Roller Roller Roller Roller: Mod. 2200 Roller Mod. 2200 Roller Mod. 2200 Roller Mod. 2200 Roller

GB
ROLLER
13RO2200GB 06/02/2004
MOD. 2200 ROLLER
STANDARD OPERATION INSTRUCTIONS
®
13RO2200GB Mod. 2200 ROLLER ENGLISH
Dear Customer,
the tool you have chosen is part of the MOTORSCAN® range of products and
encompasses the whole technology our staff has acquired in its years long
experience. It will be a useful working tool to satisfy both you and your
customers.
MOTORSCAN® is glad to include you among its Customers; furthermore,

thanks to our wide range of products we are confident we will satisfy your current
and future needs.
Our authorised resellers and our "CUSTOMER SERVICE " are at your complete
disposal to solve any technical problem.
®
ENGLISH Mod. 2200 ROLLER 13RO2200GB
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®
INDEX
PRELIMINARY INFORMATION
IMPORTANT INFORMATION ABOUT PERSONAL SAFETY...................................................... 2
RULES FOR SAFE TEST BENCH OPERATION ............................................................................ 6
TEST RIG SAFETY FEATURES ..................................................................................................... 7
INSTRUCTIONS FOR SAFE OPERATION..................................................................................... 8
DRIVING OFF THE TEST RIG.................................................................................................. 8
TESTING FOUR-WHEEL-DRIVE VEHICLES .......................................................................... 8
INADMISSIBLE FORMS OF USE ............................................................................................. 8
GENERAL INFORMATION............................................................................................................ 9
INSTALLATION........................................................................................................................ 9
OPERATIONAL INFORMATION.............................................................................................. 9
WHEN YOU DON'T USE THE INSTRUMENT ......................................................................... 9
CLEANING ................................................................................................................................ 9
SYMBOLS ..................................................................................................................................... 10
PRELIMINARY DESCRIPTION
1.1 INTRODUCTION.................................................................................................................... 1.1
1.1.1 PRINCIPLE OF EUSAMA .............................................................................................. 1.2
1.2 TECHNICAL DATA ............................................................................................................... 1.5
1.3 VIEW MOD. 2200 AND OPTIONAL ...................................................................................... 1.6
INSTALLATION
2.1 PRINTER SETUP.................................................................................................................... 2.4
PEDALFORCE
3.1 PEDALFORCE INSTALLATION ........................................................................................... 3.2
INDEX i ®
FUNZIONAMENTO MANUALE
4.1 DISPLAY OF THE REMOTE CONTROL ON THE PC...........................................................4.1
4.2 INFRARED REMOTE CONTROL FUNCTIONS ....................................................................4.2
4.2.1 STORE FUNCTIONS ......................................................................................................4.3
4.2.2 DELETE FUNCTIONS....................................................................................................4.3
4.2.3 PRINTOUT......................................................................................................................4.4
4.2.4 ENTERING GROSS WEIGHT ........................................................................................4.4
4.3 NORMAL OPERATING MODE..............................................................................................4.5
4.3.1 THE LEFT-HAND AND RIGHT-HAND SIDES ARE TESTED SIMULTANEOUSLY ..4.5
4.3.2 REPEAT DISPLAYS .......................................................................................................4.6
4.3.3 BRAKING DECELERATION DISPLAY ........................................................................4.6
4.4 INDIVIDUAL-WHEEL MODE ...............................................................................................4.7
4.5 FOUR-WHEEL DRIVE MODE (4WD)....................................................................................4.8
AUTOMATIC MODE
5.1 DATA STORING.....................................................................................................................5.2
SUPERAUTOMATIC MODE
6.1 SUPERAUTOMATIC MODE SEQUENCE .............................................................................6.2
6.1.1 VEHICLE-CUSTOMER DATA ENTRY .........................................................................6.2
6.1.2 SIDE-SLIP TEST (OPTIONAL) ......................................................................................6.2
6.1.3 SUSPENSION TEST .......................................................................................................6.3
6.1.4 BRAKE TEST .................................................................................................................6.4
6.1.4.1 OVALIZATION MEASUREMENT ........................................................................6.5
6.1.5 DATA STORING IN THE DATABASE ..........................................................................6.6
6.1.6 PRINTOUTS ...................................................................................................................6.7
MAINTENANCE
7.1 MAINTENANCE AND REPAIRS – GENERAL INSTRUCTIONS .........................................7.1
7.1.1 ROUTINE AND EXTRAORDINARY MAINTENANCE ................................................7.1
7.1.2 REPAIRS.........................................................................................................................7.1
7.2 STOCKING AND SCRAPPING OF COMPONENTS ..............................................................7.2
®
ii INDEX
PRELIMINARY INFORMATION
This document is integrating part of the product it refers to and describes its technical features and uses.
Carefully read these instructions before using the tool and store them for future needs.
MOTORSCAN® apologizes for any possible error in the text.
Brand names and mentioned products in the document are registered brands of relevant owners.
In no case MOTORSCAN® will be held responsible to third parties for specific, collateral, accidental,
direct and indirect damages related to or deriving from the product purchase and use.
Requests of copies of this document or technical information have to be submitted to an authorised

reseller or a sales agent of MOTORSCAN®.
This publication cannot be copied or distributed, partially or entirely, under any form or mean, without
previous written authorisation by MOTORSCAN®.
For remarks and information on the product described in this document apply to:
MOTORSCAN® S.p.A.
Str. Martinella, 28/A
43100 PARMA - Italy
Tel. 0521-266211
Fax 0521-266279
http://www.motorscan.com
E-mail: export.dept@motorscan.com
ass.tecnica@motorscan.com
PRELIMINARY INFORMATION 1 ®
IMPORTANT INFORMATION ABOUT PERSONAL SAFETY
GENERAL SAFETY AND BEHAVIOUR PRESCRIPTIONS FOR ACTIVITY IN WORKSHOPS

