Instruction Manual and Maintenance 737 RBT3500 XS-Q Rev - 1A

Roller Bra ke Tester
RBT3500 XS -Q +T
Instruction Manual and Maintenance

Banco Prova Freni a rulli RBT3500 XSQ Manuale di servizio
1 WARNINGS ................................................................................................................................................................. 5
1.1 EXPLANATION OF SYMBOL ........................................................................................................................................... 5
1.2 CAUTIONS AND INSTRUCTIONS FOR SAFETY ............................................................................................................................ 6
1.3 POSITIONING THE IDENTIFICATION PLATE ............................................................................................................................ 6
1.4 WARRANTY ................................................................................................................................................................... 6
2 COMPOSITION OF THE ROLLER BRAKE ........................................................................................................................ 7
3 PACKING /TRASPORTATION ........................................................................................................................................ 7
3.1 MOVEMENT ..................................................................................................................................................................... 8
3.2 USING THE MACHINE.......................................................................................................................................................... 9
3.3 OPERATION NOT PERMITTED................................................................................................................................................ 9
3.4 GENERAL INFORMATION ..................................................................................................................................................... 9
3.5 PERSONNEL SELECTION AND QUALIFICATION ......................................................................................................................... 10
3.6 SAFETY RULES FOR USE ..................................................................................................................................................... 10
3.7 SAFETY RULES FOR MAINTENANCE AND REPAIRS..................................................................................................................... 11
3.8 RULES FOR WORKS ON ELECTRICAL COMPONENTS .................................................................................................................. 12
4 UNPACKING AND INSTALLATION ............................................................................................................................... 12
4.1 UNPACKING ................................................................................................................................................................... 12
4.2 RECESSED DRAWINGS ...................................................................................................................................................... 13
4.3 WATER DRAINS SPECIFICATIONS ........................................................................................................................................ 13
4.4 ELECTRICAL CONNECTIONS ................................................................................................................................................ 13
4.5 DUCTING FOR ELECTRICAL CONNECTIONS............................................................................................................................. 13
5 INSTALLATION STANDARD ....................................................................................................................................... 13
5.1 INSTALLATION................................................................................................................................................................. 13
5.2 EARTHING OF ROLLERS ..................................................................................................................................................... 14
6 INSTALLING THE POWER MODULE ............................................................................................................................. 16
6A TRACKING INSTALLATION .................................................................................................................................... 18
7 PROCEDURE INSTALL THE SOFTWARE ........................................................................................................................ 20
7.1 DATA ENTRY SET UP ........................................................................................................................................................ 21
7.2 CHECKING THE SAFETY DEVICE ............................................................................................................................................ 23
7.3 CHECKING THE ROTATION OF MOTORS ................................................................................................................................. 23
7.4 MECHANICAL FEATURES AND DIMENSIONS ........................................................................................................................... 24
7.5 METROLOGICAL CHARACTERISTICS ..................................................................................................................................... 24
7.6 SIDE SLIP TESTER ( TRACKING) MODEL TRZ - CAR TECHNICAL DATA.......................................................................................... 25
8 PROCEDURE FOR USE RBT3500 XS-QL ....................................................................................................................... 26
8.1 CONFIGURATION SETUP ................................................................................................................................................... 26
8.2 SETTINGS ....................................................................................................................................................................... 27
8.3 TEST FIRST AXIS .............................................................................................................................................................. 29
8.4 MESSAGE AND INDICATOR................................................................................................................................................. 30
8.5 DESCRIPTION OF THE AREAS OF THE SCREEN:......................................................................................................................... 31
8.6 DESCRIPTION OF THE MESSAGES - TYPICAL TEST SEQUENCE ...................................................................................................... 31
8.7 OPERATING SEQUENCE ............................................................................................................................................... 31
8.8 BRAKES WARM UP ............................................................................................................................................................ 32
8.9 CHECK OF PARASITIC FORCES OR RESIDUAL FRICTION ................................................................................................................. 32
8.10 OVALIZATION ............................................................................................................................................................... 32
8.11 CHECK OF MAXIMUM BRAKING FORCE ..................................................................................................................... 33
8.12 SECOND AXLE TEST .................................................................................................................................................... 35
8.13 HAND BRAKE TEST (PARKING) ..................................................................................................................................... 35
8.14 DYNAMIC CONVERGENCY (IF PROVIDED) ...................................................................................................................... 35
8.15 PROCEDURE 4X4 MODE ............................................................................................................................................ 36
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9 INTERPRETING THE RESULTS ...................................................................................................................................... 37

10 USING THE DATA BANK ............................................................................................................................................ 38
11 INTERPRETING THE PRINTS ...................................................................................................................................... 40
12 ORDINARY MAINTENANCE....................................................................................................................................... 43
13 EXTRAORDINARY MAINTENANCE ............................................................................................................................ 43
14 CHECKING THE CALIBRATION AND THE SAFETY DEVICES.......................................................................................... 44
14.1 CHECKING THE CALIBRATION VALUES OF THE SENSORS ........................................................................................... 44
14.2 CHECKING THE CORRECT OPERATION OF THE SAFETY SYSTEMS............................................................................. 45
15 INITIAL AND PERIODIC CHECKS ................................................................................................................................ 45
15.1 REQUIREMENTS ....................................................................................................................................................... 45
16 TROUBLESHOOTING T ABLE ..................................................................................................................................... 46
17 PUTTING THE EQUIPMENT IN NON OPERATING CONDITIONS.................................................................................. 47
17.1 PUTTING THE MACHINE IN NON OPERATING CONDITIONS ..................................................................................... 47
17.2 FINAL STORAGE / DISMANTLING .............................................................................................................................. 47
18 CALIBER INSTALLATION PROCEDURE FOR BRAKE VERIFICATION .............................................................................. 47
18.1 CALIBRATION CONTROL PROCEDURE FOR ROLLER BRAKE TESTER RBT 3500 XSQ / XS-QL ....................................... 47
18.2 INSTRUMENTS .......................................................................................................................................................... 47
18.3 PROCEDURES FOR ASSEMBLY OF THE CALIBER (BRAKES) ......................................................................................... 48
18.4 CALIBRATION SEQUENCE (BRAKE) ............................................................................................................................ 49
18.5 METROLOGICAL VERIFICATION PROCEDURE OF BRAKE AND WEIGHT FORCES ........................................................ 50
18.6 CALIBRATION CORRECTION OF SENSOR FDN 1000 CE .............................................................................................. 50
18.7 CALIBRATION ADJUST FOR WEIGHT SENSORS .......................................................................................................... 52
19 EXPLODED VIEW ...................................................................................................................................................... 53
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Capitale Sociale € 115.500,00 int. Versati

S.r.l. C.C.I.A.A. Varese n. 164919
Tribunale N. 13172
21012 CASSANO MAGNAGO (VA) M.: VA014988
Via G. Pascoli, 15 Codice Fiscale - Partita IVA IT 01234220125
info@vamag.com TEL. 0331/ 20.59.63
DICHIARAZIONE CE DI CONFORMITA’
EC declaration of Conformity/Konformitatserklarung / Déclaration de Conformité / Declaration de Conformitad
NOI
We / Wir / Nous / Nosotros
VAMAG S.r.l. Via G. Pascoli, 15
21012 CASSANO MAGNAGO (VA) ITALIA
Dichiariamo sotto la nostra esclusiva responsabilità che il prodotto

