USER MANUAL

BM 7110 Brake tester for MOT

BM 7110 MOT BRAKE TESTER

MOT

USER MANUAL
BM7110 Brake tester for Class III, IV.

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EDITION

08-2020 Version 3.8

MANUFACTURER

BM Autoteknik A/S
Erhvervsparken 7
9632 Møldrup
Denmark

Telephone: +45 8669 2022

Fax: +45 8669 2199

Website: www.bmtest.dk
E-mail: [email protected]

© BM AUTOTEKNIK A/S

All rights reserved.

No part of this document may be reproduced or transmitted in any form or by any
means, electronically, mechanical, photocopying, recording or otherwise, without
prior written permission from BM Autoteknik A/S.
BM Autoteknik A/S reserves the right to make technical modifications without
further notice.

BM Autoteknik A/S cannot be held liable for technical or editorial errors or

omissions contained herein nor for accidental or consequential damages resulting
from the furnishing, performance or use of this product. The information contained
in this document is provided “as is” without warranty of any kind and is subject to
change without notice.

Bluetooth is a registered trademark of the Bluetooth SIG, Inc. Microsoft and

Windows are a registered trademark of Microsoft Corporation in the United States
and/or other countries.

TO THE OPERATOR

It is strongly recommended that the operator read this manual carefully before
any attempt to use the brake tester is made.

The manual might cover options and features not included in your machine.

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TABLE OF CONTENT

1 SAFETY .................................................................................................................................... 4
1.1 Symbols .......................................................................................................................... 4
1.2 Safety regulation for installation, commissioning and servicing ................................ 4
1.3 Safety regulation for usage .......................................................................................... 4
1.4 Safety regulation for operator maintenance and safety regulations ...................... 4
1.5 Safety precautions – brake testing area ..................................................................... 5
2 GENERAL ................................................................................................................................ 6
2.1 Introduction ................................................................................................................... 6
2.2 Slip system ...................................................................................................................... 6
2.3 Physical display.............................................................................................................. 7
2.4 The BM7110 roller bed ................................................................................................... 8
2.5 The Infra red and cable remote controls .................................................................. 10
2.6 System configuration .................................................................................................. 12
3 UK MOT TESTING PROCEDURE ............................................................................................. 13
3.1 MOT test procedure .................................................................................................... 13
3.2 Conducting the test to DVSA recommendations .................................................... 13
3.3 Conducting the test to DVSA MOT procedures ....................................................... 14
Test procedure by Class of Vehicle ........................................................................................... 14
3.3.1 Precautions entering the roller set. ........................................................................ 14
3.3.2 3-Wheel mode. ........................................................................................................ 14
3.3.3 Test with reverse rotation of the rollers. .................................................................. 15
4 SAFETY ASPECTS AND ERROR CODES ................................................................................. 17
5 MAINTENANCE..................................................................................................................... 18
6 MOUNTING, DISMOUNTING AND SERVICE ......................................................................... 18
7 CALIBRATION ....................................................................................................................... 18
7.1 Brake force calibration procedure ............................................................................ 18
7.2 7.2 Indication of Negative Numbers around Zero readings .................................... 21
8 CONECTIVITY TO DVSA SERVER……………………………………………………………………….21

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SAFETY

1 SAFETY
Please read this manual thoroughly before using the equipment and make sure,
that this manual is placed close to the equipment for reference. BM is not liable for
equipment damages, service costs or personal injury caused by incorrect use of
the equipment.

The BM brake testers are designed with safety precautions that comply with
demands of greatest possible safety while operating the brake tester. Nevertheless,
it is recommended that the owner and the operator are always aware of the
danger present while operating the brake tester. The following outlines general
safety precautions recommended when operating the brake tester.

1.1 Symbols

In-correct use according to instructions can cause damage to persons or

equipment.

Information to the operator, which is of high importance for operating the

equipment correctly.

1.2 Safety regulation for installation, commissioning and servicing

The equipment may only be installed, commissioned and maintained by BM
authorised service engineers.

Gloves must be worn when handling the equipment, including but not limited to all
cover plates, rails and drive on/off ramps.

1.3 Safety regulation for usage

Only operators trained by authorised BM Training Officers may use the equipment.
Keep unauthorised persons away from the equipment.

1.4 Safety regulation for operator maintenance and safety regulations

The operator must check the chain tension once a week, and then fill in
corresponding log-book.
Keep rollerbeds clean and remove mud from the roller surface to ensure a good
friction against the tire.

Check periodically that the middle roller is running freely in both roller beds.