OR SIMILAR PLACES.
DANGER OF SUFFOCATION
GASOLINE ENGINES
The exhaust gas of gasoline fuelled vehicles contains carbon monoxide, a colourless and odourless gas
that can cause serious physical problems if inhaled.
Take great care if working in inspection pits since certain exhaust gas components are heavier than air
and will therefore settle at the bottom of the pit itself.
Also take care when working with vehicles with gas systems.
DIESEL ENGINES
The composition of gas exhausted by diesel engines is not always the same. It may change according to:
the type of engine, the type of intake, the conditions of use and the fuel composition.
Diesel exhaust consists of the following gases (CO, CO2, NO and HC) and particulate (sulphate soot and
PAHs).
The small particles of carbon that form the soot remain suspended in the air and can therefore be inhaled.
Tiny quantities of toxic components are also present.
SAFETY MEASURES:
- Always ensure good ventilation and aspiration (especially in inspection pits).
- Always operate the exhaust fan system in closed rooms.
DANGER OF CRUSHING
You may be crushed against the work bench if the vehicle has not been correctly locked in place by
mechanical systems.
SAFETY MEASURES:
- Make sure that the vehicle is unable to move by engaging the hand brake and locking the wheels.
®
2 PRELIMINARY INFORMATION
DANGER OF INJURY
Whether engines are at a standstill or operating, there are mobile parts (belts, etc.) that can injure the
hands and arms.
Amongst the various engine components, mechanics should pay particular attention to electrically
operated fans since these may unexpectedly start up even when the engine itself is off.
SAFETY MEASURES:
- Never place the hands near moving parts when the engine is on.
- When working near electrically operated fans, allow the engine to cool first, then remove the fan
plug from its motor.
- Keep the connection wires of the test instruments as far as possible from moving parts of the engine.
- Wear appropriate clothing and take all necessary precautions to prevent accidents.
- Keep hands and hair away from moving parts. Do not wear neckties, loose clothing, bracelets or
wristwatches when working on a vehicle engine, particularly if it is running.
- Handle portable work lamps with care. Lamps must be provided with protective metal screen.
- Wear safety glasses or goggles to protect the eyes from gasoline, dust and metal objects.
DANGER OF BURNS
Some of the components in engines (exhaust gas manifold, etc.) can become very hot, as can certain
sensors.
Remember to never touch these parts.
SAFETY MEASURES:
- Wear protective gloves.
- Allow the engine and any self-contained accessory heaters to cool.
- Never allow the connection wires of test instruments to rest on or near hot parts.
- Never keep the engine running after the tests.
DANGER OF FIRE OR EXPLOSION
When work is being carried out on the fuel system (gasoline pump, injectors and carburettor, etc.) there
may be a risk of fire or explosion owing to the fuels used and/or the vapours that these products form.
SAFETY MEASURES:
- Disconnect the ignition system.
- Allow the engine to cool.
- Do not use open flames or anything liable to produce sparks.
- Do not smoke.
- Collect any spilt fuel.
- Operate exhaust fans in closed rooms.
- Remember that a catalytic converter can reach extremely high temperatures that can cause burns or
lead to fires. Be careful not to spill oil or leave rags, paper or other highly flammable materials in the
vicinity of the catalytic converter.
SOUND LEVEL
When measurements are made on vehicles, sound levels well above 90 dB may be produced, especially
at high engine rates.
These noise levels may damage the hearing if they continue for an extended period of time.
SAFETY MEASURES:
- If necessary, the user is obliged to protect work stations near places in which tests are conducted,
from noise.
- The mechanic must take all the necessary individual protection measures.
®
DANGEROUS VOLTAGE
Voltage is always a danger in civil or industrial electricity mains or the electric systems of vehicles.
When a person touches test instruments or parts of engines to which electricity has been applied, there is
always a risk of electric shock due, for example, to damaged connections (ex. damage to ignition wires
caused by animals).
This is true of both the primary and secondary of the ignition system and for test instrument connections.
SAFETY MEASURES:
- Connect the test instruments to a socket with a protection contact and which is correctly grounded.
- Only use the supplied cables to connect the test instrument. Make sure that the insulation is not
damaged.
- Make sure that the test instrument is grounded before it is switched on.
- Always disconnect the power source (eg. battery) when working on the electrical system (connecting
test instruments, replacing parts of the ignition system).
- Make sure that you do not touch live parts of the vehicle when testing and regulating with the engine
running.
- Only make test connections with suitable systems (test cables, specific adapter cables).
- Never touch anything with wet hands.
- Make sure that all electrical connections are secure and well insulated.
- Never touch anything with wet hands.
- Make sure that all electrical connections are secure and well insulated.
WARNING !
All work on the electrical system, no matter how minor, must be carried out only by qualified
personnel.
DANGER OF INTOXICATION
If subjected to high temperatures ( over 250 °C or owing to fire outbreaks), the tubes and plastic
components used in the unit release highly toxic gas which, if inhaled, may be harmful to the health.
SAFETY MEASURES:
- Immediately contact a physician if such gas is inhaled.
- Use neoprene or PVC gloves to eliminate combustion residuals.
- Fire residuals can be neutralized with a calcium hydroxide solution. This forms calcium fluoride
which can be removed with water.
RULES FOR SAFE TEST BENCH OPERATION
Use the brake and suspension test benches only for the purpose for which they are designed and
constructed. Using the benches for any other purpose constitutes improper use and is thus hazardous.
The manufacturer will accept no liability for damages caused by improper or irrational use of the
equipment.
PINCH POINT
There are a number of different moving parts on the machine. During operation, keep hands
away from potential pinch points.
ABRASION HAZARD
Roller surfaces are covered with a high friction coefficient granular material. To prevent
abrasion injuries, keep hands away from moving rollers.
DO NOT LUBRICATE MOVING PARTS

