CAR BRAKE TESTER

INSTALLATION
A short guide to perform test and parameters check before calibrating
and using the car brake tester
This guide is made to help you
to install the bench showed in the
figure, just this with no other
option as suspension tester,
Gas analyzer ……..

You have already fit the brake tester inside the pit.

The drive direction is respected.

 DRIVE DIRECTION

Position of brake tester is respected when, watching the drive direction of the car, the speed
roller is moving down following the drive direction.
 The brake tester is supplied with 4 signal cables already connected to the sensors fitted
inside the bench. You have already connected this 4 cables to the CPU fitted in the
console (control unit).

Inside the brake tester there are 2 electric motors that must be connected to the electric
control panel with 2 power cables not supplied by us.

In the service manual you found all references to connect power and signal cables.

Also the control unit is already connected to the main power supply line.

AT THIS POINT TURN ON THE MAIN POWER SWITCH. THE COMPUTER STARTS.

THE BRAKE TESTER PROGRAM ALSO WILL START AUTOMATICALLY.

 This is the LOGO page, the screen that you see when the program starts.

Here you can see which kind of program is running:

Auto for Car; Moto for Bike; Trk for Truck; Univ for car and bike testing

This is the firmware release of the brake tester CPU connected to the Computer

This is the Brake tester program version

 The LOGO page is a movie that play itself until you press a buton

The 5 button below have effect if you press the follow FUNCTION KEYS on the keyboard:

RED BUTTON = F1 BLUE BUTTON = F2 GREY BUTTON = F5 YELLOW BUTTON = F3 GREEN BUTTON = F4

Now we go to press GREY BUTTON = F5 in order to enter in our technical setting.

Press F3 (yellow button) to move the cursor on Technical assistance
Press F3 (yellow button) to move the cursor on Tests
and press F4 or ENTER
Press the F3 function key to select Analog devices
and press F4 or Enter
In this page we check that the 4 signal cables coming
from the brake tester and connect to the brake tester
CPU are well connected and working.
 Now we test the «CAR-ON» signal: by pressing
the speed roller of the left side of the brake tester
(following the drive direction) the wheel on the
page switch from GREEN to RED.
Microswitch, cables and connections are well
connected and working !!
(click on the video to play it)
 Now we test the «TACHO - SPEED» signal: by
rotating the speed roller of the left side of the
brake tester (following the drive direction) the
Idle Roller SX on the page will show number
instead of STOP. Pick-up sensor, cables and
connections are well connected and working !!
(click on the video to play it)
 Now we check the CH0 (left brake
force signal). Put your foot on the first
big brake tester roller following the
drive direction and try to turn it inside
the bench. CH0 have to increase the
number. This means that the signal is
working and the connections are well
done respecting the polarity of the
signal.
Perform the same test on the right side of the Brake tester to check the right CAR-ON signal(right wheel
switch from GREEN to RED); right Speed roller signal «TACHO» (Idle Roller Dx shows number instead of
STOP when rotating) and right brake force (load cell signal CH1 have to increase number when roller is
pushed).
 The Test of the connection is finished.
Press the F1 function key to exit this page.
 Other option in this page allow to test the
Remote Control button and the Electrical
motor of the Rollers, useful to check that the 3
phases power cables are well connected
and the motors are turning in the right way.

Before doing it, it is very important to check

the program parameters to be sure that they
are set and working properly.

Press the F1 function key to exit this page.

Press the F2 function key to move the cursor
on the «Parameter change» selection and
press F4 to enter.
 This page will allow you to modify the setting of the brake tester program and
the setting of the brake tester CPU.
It is also possible to modify some more parameters refer to external devices
connected to the brake tester lane like Gas Analyzers; Light Beam Tester etc. but
you cannot enter in this option because the smart card doesn’t allow you.
You have ordered just a brake tester lane.

PLEASE NOTE THAT IN THIS «PARAMETERS» AREA YOU HAVE TO USE THE FUNCTION
KEYS F1; F2; F3; F4 TO MOVE IN AND SELECT ITEM. DO NOT USE OTHER KEYS!!

Press the F3 function key to select GENERAL SETTINGS and press F4

 This is the General settings parameters list.

Check that CAR Board, parameter no. 802, is set on

COM1 serial port and that the COM1 port is present in
the computer.

Remember that this is a guide made for a brake tester

only for CAR, so the parameters 803, 804, 805 must be
set on ABSENT.
 Press F1 function key, the program goes out from General Settings list
and the voice General settings in the Main Menu will be highlight.
Move the cursor by pressing F2 on System and press F4 to go inside the System
parameters list.
 As you can see, by pressing F4 the menu explodes in different options:
«Board Parameters» are referred to Brake tester CPU settings.
«Program configuration» are referred to brake tester software program
configuration.
«Devices configuration» are referred to external devices like gas analyzer;
noise measurement; light beam tester etc. normally used in Italian test lane
that is possible to connect also in other country if this option is set buying the
relative option.
«Environmental conditions» is to set the equipment that informs the program
about air temperature, air pressure, wind force and air humidity – for the
moment used only in Italy.
«Visual time parameter» : How much time (in seconds) one page stays
visualized before changing automatically to the next page.