Declare, undertaking sole responsability, that the product
Erklaren unter unserer alleinigen Verantwortung, daas dasProduckt
Déclarons, sous notre entiére responsabilité, que le produit
Declaramos hajo nuestra exclusiva responsabilidad, que el product
PROVA FRENI RBT3500 XS-Q
al quale questa dichiarazione si riferisce è conforme alle seguenti norme o altri documenti normativi
to which this declaration applies is in compliance with the following standards and other normative documents
auf das diese Erklarung bezieht, den nachstehenden Normen oder anderen Normunterlagen entspricht
objet de cette déclaration est conforme aux normes suivantes et à d’autres documents réglementaires
al que se refiere esta declaracion es conforme a las siguientes normas o a otros documentos normativos
EN 12100:2010 – EN 60204-1 del 2016 – EN61000-6-1
…………………………………………………………………………………………………………..
in base a quanto previsto dalle Direttive
2006/42/CE ; 2006/95/CE ; 2014/30/CE ; 2014/35/CE
According to the provisions of the Directives : 2006/42/CE -2006/95/CE – 2014/30/CE -2014/35/CE

Gemass den Richtlinienen : 2006/42/CE -2006/95/CE – 2014/30/CE -2014/35/CE
Comme prèvu par la Directive : 2006/42/CE -2006/95/CE – 2014/30/CE -2014/35/CE
En base a cuanto està previsto por la Directiva: 2006/42/CE -2006/95/CE – 2014/30/CE -2014/35/CE
Nome e indirizzo della persona autorizzata alla costituzione del fascicolo tecnico:
Name and address of the person authorised to compile the technical file:
Name und Anschrift der Person, die bevoltmächtigt ist, die technischen Unterlagen zusammenzustellen:
Nom et dresse de la personne autorisée à constituer le dossier technique :
Nombre y direcciòn de la persona facultada para elaborar el expediente técnico :
Oliviero Giorgetti, VAMAG SRL Via G. Pascoli 15, 21012 Cassano Magnago (VA), ITALIA
Cassano Magnago, 15 Marzo 2017

Gianfranco Crosta
L’Amministratore
Il modello della presente dichiarazione è conforme alla norma EN 45014

The version of the present declaration conforms to the regulation EN 45014 (BS 7514)
Das Formular der worliegenden Eridarung entspricht den Normen EN 45014
Le modèle de la présente déclaration est conforme à la norme EN 45014
El modelo de la presente declaration es conforme a la norma EN 45014
Pag 4 di 54
1 WARNINGS
1.1 EXPLANATION OF SYMBOL
The following instruction text contains the symbols shown here below, aimed at drawing the
operator’s attention to the hazard signals .
Warning signal for safety at the workplace.

This symbol is used in the service instructions along with warnings concerning operating conditions which involve
severe hazards for the persons’ safety and health. All the machine operators and maintenance personnel must be
aware of the above warnings and are supposed to strictly follow them and to work with the utmost care and
caution. In addition to the specific warnings, all general safety precautions must be carefully followed
Electric power hazard signal.

Getting into contact with alive parts may result in the operator’s immediate death. All coverings (i.e.
caps and covers) carrying this signal must be removed by “qualified and/or trained operators” only,
after cutting out the operating power (power supply voltage or separate operating voltage and power
supply).
Limbs crushing hazard signal.

This symbol is placed at all the machine spots where operating it or parts of it may result in hands or
feet crushing. All operators must be aware of this, and pay the utmost attention and care when
working nearby the moving parts of the machine.
Hanging loads hazard signal.

Standing within this hazardous area can result in severe injuries or death. Make sure that no one
passes below hanging loads or accidentally puts a part of the body on the load vertical line or in the
surrounding area.
Dangers for the plant safety.

This symbol in the operating instructions points out that failure in complying with mentioned warning
can cause damages to the machine components.
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GENERAL INFORMATION FOR USERS

disposal of equipment
This device may not be disposed of as normal household waste. Dispose of as "special waste".
The reuse or recycling, in accordance with the regulations concerning electrical and electronic
equipment (CEE), which is useful for protecting the environment and our health.
In accordance with the European WEEE 2002/96/EC, there are specific collection centers available to
citizens that carry electrical appliances that you no longer use.
Public administration and producers of electrical and electronic equipment are committed to simplify
the process of re-use and recycling of waste electrical and electronic equipment by means of which the collection and
measures to comply.
The law agrees with the corresponding penalties to punish those who do not respect the rules and do not dispose of
electrical and electronic equipment in accordance with the provisions of the law.
Battery Disposal
The batteries must be recycled or disposed of according to regulations. Do not dispose of in household
rubbish.
Never dispose of batteries in a fire!
1.2 Cautions and Instructions for Safety

The activity of installation, maintenance, service and metrological verification and reserved service personnel authorized
by the manufacturer, and is expressly forbidden to work on mechanical electronic and electrical by unauthorized
personnel.
It 'is mandatory before any intervention technician disconnect the appliance from the mains power supply and observe the
following safety rules
1.3 POSITIONING the identification plate
The identification tag is located both on the Inspector console and in

the RBT module; it carries the serial number, the manufacturing date,
as well as the machine power voltage; the tag is put on the console
rear panel, inside the Roller Brake Tester.
1.4 WARRANTY
Vamag S.r.l. guarantees that the reference machine has been tested under maximum stress with successful results. The
warranty period is twelve months, which only covers the good quality of the materials and the lack of manufacturing defects.
The Customer is only entitled to the replacement of the defective parts. The costs for transportation,
packing and replacement, if any, are not included.
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The warranty does not cover any damages resulting from dropping or tampering with, or due to incorrect machine handling,
failure in complying with the maintenance instructions set forth in the manual, or due to wrong use by the operator. No
compensation can be asked if the machine is kept non operating. The warranty is valid only if the payment conditions have
been duly fulfilled.
The Customer service fees, along with the costs of the spares which are not covered by warranty must be paid directly to
the technician in charge of the works performance. He will draw up a written Customer service form; a regular invoice will
follow. The service fees and the costs for the used spares are those shown in the latest price-list in force.
2 COMPOSITION OF THE ROLLER BRAKE
Roller Test bench

Power Box
Remote Control
3 PACKING /TRASPORTATION
The movements must be performed by means of trans pallet or forklift.
The outlet points of the forks are made by the appropriate spaces in the pallet.
The brake tester is in turn covered by protective cardboard secured with plastic strap and placed on wooden pallet palettabili size
2570x830x550, and weighing about 400 kg
Identification and
Weight
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After removing the packaging, carefully check that the delivery corresponds to the shipment documents and that has not been
damaged during transportation.
In case of detection of damage not operate the equipment and contact your dealer for any damage or discrepancy in the goods
received.
The packaging materials (plastic bags, polystyrene foam, nails, screws, wood, etc..) Must not be left within reach of children as
they are potential sources of danger.
Take these materials in the appropriate collection points.
3.1 Movement
For handling and lifting bench still packed, use only pallet truck or forklift. Avoid the use of unsuitable equipment or systems
in order to prevent damage to property or persons.
CAUTION:
DO NOT USE WIRE ROPES FOR LIFTING.
MAKE SURE THAT DURING THE MOVING THERE ARE PEOPLE IN THE RANGE OF MACHINES SUITABLE LIFTING.
Remove the central cover by unscrewing the fixing screws and screw them in place 4 M6 eye bolts (not supplied) for
handling
.
Connect to the eye bolts or straps 4 straps for moving and lifting the bench with a forklift
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3.2 Using the machine

The machine model RBT3500_XS-QL is designed to be used as an instrument for the measurement of parameters of the
braking of motor vehicles with two, three, four wheels and quad (only quad with iterasse than 80cm); passenger cars and
commercial vans up to a maximum limit of 35q.li totals
The measurement parameters are the following:
• wheel braking force to the wheel and axle in Newtons (N);
• braking force of the hand brake in Newtons (N);
• braking imbalance in percentage (%) of each axis (static and dynamic);
• residual friction in Newtons (N) and ovality in percentage (%) refers to the maximum force;
• braking efficiency percentage (%) (introducing the mass of the vehicle.) Keyboard or RMC (remote control device).
• static weight of the vehicle under test
3.3 Operation not permitted