Do not attempt to lubricate brake test bench drives while in motion.
DO NOT STAND ON VIBRATING PLATFORMS

Do not walk or stand on suspension test bench vibrating platforms during operation: though
vibrations are not hazardous, incorrect measurements could result.
The following additional precautions should be taken:

- Mark off the area used for brake and suspension test benches and for vehicles under test by means of
yellow/black lines on the floor. If necessary, the area should also be segregated with posts and chains
or similar means.
- Operators must be thoroughly trained in safe, correct use of the test benches, given the complexity of
the procedures involved.
- Never allow untrained personnel who have not been authorized by the workshop supervisor to use the
test benches.
- Do not use the equipment for purposes other than those for which it is designed.
- Do not allow visitors, customers or animals to approach the brake and suspension test benches, where
they could be exposed to hazards.
Brake and suspension test bench operators must wear clothing complying with safety regulations (e.g.,
safety shoes, etc.).
®
Operators must bear the need to prevent accidents in mind at all times, even in cases where the
probability of accidents appears to be remote. Consequently:
- Never allow anyone to remain less than 2 meters from the rear of the vehicle: the vehicle could be
pushed backwards and off the rollers during testing.
- Never allow anyone to stand at the sides of the test area, blocking the operators' view of signaling
devices.
- Before starting a test of any kind, make sure that there are no objects or tools in the roller housings or
on the suspension test;
- Make sure that the area surrounding the equipment is clear of flammable or explosive materials and
objects, and that there are no oil spills on the floor that could be hazardous for the operator.
- WHEN THE TEST BENCHES ARE NOT IN USE, THE ROLLER HOUSING MUST BE
COVERED BY THE PROTECTIVE GUARDS AT ALL TIMES.
- Do not make changes of any kind to the equipment or electrical connections, as this could alter
machine operating conditions.
- Tampering or changes to the machine carried out without authorization from the manufacturer will
relieve the latter of all criminal or civil liability.
- Always use genuine spare parts and accessories, as they are the only ones designed for the unit.
Maintenance operations must be performed only by trained, authorized personnel.
TEST RIG SAFETY FEATURES
• If a difference of at least 2 seconds between the left and right sensing roller position occurs (one at
top, one at base), operation cannot continue.
• If braking power does not change for more than 60 seconds, the test rig shuts down the motors. The
automatic mode is likewise deactivated.
• If the vehicle's wheels lock when the motors start up, the test rig cuts out immediately. During testing
of the brakes, the test rig automatically cuts out as soon as one wheel starts to lock. The test rig only
starts up if pressure is applied to both sensing.
INSTRUCTIONS FOR SAFE OPERATION
• Before testing the brakes, check that the cold tyres are inflated to the correct pressure
• Apply the brakes slowly, gradually increasing the pressure
• Position the vehicle as centrally as possible on the rollers, pointing straight ahead
• Drive slowly onto the test rig
DRIVING OFF THE TEST RIG
• Depress the clutch and engage 1st gear