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SAFETY

1.5 Safety precautions – brake testing area

It is preferred to place the brake tester in a designated and clearly marked area:

“ TESTING AREA - FOR USE BY AUTHORISED PERSONNEL ONLY”

When the brake tester is NOT IN USE:

• A vehicle should never be left standing on the rollers as this can cause the
rollers to start if automatic operation is accidently engaged.
• If supplied, it is recommended that separate roller cover plates should
always be placed over the rollers.

When the brake tester is IN USE:

• No persons should be allowed near the rollers.
• No persons should be allowed examining or working on the wheels or
under the vehicle for any reason at all.

The brake tester should not be left switched on while unattended.

Where the test area is inside a building we recommend provision is made to

extract the exhaust gases from the vehicle being tested.

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BM 7110 Brake tester for MOT
GENERAL

2 GENERAL
2.1 Introduction
The BM7110 brake tester is an advanced microprocessor based brake tester for
test of light vehicles. The brake tester BM7110 are designed for test of class I, II, III,
IV,
The brake tester is marked with the following machine label, that shows electrical
requirement:

The brake tester is operational within environmental temperature range from –10
°C to + 50 °C.

The brake testers consist of a roller set and a display. The roller set consists of an
integral motorised gearbox, two main rollers and a spring loaded sensor roller, all
placed in a galvanized steel frame.

The main rollers are supplied either with a synthetic coating made of an
epoxy/flintstone compound, stretch metal or with a ripped steel cover. The main
rollers are connected to the motorised gearboxes with a chain. The brake force is
transmitted through the chains and the motorised gearboxes to the brake force
transducers.

2.2 Slip system

The brake testers are equipped with a speed sensing system that enables control
of the wheel lock situation.

During a brake application, the brake tester determines the slip between wheel
and main roller continuously. If the slip value exceeds a reference value, the
computer automatically stops the gear motor. The reference value is set from
factory, so slip is defined in range between 20 – 30 %.

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GENERAL

2.3 Physical display

The display is made of aluminum and contains a gauge with a brake force scale
from 0 to 620 kgf.

The ARROWS in the digital windows show when rollers are running (flashing) and if
one or both side has locked (remains on after wheel lock) The wheel lock arrows
do not remain illuminated if the wheel fails to lock after the roller are stopped, or,
the axle exits the rollers during the brake test. The DOTS in the digital windows
shows if the brake tester is running in manual or automatic mode.

The 2-digit display shows the error code 01 if only one wheel of an axle is in the
rollers

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GENERAL

2.4 The BM7110 roller bed

The roller bed of BM7110 is in principle a split bed unit:

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GENERAL

BM7110 DESCRIPTION
Roller bed LxWxH 910 x 800 x 220 mm
Roller diameter 182 mm
Roller length 600 mm
Friction coefficient of roller from factory dry/wet Min 0.7/0.6
Min. wheel span (can be customised) 880 mm
Max. wheel span (can be customised) 2080 mm
Distance between roller centres 350 mm
Max. test axle weight 3500 kg
Gear motor size 3.8 kW
Max brake force measurement 600 kgf
Test speed 4.5 km/h
Display LxWxH 735 x 500 x 140 mm
Display brake force scale 0 – 620 / 1500 kgf
Brake force measuring accuracy 0 – 100 kgf: ± 2 kgf
> 100 kgf: ± 2 % FS

0 – 100 kgf: ± 2 kgf

> 100 kgf: ± 2 % FS
Power and fuses 3 x 400 Vac + N + PE
Minimum 13/20 Amp

3 x 230 Vac + PE
Minimum 20/35 Amp

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GENERAL

2.5 The Infra red and cable remote controls

The key label of the BM Infra Red remote control unit is illustrated below.

The infra red remote control has an operation distance of 15-20 meters, depending
on the operation conditions.

DO NOT increase pressure on keys to increase range - it will only brake the key
pad! Instead make sure that the remote control can transmit without physical
obstruction.

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GENERAL

Start both roller sets.

Start left and right roller set

Not Used

Not used

Not used Shift between revesible (4x4) and normal test mode.

Start left or right roller set for reversible test mode for 4wd vehicles.

Stop roller set.

Not Used

+ , or Start motor brake.

Not Used

Shift between normal and 3-wheel mode.

Not Used Configuration keys. For use by service

engineer only

Not Used

SPECIAL FUNCTIONS

Test in automatic mode

1. Press on the remote control or on the display.

2. Drive the axle on to the brake tester (the brake tester will start after 4
seconds) and perform the brake test.

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GENERAL

Cable remote control has cable of 15 meters.

