sensor BFB-108 080SRCPF
13SM4400*A 79 13SM4400_A
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Name Part Number

electronic parts
CPU-board with clock, without eprom 33SMZR2200
PS-DS board 33SMPSDS2200
PM-PZ board 33SPMPZ2200
Relay board N.1 33SRY2200
Relay board N.2 33S4WD2200
power supply 12V/30W 33SASW2200
IR-receiver (old) 33SIR2200
IR-receiver (new) 33BOX2200SRIR
Sensor components
Brake force sensor BFS-103 2700CDC4400P
Weight sensor BFS-106 2700CDC4400F
6.4 APPENDIX D – SERVICE EQUIPMENT
Service-LCD’s
This universal indicator module should be used for
service, if the test stand is not fitted with LCD displays
and IR receivers.
 LCD with four digits and LCD with two digits
 installed IR receiver
 Set of cables for attaching in the control cabinet
Note:
Service work can also be accomplished with Laptop and
PC visualisation, if the control cabinet is fitted with a PC
Com pcb.
Universal Calibration tool "exclusive" code 35KCU

- Calibration tool with adapter elements
- User manuals
- Transport suitcase
- Includes dynamometer
13SM4400*A 80 13SM4400_A
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Spare parts for 35KCU Part Number Imaging
n.1 Dynamometer 08KCU001
n.1 Calibration unit 08KCU002
n.2 Calibration unit extension 08KCU003
n.1 Adapter 2200 PROFI 1 08KCU004
n.1 Adapter 2200ROLLER 08KCU005
n.2 Fixing bar 08KCU006
13SM4400*A 81 13SM4400_A
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n.1 Eyebolt – 8 cm 08KCU007
13SM4400*A 82 13SM4400_A
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n.1 3 mails chain 08KCU010
n.1 11 mails chain 08KCU011
n.2 Traction ring 08KCU012
n.1 Collimator 08KCU013
13SM4400*A 83 13SM4400_A
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6.5 APPENDIX E – FOUNDATION PLANS
13SM4400*A 84 13SM4400_A
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13SM4400*A 85 13SM4400_A
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13SM4400*A 86 13SM4400_A
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13SM4400*A 87 13SM4400_A
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13SM4400*A 88 13SM4400_A
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13SM4400*A 89 13SM4400_A
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13SM4400*A 90 13SM4400_A
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MOUNTING PLAN FOR ROLLER SETS
13SM4400*A 91 13SM4400_A
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WALL BRACKET
13SM4400*A 92 13SM4400_A
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6.6 APPENDIX F – ELECTRICAL PLANS
SCHEMATICS FOR CONNECTION (3 X 400V) DAHLANDER
13SM4400*A 93 13SM4400_A
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13SM4400*A 94 13SM4400_A
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SCHEMATIC FOR CONNECTION WITH MOTOR BRAKES (3 X 400V) DAHLANDER
13SM4400*A 95 13SM4400_A
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13SM4400*A 96 13SM4400_A
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13SM4400*A 97 13SM4400_A
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SCHEMATIC FOR CONNECTION WITH 4X4 (3 X 400V) DAHLANDER
13SM4400*A 98 13SM4400_A
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13SM4400*A 99 13SM4400_A
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13SM4400*A 100 13SM4400_A

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SCHEMATICS FOR CONNECTION WITH 4 X 4 AND MOTOR BRAKES (3 X 400V) DAHLANDER
13SM4400*A 101 13SM4400_A

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13SM4400*A 102 13SM4400_A

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13SM4400*A 103 13SM4400_A

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SCHEMATICS FOR 8-POINT WEIGHT SYSTEM (GSA-0025 LEFT ROLLER-SET)
13SM4400*A 104 13SM4400_A

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SCHEMATICS FOR 8-POINT WEIGHT SYSTEM (GSA-0030 RIGHT ROLLER-SET)
13SM4400*A 105 13SM4400_A

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6.7 APPENDIX G – SCHEMATICS FOR THE SENSOR BOX GSA-0030 AND GSA-0025
CONNECTION BOX – 8 POINT WEIGHT SYSTEM
13SM4400*A 106 13SM4400_A

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CONNECTION BOX – 8 POINT WEIGHT SYSTEM
13SM4400*A 107 13SM4400_A

Service 4400 Truck

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Service 4400 Truck

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2.0 GENERAL INFORMATION ...................................................................................................................... 5

3.0 MOUNTING THE 4400TRUCK STEP BY STEP ................................................................................... 10

5.0 SPECIAL OPTIONAL COMPONENTS.................................................................................................. 66

6.0 APPENDIX ............................................................................................................................................. 71

2.0 GENERAL INFORMATION

2.1 DIVIDED ROLLER SET

Universal mounting – in-floor, cross-pit and at required track width.

Divided unit roller length W x L x D (mm)

2.2 CONTROL CABINET

Product picture W x H x D (mm)

Storage temperature -10 to +60 °C

2.3 ANALOG CABINET

2.4 INFRARED REMOTE CONTROL

To control the operation modes, printout and

2.5 ELECTRICAL DATA

2.5.1 MOTOR DATA

2.5.2 MAINS SUPPLY

Voltage 3 x 400 V (AC)

2.5.3 ENVIRONMENTAL CONDITIONS

Admissible air humidity (relative without

Base station Interface RS232

Voltage supply load electronics 24V DC

PEDALFORCE (complete kit)

2.6.1 RADIO DATA

2.6.2 ACCURACY AND DISSOLUTION

2.6.3 AIR PRESSURE MEASUREMENT

Maximum load 23 bar

3.0 MOUNTING THE 4400TRUCK STEP BY STEP

3.1 FIRST STEP: PREPARING ACTIONS

Before starting installation check the following important points first.

Check the building dimensional and level

3.2 OVERVIEW OF INSTALLATION

1 Toe-tester (side slip) 6 Joint Play Tester

3.3 NEXT STEPS: INSTALLATION AND WIRING

Now the following components will be installed and connected.

3.4 MOUNTING THE ROLLER SET WITHOUT WEIGHT SYSTEM

Standard mounting set for roller-bed (without weight system)

The roller set is fixed with 12 pieces of bumper

Exact levelling of the rollers is done with locking

Retrofitting to axle weight system is conditionally

1. Fit support blocks 1 on the IPB 140 girder

3. Remove cover plates and motor cover.

4. Lift roller sets at the brackets for the cover plates,

The hoist should be rated for a carrying capacity

5. Set the roller sets to 740 mm roller distance.

6. Average roller sets in direction of travel. The roller

7. The stops position 8 and the supports position 1

8. To protect the electronic parts, lift roller sets out of

9. The stops position 8 and the supports position 1

3.5 MOUNTING THE ROLLER SET WITH WEIGHT SYSTEM

8-point axle weight system

Mounting set for axle weighting system with bearing elements

1. Fit support blocks 1 on the IPB 140 girder

3. Remove cover plates and motor cover.

The hoist should be rated for a carrying capacity

7. Set the roller sets to 740 mm roller distance.

8. Average roller sets in direction of travel. The roller

9. The Steel cylinders position 3 with a spot welding

10. To protect the electronic parts, lift roller sets out

9. Weld together the Steel cylinders.

3.6 MOUNTING DISPLAY CABINET

Install the wall bracket at the intended position.