• Wait for the output message
• Release the clutch and drive swiftly off the test rig
• If the vehicle needs to be reversed off the test rig, engage reverse gear now and drive the vehicle off
the test rig with a certain amount of momentum, to overcome the mechanical resistance of the rollers
TESTING FOUR-WHEEL-DRIVE VEHICLES
On vehicles with manual four-wheel drive, it must be disengaged before testing work commences.
On vehicles with permanent four-wheel drive, the test specifications for that particular model must be
observed (see also testing program for four-wheel-drive vehicles).
INADMISSIBLE FORMS OF USE
• Driving in at an angle, with a tyre scraping against the test rig's frame
• Driving onto or across the roller mechanism too quickly
• Actuating the brakes before the lock telltales go out
• Depressing the brakes too abruptly
• Abrupt steering movements when testing the front axle
• Exceeding the permitted testing load limit (includes driving across the test rig)
• Driving off the test rig without switching on the electric motors (the bearings will otherwise be
damaged)
®
GENERAL INFORMATION
INSTALLATION
Protect 2200ROLLER from the rain or from excessive moisture to prevent irreparable damage to the
parts.
OPERATIONAL INFORMATION
Do not place items on the equipment that could fall into drives or other mechanical systems.
WHEN YOU DON'T USE THE INSTRUMENT
Disconnect 2200ROLLER from the power source when it is not be to used for a long period of time.
CLEANING
When necessary, the surfaces of 2200ROLLER should be cleaned never use cleaning products containing
spirits, ammonia or gasoline.
ATTENTION ! Always disconnect 2200ROLLER from the power source before proceeding with the
cleaning operations.
SYMBOLS
This paragraph describes the symbols used in the instrument.
ALTERNATE CURRENT
PROTECTING GROUND
CONSULT THE INSTRUCTION MANUAL
ATTENTION ! RISK OF ELECTROCUTION
CE CONFORMITY MARK
®
PRELIMINARY DESCRIPTION
1.1 INTRODUCTION
The MOTORSCAN ROLLER BENCH MOD. 2200ROLLER tests the brake force of the foot brake
and the emergency/parking brake of every wheel separately. The values are displayed per axle while at
the same time it displays the percentile difference between the right and left wheel.
The brake forces are electronically amplified and recalculated by a microprocessor. The digital and
graphically displayed brake forces are displayed on the display up to 10 newtons accurate. The
MOTORSCAN roller bench has two independently turning roller pairs. By this an independent
measurement of the right and left wheel is possible. The wheels are driven by the testing bench. A torque
force will arise while braking which is turned into a digital value by the transducer and the
microprocessors.
The MOTORSCAN SIDE-SLIP TESTER MOD. 2215 gives exactly the total side-slip or tracking per
axle, while the diagonal forces of the tires have no influence on the test.
The sideslip/tracking meter can be moved sideways and rolls over balls. The measuring is done through a
direct connection of a transducer to a movable top plate and a fastened under plate. The resting position
of the top plate is always displayed by the computer with a "0" on the display.
With the MOTORSCAN SUSPENSION TESTER MOD. 2210 we introduce the possibility to test the
suspension of the cars objectively and quicker than that was possible until now. The suspension tester is
designed to compare dynamic wheel-road contact to the static wheel-road contact under the most
unbearable circumstances.
The wheel-road contact depends on a lot of factors, but the most important factor is the working state of
the shocks. The shocks play an important role for the safety of the passengers.
The suspension is put into a vibration of 25 Hz. At the moment that this frequency is reached, the engines
will stop and the frequency will slowly go back to 0 Hz. The fly-wheel in the suspension tester makes
sure that the rpm's slowly go down. The suspension is brought to it's vibrating frequency during this
cycle. The wheel wants to loose contact with the road under these circumstances. The suspension tester
measures the minimum wheel pressure and compare this to the static wheel pressure. The results are
displayed in percentages.
The used testing method to test the suspension, has been researched and established by the EUSAMA
(European Shock absorber Manufacturers) with cooperation of the university of Gent (Belgium). This
principle makes the test procedure universal and independent of the car brand and type.
PRELIMINARY DESCRIPTION 1.1 ®

1.1.1 PRINCIPLE OF EUSAMA
The suspension tester adopts the PRINCIPLE OF EUSAMA: during the measuring operation, the
computer calculates the minimum weight on the axle in relation to the static axle weight. The results are
displayed in percentages. This measuring system is universal and does not depend upon the type of car,
nor on the model. The percentage represents the qualitative degree of the wheel-road contact. The
suspensions play a key role in this type of wheel-road interaction. The better the suspensions, the greater
the grip to the road. The suspension is made up of a spring, a shock absorber, the arms and the wheel.
M1 = car bodywork
C1 = spring
C2 = shock absorber
M2 = axle, wheel etc.
Assessment graph:
The previous figure shows a suspension testing graph. During the initial phase, the engine causes the
suspension to reach a frequency of 25 Hz. Then the engine stops and the measurement starts. In this
phase the suspension frequency is back to normal. At this point, the minimum pressure exerted by the
tyre onto the ground is measured. After that, the suspension frequency decreases to 0 Hz.
The grip is the relation between the minimum level measured and the static axle weight.
An example of this is as follows:
 190 
Aderenza :   * 100% = 47%
 400 
® 1.2 PRELIMINARY DESCRIPTION

After this measurement only 47% of the static axle weight seems to be resting on the testing bench.
Here you can see an example of an assessment graph, through which one can control the degree of
efficiency of the suspension (very good, good, moderate, bad).
WARNING:
PLEASE MAKE SURE THAT THE TYRE PRESSURE IS CORRECT.
DIFFERENT TYRE BRANDS ON THE SAME AXLE CAN LEAD TO DIFFERENT
RESULTS.

With light vehicles the frequency range can be smaller (A), in

comparison with heavier vehicles which usually have softer
suspensions and bigger frequency range (B). The right-hand side and
the left-hand side of the graph must show the same trend.
Some sport cars have a rigid stabilization bar: in this case the graph
can be like the one in this figure. The graph must in any case be
symmetrical.
In this graph the left wheel suspension has reached its resonance
frequency earlier, compared to the right wheel. This means that if the
difference in grip between the right and the left wheel is too great, the
driving will be unstable.
The right-hand side and the left-hand side have two different graphs.
Left-hand side: damaged shock absorber. See figure at the bottom.
The degree of left-wheel oscillation is too wide.
When a secondary frequency is detected at the point of minimum

weight, this usually means that the spring is broken.
On the left-hand side you can see an additional resonance. This

graph’s trend (wheel test) might indicate that the bearing is worn out,
the stabilization bar is broken, a spring is damaged, a steering bearing
is broken or a rubber pad of the shock absorber is worn out.
When at the beginning of intermediate frequencies the graph is as this

one, this usually stems from a problem with a steering bearing.
The difference might be caused by the breaking of the stabilization

bar.