The key icons are similar on the two types of remote controls. However, on the
cable remote control unit following keys are “second value keys”: These keys are
not active on an MOT braketester

Optionally the brake tester can be supplied with options for test of 4x4 driven
vehicles and also for bi-directional test.

2.6 System configuration

The BM7110 can be supplied in following variations:

• BM7110 with physical display and cable remote control. The cable remote
control is installed to the physical display.

• BM7110 with physical display and IR remote control. The IR receiver unit
installed inside the physical display.

• BM7110 with physical display and IR and Cable remote control.

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BM 7110 Brake tester for MOT
SAFETY ASPECTS AND ERROR CODES

3 UK MOT TESTING PROCEDURE

3.1 MOT test procedure

3.2 Conducting the test to DVSA recommendations

If at any time the vehicle wheels leave the roller bed (this is most likely during the
park brake test), the vehicle will not have been given the best opportunity to meet
minimum requirements.

There are two reasons for this:

• The maximum available brake force cannot be recorded if an axle

‘jumps’ out of the rollers.
• A vehicle wheel ‘lock’ will not be recorded if the axle jumps out of the
rollers, this means that the ‘automatic pass on locks’ requirement can
never be fulfilled. This can result in a vehicle being ‘Failed’
unnecessarily under DVSA UK regulations.

If a vehicle fails to meet minimum requirements and an axle had left the rollers
during testing BM recommend the following remedies to be tried in this order:

1. Relocate the axle in the rollers, and place wheel chocks behind the wheels of
the other axle. If the wheels of the axle resting on the floor are fitted with the
park brake, then engage the park brake.

2. If remedies 1 and 2 fail, then remove the vehicle from the brake tester and
conduct a decelerometer brake test.

Cable remote control has cable of 15 meters.

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3.3 Conducting the test to DVSA MOT procedures

To conduct a MOT brake test, follow the test procedure as set out in the latest version of
the DVSA’s "MOT. Inspection manual for class 3, 4 and 7 vehicles":

https://www.mot-testing.service.gov.uk/documents/manuals/class3457/#

Test procedure by Class of Vehicle

Testing the Front Axle
Step:
1. With the RBT switched on drive into the rollers.
2. Start rollers and allow vehicle to centralise for 2 seconds.
3. Gradually apply the service brake until wheel lock occurs or maximum brake effort is
achieved, release the brake and store results.
4. Rollers restart and note/record any significant brake effort from a wheel without any brake
being applied.
5. With the rollers still running gradually apply the service brake and watch how the braking
effort for each wheel increases, continue until just before wheel slip occurs (noted from
step 2) . If wheel slip does occur then step 4 must be repeated. Gradually release the
service brake and note/record how the brake effort at each wheel reduces then stop rollers.
6. If the parking brake is on the front wheels rollers start and step 2 is repeated but applying
the parking brake instead of the service brake. Store the results

Testing the second axle

Step:
1. If the parking brake is on the second axle move the vehicle forward so as the second axle is
in the rollers, allow 2 seconds for the vehicle to centralise then gradually apply the parking
brake until wheel lock occurs or maximum brake effort is achieved, release the brake and
store results.
2. Rollers restart and conduct steps 2, 3, 4 & 5 on the second axle

3.3.1 Precautions entering the roller set.

When entering the rollerset ensure that the speed of the vehicle is reduced to 2-4 km/h.
This speed will reduce risk of damaging the vehicle from compressing the suspension
system to an extent where the vehicles spoilers or other components touches the brake
tester body.

3.3.2 3-Wheel mode.

In order to run in this mode the operator has to select the 3-Wheel mode on the front of

the cabinet or use remote control unit (see section 1.2).

Basically, this mode allows the operator to start one side of the rollerbed, if the middle
roller of this one side is pressed down.

NOTE: When the brake tester is in 3-Wheel mode, an ERROR CODE will occur if both middle
rollers are pressed down.

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3.3.3 Test with reverse rotation of the rollers.

"REVERSE direction of main rollers is only possible in MANUAL mode"

This facility is normally used for testing constant 4-wheel drive vehicles. You can shift to this
mode on the remote control by pressing once the key 2x4/4x4. The selected mode is
shown in the display.

Note that during test only one side (left or right) will reverse (see the procedure below)

Service brake:

1. Drive axle into the rollerbed

2. Select Reverse mode by pressing once on key on the remote control.

3. Start Left rollerbed. Left rollerbed is now turning in reverse, so you are therefore
testing right wheel, which is turning forward. Apply brake pedal slowly until you
reach maximum brake force either at lock or by pressing STOP when highest brake
force is reached.
4. Take note of brake force value and whether the wheel locks
5. Start Left rollerbed again – you are there still testing right wheel.
6. Apply brake force to app 70-100 kgf and maintain a constant pedalforce. Observe
for and take note of excessive brake force flucturation (ovality)
7. Increase and reduce brake pedal force slowly and observe for and take note of
flutter, judder og any other fault.
8. Repeat same procedure for other wheel.