«GAS-OPAX-PHONOM.» : set the limits to pass or fail the test with the
instruments used.

«Car parameters»: set the lower, medium and higher limits value to give the
final result of the test done (REGULAR – WARNING – FAIL).
Move the cursor from System to Board Parameters
by pressing F3 and press F4 to enter.
 Press F3 function key, then press F4 to enter in the «Card Configuration
Parameter».
Because the «brake tester CPU» is the same used for Cars, Trucks and Bikes brake
testers, but works in different way, it is important that the lines highlighted in yellow
must be checked and set according the brake tester that you are installing.
Each parameter have many options that is possible to see by pressing F4 on each
parameter line.
During the installation the parameters are set according to the brake tester
installation that you have chosen but there are some parameters that you have
to manually set like, for example the weighing unit type. Here you can see the
different options for the parameter no. 4 - weighing unit type.
Here some other Card configuration parameters to check.
Press F3 to scroll the list.
Here some other Card configuration parameters to check.
Press F3 to scroll the list.
Finished to check and if need to change the «Card Configuration Parameter»,

press F1 to go out of the parameters list and press F3 to move the cursor down.

This is the parameters list used to calibrate the brake tester load cells.
We highlight in GREEN the parameters that set the ZERO force of the
cells (default values) and we highlight in YELLOW the «target» value in
daN.
For example, refer to parameter 50, 51 and 52 we inform the system
that when there is no weight on the left roller, the brake force is equal
to 0 daN and it corresponds to 800 bit; then when we put 300 daN on
the brake force the amplification circuit of the system need 1200 bit to
show such weight.
Parameters 51 = Gain LH, change automatically during the calibration
in order to respect the target point.
If you have not pressed F4 to enter in this parameters then press F3 to
select «Program Configuration CAR», other way press F1 to exit from
Offset, Gain and full scale parameters and press F3 to select «Program
configuration CAR».
 Press F4 to enter in this parameters list.

Here is possible to set the brake tester program to work with some options.

We have highlight in YELLOW the main parameters to be checked and

changed if you have the options available.

Take always note of what you change to be able to restore the

previous setting.

This option is used only in Italy.

Leave it as ABSENT.

Option no. 243 not used in

international program.
 We are still in the «Program Parameters CAR».
You have to press F3 key to scroll down the complete list.
The parameter 256 – CUSTOMER DATA BASE – will allow you to store the test
that you have done inside the computer using your own data base or to
create a file that can be used by an external database.

There are not other parameters to check here, press F1 to exit.

 Devices configuration MCTCNet – not used in this
installation

Environmental conditions– not used in this installation

«Visualization Time Parameters» This parameter freeze the results of the test
on screen for the time chosen (in seconds) before that the brake tester
program automatically passes to the next step.
 Gas – Opax – Phonom. – Lights parameters CAR - not
used in this installation.

« Car parameters » : set the lower, medium and higher limit values to give the
final result of the test done (REGULAR – WARNING – FAIL).
 « Homologation Data»
Here you have to type Manufacturer, Model, Homologation data, serial no.
of the brake tester.

Referring to Data expiry calibration, here you have to write the day of the
calibration plus one year: do you perform the calibration on 2016 May 12th,
well you have to write in this field «expiration date» 2017 May 12th if you have
to check the calibration one time to year, as it is normally done.
 The Car Parameters control is finished.

Press F1 button as many times as it is necessary until there is no escape from

the page of the Parameters.
 If you have changed some parameter, the program will ask you if you want to save the changes.
By Pressing F1 you return in the main Menu without save. If you are sure of the modification done Press F4.
From this page press F1 again: we need to enter in another configuration page.
From this page press F1 again: we need to enter in another configuration page.
From this page press F2 to enter in the User configuration menu.
Here it is possible to choose your own languages, Press F4 to enter in this selection.
Here it is possible to choose your own languages: use F1 or F2 or F3 or F4 to select your flag and confirm pressing
F5.
Here it is possible to set the Printer Type and the printout report. Press F4 to enter.
Press F4 to enter in «Personalisation Print-out».
Here you have 4 lines available to type the final user information that will be print on the test final report.
Fill the form and press F1 to exit.
Move the cursor on «Select Printer» and press F4 to select this option.
NOTE: All printer devices already installed in Windows operative system are automatically detected from our
software. Move the cursor on the printer connected to the computer and press F5 to validate.
If you select this option a printer test page starts.