1.2 TECHNICAL DATA
ROLLER BRAKE TESTER
Weight, roller set 500 kg

Max. drive-over load max 4.0 t
Max. testing load max 2.5 t
Testing speed 5 km/h
Measuring range, braking power 0 ÷ 6 kN (for side)
Roller diameter 205 mm
Motor power 3.7 kW for motor (triphase)
Track min/max 800/2200 mm
Length of rollers 700 mm
Operating voltage 3x230/240 V 50 Hz
Fuses 3x25 A
Friction valve of roller 0,7 dry and wet
Measuring system DMS-technology
Noise emissions LWA < 70 dB (A) as under DIN 45635 Section 1
Gear ratios 20.78
SUSPENSION TESTER
Weight, suspension tester 500 kg

Measuring range, weigher max 4.0 t (for axle)
Max. testing load max 2.5 t
Motor 2,5 kW for motor (triphase)
Operating voltage 3x230/240 V 50 Hz
Frequency of voltage 0.25 Hz
Measurement 0 ÷ 100%
Measurement system EUSAMA
Weighing cells 4
Track min/max 800/2200 mm
Capacity for axle 200 ÷ 1800 kg
Measuring system DMS-technology
Noise emissions LWA < 70 dB (A) as under DIN 45635 Section 1
SIDE SLIP
Weight, side slip 38 kg

Measurement range ± 12 mm/m
Max test 2500 kg

1.3 VIEW MOD. 2200 AND OPTIONAL
2 3
1. ROLLER BENCH (MOD. 2200)

2. SUSPENSION TESTER WITH WEIGHING SYSTEM (MOD. 2210)
3. SIDE-SLIP TESTER (MOD. 2215)
4 5
4. PEDALFORCE
5. REMOTE CONTROL

6. AUTOMATIC WEIGHING SYSTEM (MOD. 2207)
7. PC + PRINTER + MONITOR + TROLLEY

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INSTALLATION
To start the installation of the software, insert the specific CD, click on the NEXT button and leave the
default settings unchanged.
Once the installation is completed, restart the PC. Now the following icon will appear on the DESKTOP.
Click twice on the icon to start the 2200 program.
The following image will appear on your PC screen.
Now the bench can be turned on by means of the main switch on the right-hand side of the control panel .
DURING START-UP THE TESTING BENCH MUST NOT BE LOADED: NO

VEHICLE OR OBJECT SHOULD BE PLACED ON THE TESTING LINE.
INSTALLATION 2.1 ®
The following screen page will appear on the monitor:
The calibration options that can be selected from this screen page are normally selected by the technical
personnel (password needed).
The operator must select NO or wait for the program to scan all the screen pages and automatically select
the NORMAL MODE on the screen page of the first test available.
Please bear in mind that the screen page of the first test available changes according to the device
configuration, as indicated in the following figures.
Device equipped with:

- SIDE SLIP
- SUSPENSION TESTER WITH WEIGHING SYSTEM
- ROLLER BRAKE TESTER
® 2.2 INSTALLATION

- SUSPENSION TESTER WITH WEIGHING SYSTEM

INSTALLATION 2.3 ®
2.1 PRINTER SETUP
During the official MCTCNet test, the testing results do not have to be printed. If you want to print them
please setup the printer beforehand by clicking on the menu: OPTIONS/PRINTER.
Once the printer is setup, results of every test will be printed automatically.
® 2.4 INSTALLATION
PEDALFORCE
The pedalforce (device which measures the brake pedal effort via radio) is an accessory which measures
the force exerted on the brake pedal and transmits it by radio to the braking system testing bench.
This accessory is crucial for measuring the imbalance in the braking power during 4-wheel drive testing
(see specific chapter).
Through this test, every single wheel is tested and the results stored according to the pedal effort (that is
the effort exerted on the brake pedal, which is measured by the pedalforce).
Once the testing on both axle wheels is over, the tool software will compare the two braking actions and,
the pedal efforts being equal, it will calculate the imbalance between the two braking powers.
This tool has 4 led indicating the mode of the PEDALFORCE:

1. RED: the battery is flat;
2. ORANGE: the tool is being charged
3. GREEN: the battery is charged;
4. BLINKING GREEN: working FIXED GREEN: transmitting
PEDALFORCE 3.1 ®
3.1 PEDALFORCE INSTALLATION
CARD + ANTENNA
In the following figure you can see how the pedalforce card is connected to the DS card within the
control panel.
ANTENNA
The flat cable of the PEDALFORCE card must be connected to the X5 connector in the DS card. The
antenna must then be connected to the point as shown in the figure.
® 3.2 PEDALFORCE
MANUAL MODE
4.1 DISPLAY OF THE REMOTE CONTROL ON THE PC
To display the remote control on the PC just enter the MENU and select REMOTE. The following image
will be displayed:
The operator is now able to use the TESTING BENCH the way he prefers:
- In the Remote mode, by using the remote control;
- From the PC, clicking – through the mouse - on the remote control button to be selected;
- From the keyboard, selecting the button
The remote control on the PC will be a good alternative to the real remote control when the latter can not
be used for whatever reason.
MANUAL MODE 4.1 ®

4.2 INFRARED REMOTE CONTROL FUNCTIONS
Individual wheel test, left
Individual wheel test, right
Vehicle standing on rollers:
NORMAL MODE
Left- and right-hand motors start up.
Vehicle not positioned on rollers
AUTOMATIC MODE
See specific chapter.
Button to activate the functions indicated by the buttons on the

lower side of the remote control.
Four-wheel-drive test, left-hand side
Four-wheel-drive test, right-hand side
Imbalance measurement
STOP
® 4.2 MANUAL MODE