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Parking brake:
1. Drive axle into the rollerbed

2. Select Reverse mode by pressing once on key on the remote control.

3. Start Left rollerbed. Left rollerbed is now turning in reverse, so you are therefore
testing right wheel, which is turning forward. Apply brake pedal slowly until you
reach maximum brake force either at lock or by pressing STOP when highest brake
force is reached.
4. Take note of brake force value and whether the wheel locks
5. Repeat same procedure for Right wheel

3.35 Brake Efficiency

Total up the braking effort recorded from all the wheels of the vehicle when the service
brake is applied. Total up the braking effort recorded from the appropriate wheels when
the parking brake is applied.
Calculate the service brake and parking Calculate the parking brake percentage
brake percentage efficiencies by following efficiency by dividing the total brake effort
the procedures detailed below according achieved when the parking brake is
to the Class of vehicle tested. Class IV applied by the vehicle DGW and then
Vehicles multiplying the result by 100, as above.
From the presented weight calculate the
percentage efficiency by dividing the total
brake effort achieved when the service
brake is applied by the vehicle weight and
then multiplying the result by 100.
i.e Total brake effort x 100 = % Efficiency
Vehicle Presented Weight
Calculate the parking brake percentage
efficiency by dividing the total brake effort
achieved when the parking brake is
applied by the vehicle weight and then
multiplying the result by 100, as above.

3.36 Brake Out-of-Balance

The out of balance of the braking effort on the front steered wheels when the service
brake is applied is obtained by comparing the brake efforts at each front wheel when
they are tested simultaneously Carry out the following calculation to determine the
percentage imbalance:
(Higher brake effort - Lower brake effort) x 100 = % imbalance
Higher brake effort

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4 SAFETY ASPECTS AND ERROR CODES

The BM brake testers have integrated safety systems which meets the highest
safety demands.

The design is made with the objective to reduce the risk of having a foot
damaged in the roller set. All gaps are minimised and the gear motor will only run if
pulses are measured from the middle rollers. If middle rollers are stopped during
test by a foot, the gear motors will stop.

The gear motors will only start when the middle rollers are detected to be in its
down position (axle in the roller set). This detection is hardwired, which means that
even though the machine was forced out of its normal program, the brake tester
will still not start unless middle rollers are physically pressed down.

The imbalance window display is used to inform the operator of various situations:

Code 01:
In Manual and Automatic mode the two sensor rollers must be pressed down or
released within 2 seconds. The imbalance-display will flash the ERROR CODE 01 if
one of the sensor rollers are pressed down or released in more than 2 seconds.
Remove the vehicle from the roller bed in order to remove the ERROR CODE from

the display or press . Error code 01 can also appear if an inductive speed
sensor is defective or a cable is broken. In this case the error doesn’t disappear by
removing car.

Code 02:

Will appear when you have chosen 3-wheel mode by pressing and both
sensor rollers are pressed down. Single sided test only allows you to test one wheel
(press down one sensor roller).

Code 04:
If you start the tester and let it run for more than 1 minute without using it (the
measured brake forces do not change), the brake tester will automatically stop
the rollers and the imbalance-display will flash the ERROR-CODE 04. Remove the
vehicle from the roller bed in order to remove the ERROR CODE from the

imbalance-display or press .

Code 09:
A status code indicating that the integrated calibration printout is active. After the

calibration is finished, place the SERVICE SWITCH in position N and press .

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CALIBRATION

5 MAINTENANCE
In order to ensure a correct operation of the BM brake testers the following
maintenance procedures are recommended:

EACH DAY:
Ensure that the drive chains are tightened. A loose chain is likely to cause gear
motor failure. If the chain is loose then tighten it before use, or call for service
before use.

3-MONTHLY:
Ensure there is no vehicle placed in the roller bed.
1. Power off the brake tester.
2. Check the general condition of the brake tester. Remove any mud, grease
etc. from the rollers, roller bed and the pit. It is important to keep the
draining holes in the bottom clear and free of dirt, etc. in order for water to
leave the brake tester, otherwise the tester can be ruined by corrosion.
3. Ensure that nothing prevents the middle-rollers from revolving or from being
pressed down.
4. Check the bearing bolts on the main rollers for tightness.
5. Check the chains for correct tension.
6. Lubricate the chains.
7. Debris beneath the rollers can affect the weight measuring and potentially
stop the drain. Clean garbage from the brake tester.