When using the brake tester are not banned all activities that can harm people and things, in addition to activities that may cause
damage to the cabinet itself. It is also not allowed:
• carry out tests on vehicles having a mass greater than 2500 daN. axle;
• leave the vehicle during the course of the test;
• change the functions provided by the buttons on the control panel;
• remove or deface signs and / or warning signs placed at the edge of the bench;
• exclude the safety devices on the machine.
3.4 General Information

The operating instructions must always be kept within reach on the installation site!
The manual refers to essential aspects of the directive, Standards and provisions related to the machine use and
summarizes the most significant items thereof.
Failure to comply with the instructions and advice in this manual could cause damages to the vehicle being tested and to
the bench as well.
In addition to the given operating instructions, the general law regulations and the binding rules on accident prevention and
environmental protection must be followed and have followed.
While performing any works on or with the machine, the following provisions must be complied with, as well as the
regulations set forth by general accident prevention standards.
Neverthenless, the use of the machine by non trained or non specifically trained personnel, or for different uses than the
ones the machine has been designed for can result in severe damages to the operators.
The manual must be completed with adequate instructions, including the monitoring and reporting duties, upon corporate
specifications, i.e. concerning the operators in charge.
Prior to start the bench, the operators in charge must carefully read the operating instructions, especially the section on
warnings.
It would be too late to read it while performing the work! This applies particularly to operators that operate the bench
occasionally, i.e. for maintenance works on the machine.
It is recommended to check from time to time that the working operators are well aware of the safety standards and of the
existing hazards, and that they keep to the operating instructions given herein.
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The user must ensure that the machine is always and only used under perfect working conditions and that the essential
safety requirements and the relevant standards are always complied with. Should any defects or working irregularities be
detected, the machine must immediately be switched off.
All hazard warnings and signs, such as tags, adhesives or markings must never be removed or tampered with. Any warning
and hazard signs applied to the machine must be kept clearly readable.
No changes, additions or alterations that may jeopardize the machine safety can be made, unless expressly authorized by
VAMAG S.r.l.. This applies to the assembly, the adjustments on the safety devices, and the welding on bearing parts.
All spare parts must comply perfectly with the technical requirements set forth by VAMAG S.r.l. The compliance is assured
by the use of original spares. The check/inspection time intervals indicated in the operating instructions must always be
respected.
3.5 Personnel selection and qualification

All works on/with the machine must be carried out by reliable operators only.
The required instruction and training level of the qualified personnel is the user’s responsibility.
The user is kindly invited to establish suitable behaviour rules and directives should any irregularities occur, to provide the
operators with the proper instructions and display such rules in a suitable, clearly visible location.
Prior to starting the machine, the user must ascertain the level of knowledge of the operators in charge, especially on the
following:
- knowledge of the operating instructions contents;
- knowledge of the safety and operating rules mentioned in the above mentioned manual;
- knowledge of the law regulations in force on accident prevention.
Only well trained and instructed operators must be employed. The tasks of the operators and of the personnel in charge of
maintenance and repairs must be clearly defined.
3.6 Safety rules for use

All works on the machine electrical equipment must be carried out by skilled electricians only, in compliance with the
electrotechnics rules. People under drugs, alcohol or medecine effects which may jeopardize their quickness of reflexes
must not be allowed to operate the machine or to perform any repairs/maintenance works.
All warnings and precautions related to safety during operation, to general safety and accident prevention rules to be
adopted before, during or after the start-up of the machine must be strictly followed.
Failure in keeping to them can result in people injuries.
Should any major defects affecting the machine safety and/or performance occur, the machine must be stopped or not
started at all.
It is not allowed to cut off the safety devices, to make changes to them or to use them in a way different from the one
originally set forth.
The necessary measures must be taken to ensure that the machine is operated under perfect safety and operating
conditions only.
The machine must be operated only when all the safety and protection devices are in place and working (i.e. stationary
emergency and protective devices).
It is forbidden to make changes or modifications to the system.
The above prohibition does not apply to minor modifications that do not affect the machine static and dynamic conditions,
the operating as well as general safety features, or to measures aiming at increasing the machine safety.
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The User shall be held responsible for such changes and for the consequences thereof. Should any doubt arise, please
contact VAMAG S.r.l. before carrying out any modification, and ask for an authorization in writing.
In case of operating irregularities, the bench must be immediately stopped and switched off, and the irregularities promptly
eliminated!
Whoever detects an immediate danger for people must promptly operate the emergency pushbutton.
This also applies to any damages occurring to the system component parts, which require an immediate stop.
In the event of an emergency stop, the operator can switch on and start the machine again after making sure that the defect
cause has been removed and that the system is now in a position to work under safe conditions.
The bench must be immediately switched off in case of:
- defect of the electrical equipment and lines and of the insulating devices ;
- failure to operate of brakes and/or safety devices;
- breakage or defect of the vehicle which is being tested.
Special environmental conditions and applications can result in unexpected situations that cannot be foreseen upon
completion of this section.
If this is the case, it is the responsibility of the User to assure safe operation and, if necessary, he must stop the system
until the procedures necessary to assure safe working conditions are defined and carried out, upon previous agreement
with VAMAG S.r.l. or other competent bodies.
Before starting the machine, make sure that nobody is endangered by the machine running.
Should the operator in charge notice some people who may be endangered by the system running, he must immediately
stop it; the system must be started again only when the people are beyond the danger area.
Prior to every start-up of the bench, the operator must ascertain that the working conditions on the system are correct and
perfectly safe.
Should the operator in charge notice some people who may be endangered by the system running, he must immediately
stop it; the system must be started again only when the people are beyond the danger area.
Prior to every start-up of the bench, the operator must ascertain that the working conditions on the system are correct and
perfectly safe.
When the system is put out of service (i.e. due to ascertained lack of safety and reliability, working defects, repairs and
maintenance operations, ascertained damages, or at the shift end) the operator must take all the prescribed safety
measures or watch the automatic execution of the same.
Any works on the machine are only allowed following a specific order and after a suitable training on the machine operation
and use.
3.7 Safety rules for maintenance and repairs

All adjustment, maintenance and inspection operations set forth in the operating instructions must be carried out according
to the provided schedule, by keeping to the instructions concerning the replacement of partial components. Such operations
must be carried out by qualified personnel only.
All mechanical and electrical repairs, as well as all arrangement interventions must be carried out by qualified personnel
only.
It must be forbidden to unauthorized people to carry out any kind of work on the system machines and equipment.
Prior to proceeding to maintenance and repairs, the machine must be temporarily switched off and stopped; any
unintentional restart by unauthorized personnel must be prevented.
Before working on the electrical devices and systems, make sure that the bench is not energized The following must be
assured:
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- the main power supply line must be cut off;

- the movable parts must be at a standstill;
- the movable parts must be made unable to get into motion during maintenance operations;
- it must be impossible to unintentionally switch on again the power supply line, as long as the machine is not operationg
due to maintenance or repairs.
In disposing the waste materials and the replaced components, strictly follow the environment protection rules.
3.8 Rules for works on electrical components

All works on electrical parts or components shall be carried out by qualified technicians only, or by specifically trained
operators, under the direction or the supervision of a skilled electrician, according to the electrotechnics rules.
Before proceeding to inspection, maintenance and repairs on the machine parts, the power supply must be cut off.
The machine electrical equipment must be inspected/checked at regular time intervals. Defective parts, such as loose
connections or singed cables, must be immediately removed.
Switch off the power supply before removing or connecting the plug electrical connections (exception made for the network
connections, whenever it is not dangerous to come in contact with them, according to the safety rules).
Use original fuses only, with the prescribed current carrying capacity (in Ampere)! In case of defects in the power supply,
the machine must immediately be disconnected.
Defective fuses must not be repaired or cut off, but replaced with new fuses of the same type.
In case of intervention on alive parts, the assistance of a second operator must be provided. In case of an emergency, the
second operator will operate the emergency or the main switch. The working area must be temporarily bound by a red/white
chain and by a hazard signal. Use insulated tools only!
4 Unpacking and Installation