4.2.1 STORE FUNCTIONS
After the test, results can be stored by pushing the following buttons.
Stop the test
Store front axle
Stop the test
Store rear axle
4.2.2 DELETE FUNCTIONS
Delete last measurement
Delete complete memory
Stored values can always be overwritten by entering a new value for the same memory allocation, or
storing again for the same brake system and same axle.
The entire memory is also deleted if one or more printouts are made and a new measurement is stored.
MANUAL MODE 4.3 ®

4.2.3 PRINTOUT
The desired printout language can be selected in the configuration routine.
Standard printout
Standard printout with final evaluation
Graphic printout.
Graphic printout. With final evaluation
4.2.4 ENTERING GROSS WEIGHT
Enter gross weight
If a weight has already been entered, or a weigher is fitted, the entry mode, when called up, will display
the actual value.
Notes:
The weights can be entered before or after the individual tests.
An entry can also be made after a printout provided no new measurement has yet been stored.
If a weigher is fitted, but a different value is to be used for calculating braking powers, these can be
entered as described above (weigher values are overwritten).
® 4.4 MANUAL MODE

4.3 NORMAL OPERATING MODE
4.3.1 THE LEFT-HAND AND RIGHT-HAND SIDES ARE TESTED SIMULTANEOUSLY
The standard testing procedure is as follows:
Test the front axle:
Drive the front axle onto the test rig
Switch on the motors (both wheel slip telltales flash)
Gradually increase braking pressure until the wheel slip telltales go out
Measure any imbalance if necessary
Apply maximum braking power.

Test rig is shut down for the following criteria:
- wheel slip control pressure removed from sensing rollers.
- "STOP" button.
- With PEDALFORCE, maximum effort is reached;
- Once the maximum braking power is reached without locking the rollers you
release the brake pedal (lock after 3 seconds).
Store with the remote control for front axle.
Test the rear axle:
Drive the rear axle onto the test rig

Test the rear axle as for the front axle
Test the parking brake:
Test the parking brake as for the front axle (without imbalance)
Print out required result using the remote control
MANUAL MODE 4.5 ®

4.3.2 REPEAT DISPLAYS
Gross weight
Max. values, service brake, front axle
Max. values, service brake, rear axle
Max. values, parking brake
Imbalance:
If several imbalance measurements are made, measurement 1 is
displayed first; if the command is repeated, measurement 2
appears, etc.; unlike the max. value display, only the imbalance
values for the axle last tested are shown
4.3.3 BRAKING DECELERATION DISPLAY
Overall service brake deceleration
Overall parking brake deceleration
Overall emergency brake deceleration

(only for special Italian version)
+
® 4.6 MANUAL MODE

4.4 INDIVIDUAL-WHEEL MODE
The individual-wheel mode is identical to the regular mode with the exception that the wheels on each
side can be tested individually.
Note that the results should be stored after every testing procedure.
Example of tests on the left-hand rear axle. To carry out the test, perform the following operations:
Switch on the engines (the testing bench senses the vehicle and starts the test).
As soon as the screen page with the values appears, gradually increase the
braking power
Measure the ovalization (if necessary).
Brake to the maximum braking power. The testing bench automatically stops in
the following cases:
- Slip Control pressure removed from sensing rollers;
- STOP button.
- With PEDALFORCE, maximum effort is reached;
- Once the maximum braking power has been reached without locking the
rollers, release the brake pedal (lock after 3 sec.).
Stop the rollers
Store the rear left-hand side axle with the remote control.
Example of test on the right-hand side rear axle.

To carry out the test just follow the instructions.
Switch on the engines (the testing bench senses the vehicle and starts the test).
Carry out the test as on the left-hand side.
The individual-wheel mode is particularly suited if the vehicle tends to lift during braking.
MANUAL MODE 4.7 ®

4.5 FOUR-WHEEL DRIVE MODE (4WD)
The 2200ROLLER has a four-wheel drive option program. The left-hand side and the right-hand side
rollers sets go in opposite directions, and only the braking powers on the forward rolling side is
measured. This program is particularly suited for permanent four-wheel drive vehicles: misleading
measuring values, caused by overlapping forces, are kept to a minimum and the self-blocking differential
is protected form overload. Data storing is performed in the same way as in the individual-wheel mode.
Always follow the instructions included in the operation and maintenance manual of the vehicle!
The procedure must be performed and stored for every single test carried out in the manual mode, with a
10% threshold on the calculated speed in relation to the highest level between the left-hand and the right-
hand side detected speed. The test is carried out on the same axle through two separate tests, using the
pedal effort as reference.
The wheel which rolls in the driving direction is used as reference to calculate the imbalance in relation
to the pedal effort exerted. The calculation formula is the following:
( Vdx- Vsx) / V max ≤ 10%
When this threshold is exceeded an alarm message will be displayed and the rollers will stop.
Alarm description:
If the speed difference between the two rollers is more than 10% the following procedures will be
performed:
- An alarm message will be displayed;
- Engines stop automatically;
- The test is completed.
You can disable the messages by pushing ENTER or STOP.
® 4.8 MANUAL MODE

AUTOMATIC MODE
DURING START-UP THE TESTING BENCH MUST NOT BE LOADED; NO

VEHICLE OR OBJECT SHOULD BE ON THE TESTING LINE.
The automatic mode is particularly suited for fast vehicles: you can drive onto the testing bench without
using the remote control and the testing bench will automatically start once it senses the vehicle. The test
is automatically repeated as long as the bench senses the vehicle.
To select the automatic mode, click this button on the remote control:
If a screen page with the symbol indicated by the arrow appears on the PC you have selected the
AUTOMATIC MODE.
AUTOMATIC MODE 5.1 ®