Press F1 to exit this page.

 Move the cursor to select «Test scheduling».

This setting will inform the program in which order you will execute the complete test of all devices connected and installed in the
brake tester test lane.

Press F4 to enter in this page.

 Side -Slip Weight Adherence Brake
Unit test tester

Light Noise and Visual

Gas –
beam horn test inspection
Opax test
tester

This page is divided in 2 area. The upper side, highlight in yellow, shows which devices can work connected to the
brake tester program to perform a complete test of the vehicle in the test lane.
In the line in the bottom you set which devices you want to use and in which order.
(Now only the brake tester is set).
 Side -Slip Weight Adherence Brake
Unit test tester

Light Noise and Visual

Gas –
beam horn test inspection
Opax test
tester

Please note that devices with red cross are not enabled to be set working because the SMART CARD DOES NOT ALLOW this
configuration.
The SMART CARD is programmed according to your test Lane ORDER.
 Side -Slip Weight Adherence Brake
Unit test tester

Light Noise and Visual

Gas –
beam horn test inspection
Opax test
tester

Please note that devices with grey background and without red cross can be set as connected in the parameters setting and then
can be added into the test lane configuration.
Side -Slip Weight Adherence Brake
Unit test tester

Light Noise and Visual

Gas –
beam horn test inspection
Opax test
tester

Now we go to set the Weight Unit and the Visual Inspection present and insert in the test
sequence.
Press F1 to EXIT this page. Press F1 to EXIT this page.
 Now we are in the LOGO page.
Press F5 to ENTER in the Service Menu.

Move the cursor by pressing F3 to select «Technical

assistance».

Press F4 to enter in «Technical assistance». Press F4 F3 F2 F4

Move the cursor in order to select «Parameter change». Press F4 to ENTER in «Parameter change».

Press F3 to select «System». Press F4 to ENTER in «System».

 Press F3 to select «Board Parameters». Press F4 to ENTER in «Board Parameters».

Press F4 to ENTER in «Card

Configuration Parameters».

Press F3 to select «Card Configuration Parameters».

Press F3 to move the cursor on parameter no. 4
«weighing unit type».

Press F4 to select the Parameter.

A list of available options for this Press F3 to select «Under roller

parameter occurs. book» and press F4 to validate.
 We are in the «Card Configuration
The choose selection is now set in Parameter». Press F3 to move the
the configuration. cursor on «program Configuration
Press F1 to exit. CAR».

Press F4 to enter in this parameter Press F3 to move the cursor on parameter no. 229 «Type
list. visual inspections».
 Press F4 to select the Parameter.
Press F2 to select «Complete
Chapter» or «Only chapter» as you
A list of available options for this
like.
parameter occurs.

Press F4 to validate this parameter. The chosen selection is now set in

the configuration.
 Press F1 to EXIT from «Program
Press F1 to EXIT from «System».
Configuration CAR».

Press F1 to EXIT from «Parameters»

Menu.

The program will ask you if you want save the changes.
By pressing F1 you return in the main menu without save.
If you are sure of the modification done press F4.
 When all the data are saved the
program shows this page.

“Please Wait” will occur. In this time the program is saving the Press F1 to EXIT from this page.
parameters on Computer and Brake Tester CPU.

The program now is performing a self-reset.

Wait please.

Press F1 again to EXIT from this page.

We have to return in the Logo page
 It is possible now to return in the Test Scheduling menu in
order to set the options right now added (weight and visual
inspection).
Press F2 to Enter in configuration area.

Move the cursor to select «Test scheduling».

Press F4 to enter in this page.

Press F2 to move the cursor on

the Visual Inspection icon, now
green.
Press F2 to move the cursor on
Press F3 to add this test on the
the Weight icon, now green.
testing sequence.
Press F3 to add this test on the
testing sequence.
Move the arrow by pressing F2 over each green icon and press F3 (ENTER) to insert
the device in the test lane sequence.

In this case, every time that a new vehicle comes the test is performed in the
following order: Front axle weight, Front axle brake, Rear axle weight, Rear axle
brake, Parking brake and then Visual Inspection.
 By pressing F3 over each green devices you take out the devices from the test lane
sequence and then, selecting the devices in different order, you can decide to program
the test lane sequence in different order.

Here, for example, is showed the visual inspection before the weigh unit and brake tester
test.

Press F1 to exit this page.

 The Brake tester program will ask if you want save the change.

By pressing F1 you don’t save the changes as per pressing F4 you confirm the changes.

Both option return the program to the main menu page.

Check of the connections; control and setting of the parameters and lane configuration are finished.

You can start to Calibrate the Brake Tester and after this you can use it.