4.1 Unpacking
After removing the packing, check the integrity of the component parts of the whole machine, checking that there are no
damaged parts. The packaging materials (plastic bags, polystyrene foam, nails, screws, wood, etc..) Should be placed in
appropriate collection points where pollutants or non-biodegradable. Then remove the two side covers and unscrewing
the screws and put them in place 4 eye bolts at each end of the bench. Attach eyebolts to a four-arm spider or 4 bands for
lifting and lift the bench with a crane or a forklift.
Cutter
Cardboard
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4.2 Recessed Drawings
Note. Recessed Drawings Rollers RBT3500P/XS request in Vamag
Note From the command position, the operator must be able to see all the equipment and the surrounding area. He must
prevent that in this area there is the presence of unauthorized persons and objects that could cause injury
4.3 Water Drains Specifications

Prepare masonry suitable to drain discharges wastewater, taking into account the minimum level of collection.
4.4 Electrical Connections
For the power supply, it is necessary to provide a three-phase line to 380V (Volt) with neutral and ground, protected by a
'circuit breaker capable of delivering a maximum current. 32A (amperes).
Each connection other than that prescribed in this manual is believed to be unsuitable, so not usable.
Before applying power, comply with the following provisions:

• Check that the supply voltage corresponds to 380V;
• check the condition of the wires and the presence of a conductor to the ground;
• make the electrical connection with the utmost care in accordance with current standards.
Any damage resulting from failure to observe the above-stated provisions shall not be chargeable to the manufacturer and
may result in loss of warranty.
4.5 Ducting for Electrical Connections
During the construction of the wall paintings made for the channeling of plastic pipe with a minimum diameter of 80 mm.
intended for electrical and pneumatic connections between the roller brake tester and the power unit and associated
console with PC. The channeling and well when installed with the straight path as possible, any bends should have a radius
length and not exceeding 90 °.
5 INSTALLATION STANDARD
5.1 Installation
Remove the packing by making sure you don’t damage its content ;
b- use protection gauntlets and scissors to remove safety straps;
c- place the console INSPECTOR M about 4 m before the cavity provided for the Roller brake
Tester embedding;
d- remove the module RBT cover by loosening the 4 fixing bolts;
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e- remove the side guards by loosening the 6 fixing bolts;

f- unroll the cables ( 2 power supply and 2 signal cables) which are rolled up on the left side of the
module and gather them before inserting them in the provided raceway, connected to the console,
through the hole. Carry out this operation with the utmost care.
g- slide a belt under the module motors and lift it up;
h- lower it into the cavity;
i- though a drill with a drill bit of 12mm x 450mm, make 4 holes in the underlying floor, by using the
holes provided for the fixing of the module as template.
l- by making use of the suitable plugs and of a17mm socket spanner, fix the module RBT to the floor.
Fixing Holes
5.2 Earthing of Rollers
Each rollers is provided with an indication applied on the upper surface of the carcass in order to remind the installer to
perform the operation of earthing of the equipment
ATTENTION:
Before putting into service to connect a cable to the
appropriate terminal of at least 16mm at the point of
land where the electrical system supplies power to
the machine
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During the operation of connection of electrical cables should be connected to the Eearthing terminal of the structure of the
bank to the point of land where the main electrical system supplies power to the central unit. Use a cable of at least 16 mm
² cross-section (not supplied).
Note:
it should be noted that the operation of earthing must be done in a workmanlike manner by a qualified electrician.
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6 Installing the power module

Attach to the wall power module using the supplied plugs supplied
Connect the external power supply 400V AC from the interlocked socket terminals marked R-S-T-N and ground
and connect the motors of the bench to the power module (pictured below).
1-2-3 Left Motor
4-5-6 Right Motor
R-S-T-N Power Supply

380V+N
Connect the cable presence, the cable signals, cable relay as picture:
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Warning: check the correct setting about the 737 configuration how show below:
737 - hardware configuration
737 Jumper Brake

FW Bike
AUX1 1-2
AUX2 2-3
AUX3 2-3
FW Car/Bike
AUX1 2-3
AUX2 2-3
AUX3 2-3
FW UK
AUX1 1-2
AUX2 1-2
AUX3 2-3
FW Truck
ST AUX1 2-3
AUX2 2-3
AUX3 1-2
Pos.1-2-3 ST
737 Jumper Speedometer

AUX1 2-3
AUX2 2-3
AUX3 1 - 2 = MCTC
AUX3 2 - 3 = Calibration
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Proximity cable
Signals cable
6a Tracking installation
The tracking platform is an option.
If you have this device you must connect to the PLD cable into the middle of RBT3500_XS bench.
Open the central cover
And you must individuate the PLD cable connection:
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PLD cable box
Open this box
Connect the Tracking cable to the TRCK connector:
25- White
26- Browne
27- Green
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7 PROCEDURE INSTALL THE SOFTWARE

Insert the CD Rom to the PC, and wait the autorun tu start the Setup or opend the CD Rom and start the Setup
File..
Run the SETUP.EXE file
Once you have finished installing the software running the program with the icon on the desktop.
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7.1 Data Entry Set up

After installing the software on the rollers and you need to enter some data on the rollers
RBT3500_XS-QL.
Start the program and click the Inspector set up.
This displays the following screen:
Select the Appropriate configuration for your line:

- Serial port connection [COM_x]
- Inspector rack type [M 3500 XS-Q]
- Hardware configuration [P_R]
If you have Trackinf plate [P_R+T]
Select also TRACKING Position
- Pedal connection [absent , or what you have]
- Endscale [CAR_230]
- FLAG
o Blocked rolle [if you have]
o Integrated weight [x]
- RULLINO
o 4 Fori [x]
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Follow the check marks indicated by photo

Click on the button "Expiry Date" will be prompted for a password, type "rullo".
The following screen appears:
Click "SAVE" to display the following screen:
4
2
1
Make sure the date is correct (1) and enter the serial number of the rollers (3), type the expiry date of the next
control (4), normally one year after installation.
Enter the name of the qualified technician (2) conducting the verification.
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7.2 Checking the safety device

- remove the protective covers rollers.
- turn the power moving into the verification screen Sensor Calibration
- verify that the 2 "rectangles" associated with microswitches control the presence vehicle is red in the no
vehicle and green when the rollers shall be made low;
- also check that by slowly turning the rollers, the 2 "dots" corresponding to the speed detection are flashing;
when the proximity sensor reads the hole, the ball must be green, and when the law must become full of red,
See the following figure and also the previous figure sensors calibration.
7.3 Checking the rotation of motors
A position in the initial screen (logo) and click on the button "TEST BRAKE" or "Official test" using the
remote control
N.B. using the buttons on the remote control will change the highlighting of key ¬ to select, for
example, from black to red.
B. position with any axis of a motor vehicle inside of the rollers;
C. Click on "START MEASURE" to get the start of the rollers
D. get help from someone you trust to check the direction of rotation of the rollers is such as to induce
both wheels to turn in the forward direction NB: NO REASON TO LEAVE THE DRIVING THE
VEHICLE WITH ROLLS IN MOTION
E. press START on the remote to stop the measurement and stop the rollers;
F. if the motion of the two rollers is concordant and correct way to not have to do anything;
G. if the motion of the two rollers is concordant, but the reverse is necessary to reverse the two phase
wires in the cable that connects the relay box to the terminal block inside the compartment Power Box
.
The operations of to be carried you points G and H machine off

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7.4 Mechanical features and dimensions
Permissible axle load up to 25000 N
Total Length 2327 mm.