When the program is in the AUTOMATIC MODE, please follow the following instructions.
SIDE-SLIP
Drive the left-hand side wheels on the side-slip plates to check the vehicle’s convergence.
SUSPENSIONS
Drive both tyres of the axle to be tested on the suspension testing bench plates to check the weight and
the degree of wearing of the shock absorbers. The test will continue until the vehicle has been removed.
BRAKES
Drive both tyres of the axle to be tested onto the rollers to test the braking power (the test is repeated
until the vehicle has been removed).
5.1 DATA STORING
If the test rig is set to the automatic mode and measurements need to be stored, the STOP button should
be pressed before starting up the motors again.
The program exits from the AUTOMATIC MODE and only afterwards can the data be stored.
To store the data, press one of the following buttons on the remote control:
(for the front axle) (for the rear axle) (for the parking brake)
WARNING !
WHEN TESTING BENCH SAFETY DEVICES ARE ACTIVATED, THE
AUTOMATIC MODE IS AUTOMATICALLY DISABLED.
® 5.2 AUTOMATIC MODE

SUPERAUTOMATIC MODE
When the program is in the SUPERAUTOMATIC MODE, the user receives instructions for a complete
vehicle testing: SIDE-SLIP – SUSPENSIONS – BRAKES as you can see in the figures on the upper
right-hand side of the following image.
Each equipment (side-slip, suspensions, brakes) is used for a complete measurement. All the values will
be stored in the module and used for a final assessment and for printing.
WARNING!
DURING START-UP THE TESTING BENCH MUST NOT BE LOADED; NO
VEHICLE OR OBJECT MUST BE ON THE TESTING LINE.
To select the SUPERAUTOMATIC MODE, press the following buttons on the remote control:
when the following screen page appears on the PC screen, it means that the SUPERAUTOMATIC
MODE has been successfully selected .
SUPERAUTOMATIC MODE 6.1 ®

6.1 SUPERAUTOMATIC MODE SEQUENCE
6.1.1 VEHICLE-CUSTOMER DATA ENTRY
After selecting the superautomatic mode, the following window will appear:
6.1.2 SIDE-SLIP TEST (OPTIONAL)
The side-slip test is carried out and automatically stored during the vehicle’s driving onto the plate.
Make sure the vehicle is straight and the steering wheel can move freely when driving onto the plate.
EXPLANATIONS ON THE PLATE MEASURING SYSTEM FOR THE CONVERGENCE TEST:

The convergence test plate does not provide the electronic measurement of the axles. It is used to verify
whether such measurement should be carried out or not.
When the vehicle drives across the plate to test the convergence, the DEVIATION from the 0 value must
be ± 5 mm/m.
The values can slightly differ because of the vehicle’s specific tolerance ranges and because of differing
tyre diameters.
® 6.2 SUPERAUTOMATIC MODE

6.1.3 SUSPENSION TEST
The operator must drive the vehicle onto the suspension plates, starting with the front-wheel axle.
The software displays the single weight of each wheel and stores it automatically; suspensions are then
tested as indicated in the following figure.

6.1.4 BRAKE TEST
When the axle weight has been stored and the suspension test has been carried out, drive the vehicle’s
front-wheel axle onto the rollers.
As in the previous test, if INFO messages are available, the operator is guided by the program.
Otherwise, follow these instructions:
- Do not touch the brake pedal until the following image (with braking power values) appears;
- As soon as the image appears, start braking until the wheels are locked.
WARNING !
THE BENCH STOPS AUTOMATICALLY IN THE FOLLOWING CASES:
- THE PEDALFORCE HAS REACHED THE MAXIMUM EFFORT;
- 3 SECONDS AFTER THE BRAKE PEDAL HAS BEEN RELEASED (IF
MAXIMUM BRAKING POWER HAS BEEN REACHED WITHOUT LOCKING
THE WHEELS);
- THE SLIP THRESHOLD HAS BEEN REACHED.

6.1.4.1 OVALIZATION MEASUREMENT
In order to measure ovalization during the braking test, comply with the following procedure:
- As soon as the image with the braking power values appears, start braking until 500N are exceeded
and then release;
- Press the brake pedal again until 500N are exceeded (the following image will appear);
- Exert a constant pressure on the brake pedal for 5 seconds;
- Now you can brake until the wheels are completely locked.
After the test , the following message will be displayed:

- If the measurement needs to be repeated, immediately press the braking pedal for a second;
- If you want to end the procedure, wait for the following screen page “Î”.
THE SUSPENSION AND THE BRAKE TESTS MUST BE CARRIED OUT BOTH
ON THE FRONT-WHEEL AND THE REAR-WHEEL AXLE.
THE BRAKE TEST MUST BE CARRIED OUT ON THE HAND-BRAKE AS WELL.

6.1.5 DATA STORING IN THE DATABASE
The operator can store the data obtained through the test in the DATABASE, just select the menu and
click on SAVE.
All the stored data can be retrieved in a later phase.
In the DATABASE menu, click on LOAD and then select (RESULTS/REFERENCE GRAPH/...). the
search is carried out using the parameters in this screen page by the operator. Double-click on OK.