CALIBRATION:
1. It is recommended to perform a calibration check of the brake force and
weight measuring system twice a year. The frequency of calibration is
dependent on current national government requirements.

Furthermore it is recommended to arrange a service contract with your supplier of

the BM brake tester.

6 MOUNTING, DISMOUNTING AND SERVICE

Only personnel trained by BM should perform mounting, dismounting and servicing
of the BM brake testers. Ensure that the service engineer is certified by BM
Autoteknik Denmark. Please contact your supplier for further information.

7 CALIBRATION

7.1 Brake force calibration procedure

The following procedure describes how the brake force measurement system is
calibrated.

1. Remove vehicle from the roller bed.

2. Power off the brake tester.

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CALIBRATION

3. Take off the top of the brake force amplifier box, which is located just
beside the gear motors.

4. Power on the brake tester.

5. In order to do a zero point adjustment, place the SERVICE SWITCH in position

"0".

6. Adjust the "0-POINT" gain at the left side amplifier board until the readout is
300 kgf +/- 150 kgf.

7. Place the calibration rig in the roller set.

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CALIBRATION

8. In order to do the calibration of the brake force gain, place the SERVICE
SWITCH in position G. This will auto-zero the force of the rig.

9. Place the loads at required "load marks", which is located on the arm of the
calibration rig. Make sure, that both loads and arm is correctly marked for
use with the particular model of brake tester.

10. Adjust the "GAIN" of the brake force amplifier board until the gauges read
out a load corresponding to the "load marks" on the calibration rig.

11. Take off the load.

12. Place the SERVICE SWITCH in position N (Normal operation).

13. Repeat step 8-12 until no further adjustment is necessary.

14. Take off the calibration rig.

15. Repeat step 5-6.

16. Place the service switch in position N (Normal operation).

17. Mount the top of the amplifier box again.

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CALIBRATION

7.2 7.2 Indication of Negative Numbers around Zero readings

If during calibration the adjustment of the output is adjusted below Zero this will be
indicated by:

A) For Machines with an analogue display showing Brakeforce:

The pointer when decreased to Zero will start to rise again as the adjustment
drops below Zero into negative values.
To assist the calibration engineer in distinguishing between positive and
negative values, the ‘run’ arrows on the display will illuminate when Negative
values are displayed.

B) For machines with a PC monitor virtual display showing brakeforce:

The pointer when decreased to Zero will start to rise again as the adjustment
drops below Zero into negative values.
To assist the calibraton engineer in distinguishing between positive and
negative values, three dashes (---) will show on the digital value indicator in the
centre of the dial when Negative values are displayed.
C) Weight Display:
Negative weight values will be displayed with a minus(-) prefix to the number.

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CALIBRATION

8. Connectivity to DVSA server. ATL.

Registration of the vehicle on the DVSA web interface will create a test file that will be sent
to the braketetser PC queuing screen, select this vehicle and press ‘do braketest’ to initiate
testing.

braketesters fitted with a DVSA connectivity package, the brakeforce data needs to be
registered after testing each wheel or each axle.

Service brake forces are registered using the footbrake key on the remote control.

Parking brake forces are registered using the park brake key on the remote control.

The Total key transfers the brake force data to the PC interface for to upload to the DVSA
server.

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CALIBRATION

Visual inspection items can be added in the PC queuing menu.

The test is completed and data uploaded to the DVSA server using the ‘Finalise ‘ button on
the queuing screen.

The test data will be evaluated by the DVSA and the result transferred via the DVSA MTS
web interface. The test will be cleared once the Pass/fail certificate is printed via the MTS
web interface.
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CALIBRATION

1. Connectivity to DVSA server. MOT

Registration of the vehicle on the DVSA web interface will create a test file that will be sent
to the braketetser PC queuing screen, select this vehicle and press ‘do braketest’ to initiate
testing.

braketesters fitted with a DVSA connectivity package, the brakeforce data needs to be
registered after testing each wheel or each axle.

Service brake forces are registered using the footbrake key on the remote control.

Parking brake forces are registered using the park brake key on the remote control.

The Total key transfers the brake force data to the PC interface for to upload to the DVSA
server.

Once the data is received by the PC program, the finalise button at the lower right of the
screen will become ‘live’ press this button to send the test data to the DVSA.
The test will be cleared once the Pass/fail certificate is printed from the MTS web interface.

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