Total Width 630 mm.
Total Height 275mm.
Distance between the inner edges of the rollers 400mm.
Total Weight 380Kg.
Roller Diameter 200mm.
Coefficient of friction of not less than 0.6 even in wet condition.
Maximum load for static weighing of each individual wheel 12.500N

Maximum load for static weighing axle 25.000N
7.5 Metrological characteristics

End scale measurement of tangential forces on a single roll 6.000N.
End scale measurement of vertical forces on a single roll 12.500N.
End scale measurement of the static single roller 10.000N.
Accuracy of measurement limit the overall error does not exceed the required values (20 + / - 5 ° C).
Temperature drift + / - 0.25% of the indicated value for a field of use from 0 ° C to 40 ° C.
Minimum resolution <1N.
Automatic zero calibration.
The calibration system allows to control at least three points of the measuring range (1.000N-3.000N-5.000N).
Measurement of braking force, the asymmetry, braking efficiency both analog and digital electronic system:
resolution <1%.
Possibility to set a threshold of imbalance LIMIT to 30% for the service brake and emergency, and up to 50%
for the parking brake.
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Braking efficiency with visualized in real time using the numeric display and represen-tative by colored bars:
resolution <1%.
Note. The electrical equipment complies with the CE standards
7.6 Side Slip Tester ( tracking) model TRZ - CAR Technical data
 Dimension : 650 x 845 x 40 mm

 Measuring Range : +18 / -18 m/Km
MAIN
 Admissible transit: 1.300 Kg
FEATURES
 Data reading technology: Potenziometer
 Data acquisition: AD board
 Construction material: Galvanized Steel
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8 PROCEDURE FOR USE RBT3500 XS-QL
Run the Inspector Icon on the descktop and will see the following screen
8.1 Configuration Setup
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Note. when installing with suspension test (STL) choose the hardware configuration ST_R
When installing also the Tracking , select P_R+T (or ST_R+T)
8.2 Settings
- Proceed to the header of the software testing workshop with the data by selecting "HEADER" and
confirming Start with the remote control or the Enter from the keyboard, by doing so the data will appear on
the print workshop (test result).
- The acceptance test of vehicles can be done in 2 ways: By selecting

"OFFICIAL TEST" or "TEST BRAKE”.
By choosing "OFFICIAL TEST", the program will proceed to trial only by reference to current standards for the
testing of vehicles of less than 3.5 T. as by D.M. 08/06/1998 408. (Only for Italy).
Choosing instead to "TEST BRAKE" the program will proceed to test without considering the secondary
braking system and the limits of the law, will then provide the only useful data for diagnosis and maintenance
of the braking system. (Generic test)
Official Test
Selecting Official Test is necessary to indicate the configuration of the vehicle under test as follows:
Parking brake, position the type of system and mode of operation

Click on the mouse to select the arrows
Options Rollers Test, Heating, Ovality, Road-wheel drive 4WD check rotation
Click on the mouse to select
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Braking system, service, rescue, and appropriate diagram

The correct selection of the scheme of the system of aid and essential in the evaluation the overall efficiency of
the braking test
Enter the ambient conditions
Options measure weight, where we're going to insert only (possibly) the weight max. trailer load of the vehicle
to be tested if fitted with towbar.
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Enter customer data possibly complementing all the fields shown below:
As a last but very important setting is necessary to indicate the type of category to which the vehicle belongs,
according to the DM 20/97 of 13/01/97. (only for Italy).
For use in MCTC-Net data described above will be automatically acquired from the PC. Office (only for Italy)
8.3 Test First Axis
At this point you can start the measurement, select the button "Start Measure" and Press Start, the software
makes the 'ZERO SENSOR "for a few seconds, and then come up with the first axis on the rollers.
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After the zero sensors page will appear on the acquisition of the vehicle weight, for better readability is not
reported background
Start the test and then release the brake, leave the engine running and the transmission in neutral
8.4 Message and indicator

The test software has been designed so that it is easy to read and does not give point to Mary to doubts of
interpretation.
To respond to this need the PC screen was divided into well-defined areas and also using distinct colors
such that they are easily visible from a distance.
It is also visually indicated the passage of time available to perform operations well-defined that we will see
later.
The following describes a typical screen shown during the use of software testing coupled with the roller
brake tester RBT3500_XS-QL
2
3
4
5
6 11
7
8
9 10
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8.5 Description of the areas of the screen:

[1] - main warning area, where the messages connected with an action to be taken to perform the test
and complete it correctly
[2] - numerical indicator of the force exerted on the braking system for both right and left wheels. i
[3] - numerical indicator of the force exerted on the pedal or the lever (only if an effort gauge is used
[4] - indicator of motor start and operation. It is displayed when the motors start
[5] - area showing the type of the being performed
[6] - numerical indicator of the unbalance(%) of the braking force between wheels on sameaxle
[7] - graphic indicator of the braking force [2] and the right and left wheel ; when the force increase,
the blue bars increase in height
[8] - indicator of the available time progress for the operation shown in the red stripe [1]
[9]- emergency key; if during the test the key START on the remote control is pressed, the motors
are automatically stopped
[10]- when the symbol “door”is selected , with the ENTER key of the remote control and the key
Start is pressed, the test being performed can be finished, and next test can be performed.
[11]- zone of the graph resulting from the acquisition of the braking force
8.6 Description of the messages - typical test sequence

N.B. The check programme for the braking system on one axle performs the test in three subsequent
stages, according to a defined schedule:
- brakes warm up;

- parasitic force or residual friction;
- ovality;
- braking force.
For correct performance of test, the utmost attention must be paid to the messages and indications passing
through areas [1], [5] and [9] previously described. Each stage of the test related to each single axle is
carried out within the same video page, that shows in real time the data acquired, to inform the operator of
the instant test progress.
8.7 OPERATING SEQUENCE
After getting into the roller, the following screens are displyed, showing the test procedures for complete
and efficient test completion.
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8.8 Brakes warm up

The above screen requires warming up the brakes, i.e. over all the available time (10s) (this is shown
by the indicator [9]). Brake in a decise manner and several times, in order to warm up and set the
members of the braking system. Upon completion of this operation, the red bar [1] shows the message
“RELEASE THE PEDAL” for a short while, approx. 3 seconds.
Release the pedal as shown in the video message “DO NOT BRAKE” , enabling the programme to
acquire the data from minimum braking force to maximum braking force up to the slipping threshold.
8.9 Check of parasitic forces or residual friction
While the friction test is being performed (5 seconds), DO NOT press the pedal for any reason whatever,
and DO NOT keep the brake pedal pressed. This test is aimed at evaluating the sizes of the friction forces
(rolling friction, grip of the pads on the disk or of the shoes in the drums, bearings etc.) Check that the
above sizes fall within the allowed limits specified by the Manufacturer. The Programme goes on automatically
within the irregularity check page.
8.10 Ovalization
The ovalization is a sinusoidal change due to non continuous and uneve output of the braking force. Some
limit values are set in the programme as reference standards.
Proportionate the effort on the brake pedal step by step, check on the indicators that the braking force for
both wheel is between 500N and 1000N, as shown in the message on the screen. When the value of the
braking force exceeds the range bewteen 500N and 1000N, some BLUE oval dots are shown. If included in
the set range, the oval dots become green. Now keep the effort constant (the effort on the pedal).
If the test is not carried out within the limit time of 10 seconds, or if the braking force is not included in the
500N and 1000N range, the programme stops the rollers and the message “INCORRECT OVALIZATION
MEASURE” is automatically displayed. The irregularity trial is repeated two more times, as a maximum.
The acquired data are stored. Should the effort detected by the pedal effort gauge (if provided) exerted by
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the operator be unstable, the video shows the message “BRAKING BETWEEN 400N and 800N”.
If these indicators [ GREEN SPOT] show that the effort is within 400 and 800N (correct
value). If they become blue, it means that the effort is not kept constant.
8.11 CHECK OF MAXIMUM BRAKING FORCE
Now act on the brake pedal, press it deeply step by step. Do not brake too abruptly, because this could
alter the data.
NOTE : If the effort exerted on the pedal exceeds 500N, the software stops the test (only if apedal effort
gauge is provided).
Upon reaching the slipping limit, the rollers are automatically stopped. This happens whenever a procedu-
re is not respected, or an operating failure occurs.
If the stop results from failure in complying with a procedure, a message indicating the automatic restart of
the rollers is displayed.
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Upon completion of the axle test, it can be repeated as often as required, by selecting the key Yes with
the Enter Key of the remote control and START; the machine always stores only the latest test
performed.
COMPLETION OF THE TEST ON ONE AXLE

Upon completion of the test on one axle, a screen will automatically display, allowing to get out of the
rollers and start them until getting out.
we can select the front or rear exit, moving

with the remote control, Enter Key, and
then START.
At this stage, if we select EXIT, the program
performs the following test, even if the axle
previously tested is still in
.
The Software usually suggests to get out from

the front side. If we unable to o so for any
reason whatever, the exit direction can be
selected by pressing the START KEY on the
remote control
WARNING:
- make sure that nobody finds him/herself nearby the vehicle, because it could suddenly be projected
from the bench;
- get off in a resolute but not abrupt way.
NOTE: If you are using a bench with self-braking rollers the above operation is not necessary.
Only in case of emergency the exit backwards may also be performed. To operate in a totally safe
way, make sure that nobody finds him/herself near the vehicle because it could suddenly be projected
from the bench.
If you are using a bench with self-braking rollers the above operation is not necessary.
NOTE: if necessary, the rollers can be stopped at every test phase, by pressing the START key
(invio/enter, on keyboard).
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Should you fall inside the rollers while getting out, if this happens within a short time, the above mentioned
mask is displayed. It requests the exit direction again. Otherwise, the test must be completed by selecting the
icon “port” several times [11], up to test completion or by selecting the “Emergency” key [10] and
repeatin g the test.
N.B. se il veicolo che stiamo collaudando è dotato di freno di stazionamento sull’asse

anteriore (impostazione che avremmo dovuto impostare all’inizio, prima di iniziare il test), in
tal caso passate subito a leggere il capitolo successivo riguardante le modalità di test del freno
di stazionamento .
8.12 SECOND AXLE TEST
If getting out of the rollers with the first axle, according to the above procedure, as the car axle gets out of the
rollers, the rollers stop. The screen concerning the second axle automatically appears. Check that the screen
shows the message “REAR AXLE BRAKE TEST ”. The procedure is the same as the front axle. Execute
and pay attention to all the messages displayed on the video.
8.13 HAND BRAKE TEST (Parking)
Upon completion of the test on the rear axle (front axle when previously set) without moving the car, the
software prepares the measurement of the force exerted by the parking brake. While testing the hand
brake, the friction and irregularity (ovalization tests) are not performed.
The screen shown below is displayed:
8.14 DYNAMIC CONVERGENCY (if provided)
The values of dynamic convergency, or drift, will allow you to assess if the vehicle presents
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deformations due to trim, wear or irregular clearances in the suspension and/or steering arm systems.
The programme threshold is 5 mm.
This check is automatically performed by passing on a special board.
The vehicle final test is completed. The WinInspector programme shows again the screen on rollers exit
(the same explanations provided for the front axle apply).
8.15 PROCEDURE 4X4 MODE
If the vehicle to be tested is provided with permanent four-wheel drive, the testing software for 4WD
mode must be used.
This mode starts the rollers in counter rotation, enabling the rotation of the wheels of one single axle,
with no torque transmission to the second axle.
This procedure is different than the one described above for 2WD vehicles and consists of the
following steps:
- click the box “ 4WD” and “Counter rotation control” and select “Measurement Start”
- get in the roller, that automatically start rotating the opposite direction. The lef roller rotates in
forward direction
- perform the test of the left wheel, according to the instructions displayed on the video (friction,
ovalization, maximum force), until the rollers stop because the slipping limit or maximum effort
permitted on the pedal have been reached
- wait unitl the rollers automatically start, rotating the opposite direction, then test the right wheel.
WARNING: should the deviation of the peripheral speed of both wheels exceed 10% during the
test, the motors immediately stop. The video shows the message “SPEED
DIFFERENCE EXCEEDING 10%”
in this case the test of the concerned wheel must be repeated. If the problem occurs
for two more times, the test is completed and the acquired values are regarded as
valid values.
- repeat the sequence described for the second axle and the parking brake, upon completion of
test, for overall six braking operations, at least
- the braking forces values are displayed, along with unbalance values calculated at equal effort
values on the pedal.
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9 INTERPRETING THE RESULTS

Upon test completion, the software shows the summarizing screen on the test results, along with all the
measured data, that make the test complete.
For practical purposes, the screen is divided into 13 zones, i.e.:
1
2
7
6
3
8 9 10 11 12 13
[1] - Zone showing the test results

[2] - Calculated data for Service Brake, divided into braking efficiency, front and rear axles unbalance.
[3] - Detailed description of the data collected during the test, split per axle and single wheel,
indicating: the Braking force, the vehicle weight, the friction of the moving members with no forcesapplied,
the sheel slipping while braking on the roller, the tyre grip on the roller and finally the ovalization value.
[4] - Data related to the parking brake, the efficiency, unbalane and braking force on right and left wheel
[5] - The zone shows the data concerning the effort exerted on the pedal and/or the lever (with pedal
effort gauge connected) divided per front axle, rear axle, parking brake. The last data identifies the
vehicle overall weight.
[6] - Legend helping in interpreting the graph and in identifying the curves resulting from the meausurement
performed.
[7] - Area of the braking foce graph compared with the force exerted on the pedal (if a gauge for
pedal effort is used). The graph can be displayed on the whole screen by the icon “11” of the
page.
[8] - Icon for numerical report Print
[9] - Icona for Print of reports with graphs
[10]- Upon completion of test, prior to escaping with the icon “porta”, it is possible to store on hard
disk the test just completed, with the relevant details and graphs. The details for this function are
given in the following sections
[11]- Zoom to enlarge over the whole screen the graph resulting from the test; to go back to the
previous screen, click [11] (in addition to this graph enlargement function, it is possible to zoom a
detail of the curves acquired, by click on a spot on the screen. Keeping the mouse key pressed,
trace a sort of square around the required spot on the screen. Release the mouse key. On the
right side of the graph another key is shown, that allows going back to the previous screen (1:1)
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[12]- Option to select or deselect some curves on the graph, for better visual clarity
[13]- Upon completion of test, it is possible to scroll the different acquisition screens displayed during
the test, using the icon “arrow”. The left arrow enables shifting the test performance backwards,
while the right arrow enables shifting forwards. The icon “port” is used to finish the test and
escape (these functions can be operated by remote control, as well ).
As previously mentioned, the software WinInspector besides displaying the test final data, can display
further data, acquired during the final testing, i.e. data concerning a single rear or front axle.
In addition to the above screen, the parking screen can be displayed.
If the test bench is provided with a measurement system of drift or dynamic toe-in, these data can be
displayed both for the front and the rear axle.
10 USING THE DATA BANK
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After selecting the required test, click on OK. The test is available for reference and print, if required.
Should you require to delete some tests, no more used or obsolete, you can cancel them using the mask
shown above. Select the test to be cancelled and click
Cancel ; this procedure must be done for all tests to be deleted.
11 INTERPRETING THE PRINTS
Upon completion of test, three different types of prints can be issued, apart from the type of test
performed (official or brake tests)
- TYPE A - SUMMARIZING NUMERICAL WITH MEASUREMENT UNITS

- TYPE B - NUMERIC AND GRAPHIC E GRAFICA
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12 ORDINARY MAINTENANCE
Ensure the machinery efficiency and its correct operation, it is essential that the instructions given here
below are strictly followed: the ordinary maintenance works are to be performed at least once a month,
anyway not beyond 30 operating hours.
The ordinary maintenance works are to be carried out by authorized personnel according to the
following instructions:
1 Physically disconnect the machine from the power supply (remove the Plug).
2 Remove the roller protection covers.
3 Using an aspirator, thoroughly clean the accessible parts of the module RBT3500. Remove all
foreign matters (earth, stones, rubber).
4 Check the small roller located bwtween the rollers for correct rotation. If the small roller is jerky or
jammy, lubricate with silicone spray.
5 Check the correct operationof the “vehicle present” safety device, pressing and releasing by foot the
balancing safety device located between the rollers; once released, it must definitely return in the
original position.
Should any malfunctioning or failure be detected in the safety devices or other machine members
during the ordinary maintenance works, please DO NOT use the machine and promptly
contact the Technical Service.
13 EXTRAORDINARY MAINTENANCE
ensure the machinery efficiency and its correct operation, it is essential that the instructions given
here below are strictly followed: the extraordinary maintenance works are to be performed at least
every six months, anyway not beyond 200 operating hours.
The extraordinary maintenance works are to be carried out by authorized personnel according to the
following instructions:
1 Physically disconnect the machine from the power supply.

2 Remove the roller protection covers.
3.Remove the remaining covers and guards, allowing easy access to the machine internal components
(motors, reduction gears, chains, bearings)
4.Using an aspirator, thoroughly clean the accessible parts of the module RBT3500. Remove all
foreign matters (earth, stones, rubber).
5 Check that the chains stretching is within the set values (80mm. +/- 5mm.).
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6 Using a greaser, grease all bearings of the supports UCP205 and UCP206 through the greasing
nozzles provided.
7 Using a brush, thoroughly grease the roller pulling chains and rings.
8 Carefully reassemble all covers and guards previously removed.
Should any malfunctioning or failure be detected in the safety devices or other machine members
during the ordinary maintenance works, please DO NOT use the machine and promptly
contact the Technical Service.
14 CHECKING THE CALIBRATION AND THE SAFETY DEVICES
At regular intervals of time, during the ordinary maintenance works, it is a good practice to check the
calibration thresholds, and check the safety systems for correct operation.
The checks are to be carried out as follows:
14.1 CHECKING THE CALIBRATION VALUES OF THE SENSORS
1- Turn the disconnecting switch to the position “1” and switch on the equipment.
2- Wait until the program is loaded and the screen “VAMAG” is displayed.
3- Access the screen on sensors calibration
4- Check that the calibration values match those shown in the table here below.
The allowance for all values is approx. 1500 points.
NB: The check page only shows the signals related to the connected sensors, therefore the sensors
related to WEIGHT, PEDAL, TOE-IN signals (that are optional) may not be shown.
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14.2 CHECKING THE CORRECT OPERATION OF THE SAFETY SYSTEMS
1 - To check the correct operation of the safety devices VEHICLE IN PLACE press by foot the left/
right safety device alternately; when the internal small dots are green, the safety device must be
lowered (vehicle in place).
2 - To check the correct operation of the safety devices ROTATION, slowly rotate the galvanized
small roller located between the rollers and check that the external small dots change their colour
from red to green while the small roller is turning.
15 INITIAL AND PERIODIC CHECKS
15.1 REQUIREMENTS
The initial and periodic checks procedure is related to two essential parameters; if these are lacking, it is
not possible to proceed with this operation.
The first essential requirement is the availability of a software version of homologated type, i.e. it
must be provided with a governmental homologation number proving that its features comply with the
regulations of the Italian Ministry of Public Transport.
The second essential requirement is holding and implementing the metrologic boolets, where all
check, repair and maintenance works are shown and recorded.
Such booklets are released upon written request from VAMAG s.r.l., and carry all the machine
identification data (picture, model, serial number, homologation number).
When the above requirements are met, it is possible to ask an authorized dealer and implement the
metrologic booklets while performing the initial check. This check is subjected to government
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specifications and has one year validity. Upon expiry, the periodic checks must be performed.
The above procedure enables using the machine in overhauling motorvehicles up to 3500 kg, according to
the provisions of the law currently in force.
16 TROUBLESHOOTING T ABLE
FAILURE POSSIBLE CAUSES REMEDIES

COMPUTER AND MONITOR DO LACK OF POWER SUPPLY TO CHECK: PLUG, DISCONNECTING
NOT SWITCH PC, MONITOR. SWITCH, PC SWITCH,
PC, MONIOR FAILURE. MONITOR
THE PROGRAMME IS NOT PROGRAMME CORRUPTED, CONTACT THE ASSISTANCE

LOADED HARD DISK DEFECTIVE, SERVICE
AUTOMATIC START
CONNECTION MISSING REINSTALL SOFTWARE
WININSPECTOR
UPON COMPLETION OF THE FAILURE IN THE ACQUISITION CONTACT THE ASSISTANCE

PROGRAMME LOADING, THE CARD SERVICE
MESSAGE" ANALOG CARD
MISSING, ANALOG CARD
FAILURE" IS DISPLAYED
THE PROGRAMME IS STARTED THE DRIVER VXD IS NOT PERFORM THE CHECKS
BUT INDICATES "DRIVER VXD PRESENT IN THE WINDOWS DESCRIBED IN THE
NOT LOADED" SYSTEM FOLLOWING SECTION. IF
REQUIRED, INSTALL THE
SOFTWARE AGAIN. CONTACT
THE ASSISTANCE SERVICE
UPON COMPLETION OF THE THE CONFIGURATION HAS BEEN CONTACT THE ASSISTANCE
PROGRAMME LOADING, THE TAMPEREDWITH, THE SERVICE
SENSORS CALIBRATION CHECK THERESHOLD VALUES OF SOME
PAGE IS DISPLAYED SENSORS ARE WRONG
THE PROGRAMME STARTS THE RMC BATTERY IS REPLACE TYHE RMC BATTERY,
CORRECTLY, BUT DOES NOT DISCHARGED, RMC FAILURE, CONTACT THE ASSISTENCE
RECEIVE COMMANDS FROM FAILURE IN THE RMC RECEIVER SERVICE
THE INFRARED REMOTE
CONTROL (RMC)
DURING THE TEST , THE THE MOTOR THERMAL RESET THE MOTOR SAFETY
ROLLERS MOTORS FAIL TO PROTECTION DEVICE OF THE DEVICE INSIDE THE RELAY BOX,
START MOTOR IS ENGAGED CHECK CORRECT POWER
SUPPLY BY SUITABLE EQUIPMENT
DURING THE TEST, THE MOTORS ADJUSTMENT THE PROXIMITY CONTACT THE ASSISTANCE
START, BUT STOP AFTER A FEW SENSOR, PROXIMITY SENSOR SERVICE
SECONDS WITH NO COMMANDS FAILURE
GIVEN
WHILE LOADING THE PROGRAMME, PROGRAMME READING ERROR. REPEAT THE START
THE PROCEDURE STOPS AND AN HARD DISK DEFECTIVE PROCEDURE, REPLACE
ERROR MESSAGE IS DISPLAYED DISKETTE, CONTACT THE
ASSISTANCE SERVICE
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17 PUTTING THE EQUIPMENT IN NON OPERATING CONDITIONS
17.1 PUTTING THE MACHINE IN NON OPERATING CONDITIONS
If the machine is kept non operating for a long time, disconnect all supply connections. All components
that could be damaged by dust deposits must be duly protected. Grease all components that could be
damaged if excessively dried at next start up; replace all gaskets mentioned in the spares section.
17.2 FINAL STORAGE / DISMANTLING
When the machine is no longer used, it must be put in non operating conditions. The materials the
machine consists of do not require special treatments upon dismantling the equipment. WHen
dismantling the equipment, all components that are no to be recycled must be conveyed to the authorized
disposal centers. The goods rating according to the disposal degree must be duly assessed. All parts
that can be recycled must be preferably segregated and delivered to the authorized disposal bodies.
18 CALIBER INSTALLATION PROCEDURE FOR BRAKE VERIFICATION
18.1 CALIBRATION CONTROL PROCEDURE FOR ROLLER BRAKE

TESTER RBT 3500 XSQ / XS-QL
To perform calibration check of VAMAG brake tester Mod. RBT 3500XSQ / XS-QL, an in-
depth knowledge of the of instructions and specification written in this manual.
It is also possible to contact a VAMAG assistance centre to ask for information or a
calibration check.
If you have to perform a calibration check for the initial or periodic verification following the
use of the brake tester together with a metrological logbook, please contact the authorised
centres.
18.2 INSTRUMENTS
To perform calibration check of VAMAG brake testers Mod. RBT 3500XSQ / XS-QL you
need to have specific calibration instruments and accessories.
For the Brake test

- CALIBRATION BAR
- CALIBRATION BAR SUPPORT
- WEIGHT HOLDER DISH
- WEIGHT SAMPLES
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18.3 PROCEDURES FOR ASSEMBLY OF THE CALIBER (BRAKES)
Remove the central cover of roller brake tester module by unscrewing the four screws that
fix it to the chassis.
Mount the calibration bar support using the free holes in the gearbox using M10x45 bolts
and their nuts.
Lay the calibration bar on the support, aligning its hole with the hole of the support; fix it by
using the M12x40 bolt and make sure that the bar is perfectly horizontal with a bubble level.
Place the weight holder dish in its foreseen place at the end of the calibration bar.
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18.4 CALIBRATION SEQUENCE (BRAKE)

Remove the metal cover of the amplifiers.
Open the amplifiers aluminium boxes.
Turn on the PC and go to the Periodical check page
Proceed with the load sequence at:

5-10-20-30-50 Kg.
That correspond, thanks to the multiplier factor, the conversion in Newtons, and the
calculation at the periphery of the roller, to:
495N, 990N, 1981N, 2972N, 4953N.
Pag 49 di 54
The calibration bar has a multiplier effect of x10 but in the periodical check page the shown
value is the one related to the roller periphery.
THE WEIGHT HOLDER DISH MUST BE APPLIED ON “RBT 1000/XSQ”
Enter the Periodical Check page using the password “rullo”.

Check that in the right column of the page Periodical Check , the weights steps are
respected with a tolerance of 2% for values above 1000N, while admitted tolerance for
values less than 1000N should be not higher than 20N.
If this is not the case, a correction of sensor calibration will be necessary, working on the
potentiometers inside the amplifier (see ch. 6).
18.5 METROLOGICAL VERIFICATION PROCEDURE OF BRAKE AND

WEIGHT FORCES
Ensure that no pressure force is applied on the sample load cell.

Perform a zeroing procedure on the calibration verification programme installed on the brake
tester PC. Zero the measurer or the software for sample load cell visualisation, then screw
the pressure screw of the vise until it reaches the values shown in the metrological logbook.
Enter the Periodical Check page using the password “rullo”.
Check that in the right column of the page Periodical Check , the weights steps are
respected with a tolerance of 2% for values above 1000N, while admitted tolerance for
values less than 1000N should be not higher than 20N.
If this is not the case, a correction of sensor calibration will be necessary, working on the
potentiometers inside the amplifier (see ch. 7).
18.6 CALIBRATION CORRECTION OF SENSOR FDN 1000 CE
If the measure does not coincide with that of the force applied on the brake sensors,
use a screwdriver on the trimmer Pv (SPAN), placed in the amplifier box; turn the
Pag 50 di 54
trimmer 90° clockwise if you want to increase the measure, or turn it 90° c ounter
clockwise if you want to decrease it.
Complete the sequence of the weight samples.
After the regulation remove the weights from the weight holder dish on the calibration
bar.
Repeat again the measuring procedure applying the sample weights to check that the
correction had the desired effect.
NOTE: If the difference between the sample value and the read value is
large, there might be the need to repeat the procedure described above
many times, as the value correction is within few percentage points o nly.
FDN1000 Amplifier
Screen Gnd
White 0 Vcc
Green + 12 Vcc
Brown or Blue SGN
Exit 12,5 mA=0 Kg
25 mA = + 1000 Kg
0 mA = - 1000Kg
Pag 51 di 54
Roller Brake Tester RBT3500 XS-Q Instruction Manual and Maintenance
18.7 CALIBRATION ADJUST FOR WEIGHT SENSORS
If the measure does not coincide with that of the force applied on the lead cells, use a screwdriver
on the trimmer Pv (SPAN), placed in the amplifier box; turn the trimmer 90° clockwise if you
want to increase the measure, or turn it 90° counter clockwise if you want to decrease it.
After the modification turn the screw of the vise counter clockwise until complete removal of the
force applied on the sample load cell, then perform a zeroing procedure on the console and on the
measurer on display. Repeat again the measuring procedure to check that the correction had the
desired effect.
Schermo Gnd
Bianco 0 Vcc
Verde + 12 Vcc
Marrone o bleu SGN
Uscita 0 – 25mA
25 mA = + 2500 Kg
NOTE: If the difference between the sample value and the read value is
large, there might be the need to repeat the procedure described above
many times, as the value correction is within few percentage points only.
Pag 52 di 54
19 EXPLODED VIEW
Pag 53 di 54
Pag 54 di 54

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Roller Bra ke Tester

Instruction Manual and Maintenance

9 INTERPRETING THE RESULTS ...................................................................................................................................... 37

Capitale Sociale € 115.500,00 int. Versati

Dichiariamo sotto la nostra esclusiva responsabilità che il prodotto

PROVA FRENI RBT3500 XS-Q

According to the provisions of the Directives : 2006/42/CE -2006/95/CE – 2014/30/CE -2014/35/CE

Cassano Magnago, 15 Marzo 2017

Il modello della presente dichiarazione è conforme alla norma EN 45014

1.1 EXPLANATION OF SYMBOL

Warning signal for safety at the workplace.

Electric power hazard signal.

Limbs crushing hazard signal.

Hanging loads hazard signal.

Dangers for the plant safety.

GENERAL INFORMATION FOR USERS

1.2 Cautions and Instructions for Safety

1.3 POSITIONING the identification plate

The identification tag is located both on the Inspector console and in

2 COMPOSITION OF THE ROLLER BRAKE

Roller Test bench

3.2 Using the machine

3.3 Operation not permitted

3.4 General Information

3.5 Personnel selection and qualification

3.6 Safety rules for use

3.7 Safety rules for maintenance and repairs

- the main power supply line must be cut off;

3.8 Rules for works on electrical components

4 Unpacking and Installation

4.2 Recessed Drawings

Note. Recessed Drawings Rollers RBT3500P/XS request in Vamag

4.3 Water Drains Specifications

4.4 Electrical Connections

Before applying power, comply with the following provisions:

4.5 Ducting for Electrical Connections

e- remove the side guards by loosening the 6 fixing bolts;

5.2 Earthing of Rollers

6 Installing the power module

1-2-3 Left Motor

4-5-6 Right Motor

R-S-T-N Power Supply

737 - hardware configuration

737 Jumper Brake

737 Jumper Speedometer

Open the central cover

And you must individuate the PLD cable connection:

PLD cable box

Open this box

Connect the Tracking cable to the TRCK connector:

7 PROCEDURE INSTALL THE SOFTWARE

Run the SETUP.EXE file

7.1 Data Entry Set up

Select the Appropriate configuration for your line:

Follow the check marks indicated by photo

Click "SAVE" to display the following screen:

7.2 Checking the safety device

7.3 Checking the rotation of motors