6.1.6 PRINTOUTS
When the test is completed, you can get printouts about the test, as you can see in the following figures:
TOTAL PRINTOUT

DETAILED PRINTOUT

SUSPENSION GRAPH PRINTOUT

BRAKE GRAPH PRINTOUT

MAINTENANCE
7.1 MAINTENANCE AND REPAIRS – GENERAL INSTRUCTIONS
- Maintenance operations must always be carried out by skilled and authorized personnel only.
- Never clean, lubricate or carry out operations while the machine is working.
- Do not wear rings, jewels or any other object (e.g.: ties, worn clothes or shoes) which might get
caught in the vehicle’s moving parts.
- always wear protective clothes (e.g.: anti-slip accident prevention shoes, noise-proof headset, safety
glasses and gloves etc...).
- before starting any maintenance operation, set the main switch to the OFF position; this is aimed at
preventing electrocution and other possible dangers resulting from mishandling.
- Do not use fuel or inflammable solvents to clean the machine.
- After maintenance, carefully reassemble all the safety guards that have been removed.
Never turn on the machine unless all safety guards are in place.
7.1.1 ROUTINE AND EXTRAORDINARY MAINTENANCE
Remove dust, water or dirt when they can jeopardize the proper functioning of the equipment.
The brake and suspension testing benches do not require particular ordinary maintenance. Any operation
must in any case be carried out during the planned verification performed by the specialized technician.
7.1.2 REPAIRS
If you have to remove parts of the machine, please contact the After-Sales Technical Service Department.
WARNING !
The guarantee is valid only for original or approved spare parts.
Before any repair by the skilled technician, always power off the tool through the main switch!
MAINTENANCE 7.1 ®
7.2 STOCKING AND SCRAPPING OF COMPONENTS
Some of the materials used to construct the machine can be recycled and reused. Different materials
should be collected separately.
Specialized companies can recycle these materials and reuse them; the waste is thus reduced to the
minimum, in compliance with the regulation in force.
The documents certifying the recycling must be kept by the user, as provided for by the relevant
regulation.
PLASTIC IRON OIL AND GREASE
WARNING !
- WHEN PERFORMING OIL-CHANGE, WEAR OIL-PROOF GLOVES AND THEN WASH
YOUR HANDS WITH SOAP AND WATER.
- IN CASE OF OIL LEAKS, WIPE IMMEDIATELY AND REPAIR THE DAMAGE.
LUBRICANT ON THE FLOOR INCREASES THE RISK OF ACCIDENT FOR THE
OPERATORS.
WARNING !
Dispose of Depleted Oils in special tanks; do not dump in places where they might pollute the
ground water.
® 7.2 MAINTENANCE

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MOD. 2200 ROLLER

STANDARD OPERATION INSTRUCTIONS

MOTORSCAN® is glad to include you among its Customers; furthermore,

MOTORSCAN® apologizes for any possible error in the text.

Requests of copies of this document or technical information have to be submitted to an authorised

IMPORTANT INFORMATION ABOUT PERSONAL SAFETY

GENERAL SAFETY AND BEHAVIOUR PRESCRIPTIONS FOR ACTIVITY IN WORKSHOPS

DANGER OF FIRE OR EXPLOSION

RULES FOR SAFE TEST BENCH OPERATION

DO NOT LUBRICATE MOVING PARTS

DO NOT STAND ON VIBRATING PLATFORMS

The following additional precautions should be taken:

Maintenance operations must be performed only by trained, authorized personnel.

TEST RIG SAFETY FEATURES

INSTRUCTIONS FOR SAFE OPERATION

DRIVING OFF THE TEST RIG

• Depress the clutch and engage 1st gear

TESTING FOUR-WHEEL-DRIVE VEHICLES

INADMISSIBLE FORMS OF USE

WHEN YOU DON'T USE THE INSTRUMENT

This paragraph describes the symbols used in the instrument.

CONSULT THE INSTRUCTION MANUAL

ATTENTION ! RISK OF ELECTROCUTION

PRELIMINARY DESCRIPTION 1.1 ®

1.1.1 PRINCIPLE OF EUSAMA

An example of this is as follows:

® 1.2 PRELIMINARY DESCRIPTION

PRELIMINARY DESCRIPTION 1.3 ®

With light vehicles the frequency range can be smaller (A), in

When a secondary frequency is detected at the point of minimum

On the left-hand side you can see an additional resonance. This

When at the beginning of intermediate frequencies the graph is as this

The difference might be caused by the breaking of the stabilization

® 1.4 PRELIMINARY DESCRIPTION

1.2 TECHNICAL DATA

ROLLER BRAKE TESTER

Weight, roller set 500 kg

Weight, suspension tester 500 kg

Weight, side slip 38 kg

PRELIMINARY DESCRIPTION 1.5 ®

1.3 VIEW MOD. 2200 AND OPTIONAL

1. ROLLER BENCH (MOD. 2200)

® 1.6 PRELIMINARY DESCRIPTION

6. AUTOMATIC WEIGHING SYSTEM (MOD. 2207)

7. PC + PRINTER + MONITOR + TROLLEY

PRELIMINARY DESCRIPTION 1.7 ®

® 1.8 PRELIMINARY DESCRIPTION

The following image will appear on your PC screen.

DURING START-UP THE TESTING BENCH MUST NOT BE LOADED: NO

The following screen page will appear on the monitor:

Device equipped with:

Device equipped with:

Device equipped with:

2.1 PRINTER SETUP

This tool has 4 led indicating the mode of the PEDALFORCE:

3.1 PEDALFORCE INSTALLATION

4.1 DISPLAY OF THE REMOTE CONTROL ON THE PC

MANUAL MODE 4.1 ®

4.2 INFRARED REMOTE CONTROL FUNCTIONS

Individual wheel test, left

Individual wheel test, right

Vehicle standing on rollers: