Operation Manual VIDEOline 2000 with

Suspension Tester FWT 2005 KS-Eusama

Operation Manual

VIDEOline 2000
with Suspension Tester FWT 2005 KS-Eusama

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Operation Manual VIDEOline 2000 with
Suspension Tester FWT 2005 KS-Eusama

INDEX

CHAPTER PAGE

ABBREVIATIONS..................................................................................5

SAFETY INSTRUCTIONS AND PREVENTION OF ACCIDENTS.........6

PRODUCT SPECIFICATIONS...............................................................8

USE OF PRODUCT .................................................................................8

MANUFACTURER ...................................................................................8

1. INITIAL OPERATION ........................................................................9

2. OPERATING ELEMENTS ...............................................................10

2.1 INFRARED REMOTE CONTROL ........................................................10

2.2 OPERATING ELEMENTS ON THE PC KEYBOARD ...............................11

3. TEST SEQUENCE SEMI-AUTOMATIC...........................................12

4. TEST SEQUENCE AUTOMATIC OPERATION MODE...................17

5. BRAKE TESTER EMERGENCY OPERATION ...............................18

6. SINGLE-WHEEL OPERATION........................................................19

7. REPETITION OF DISPLAY .............................................................20

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INDEX

CHAPTER PAGE

8. STORING REFERENCE CURVES.................................................. 21

9. CALLING OF REFERENCE CURVES ............................................ 22

10. LIST OF FILE NAMES .................................................................. 23

11. DATA INPUT AND ADVERTISING TEXT ..................................... 24

11.1 OPTICAL DETECTION OF FAULTS .................................................. 24

11.2 MEANING OF THE KEY "L"........................................................... 25

12. DELETE FUNCTIONS................................................................... 26

13. WEIGHT INPUT............................................................................. 27

14. SERVICE ROUTINE ...................................................................... 28

15. STEERING GEOMETRY TESTING............................................... 32

15.1 TEST SEQUENCE......................................................................... 32

15.2 CALLING OF SDW DATA ............................................................. 33

16. TECHNICAL DATA ....................................................................... 34

DATABASE

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Congratulations!
With the VIDEOline 2000, you have acquired a test equipment of high
quality.

We congratulate you on this decision.

As our products have passed through innumerable in-house tests, it is

safe to say:
This test equipment functions perfectly.

Please, draw your attention to the following points in order to

exclude possible failures:

Keep the units dry!

Avoid intense solar radiation!
Connect the units to a suitable power supply system!

Attention:

Initial operation and repairs must be executed by

authorized personnel.

In case of improper use or wilful damage, no warranty

claim can be made.

Electrical repairs may exclusively be performed by

skilled or authorized personnel.

Only trained personnel is allowed to operate the

COMBIline.

Should, contrary to expectations, a failure occur, please inform

your service centre. We should be pleased to be at your disposal.

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Abbreviations

Description of the abbreviations used in all CARTEC Operation and

Installation Manuals.

Products:

BDE = Brake Diagnosis Unit (roller brake tester)

PROFI = Plate Brake Tester
FWT = Suspension Tester
SSP = Track Test Unit
SDW = Steering Geometry Tester
GST = Joint-Play Detector

General Terms:

FAX = front axle

RAX = rear axlese
HDB = hand brake
FSB = manual hand brake
BBA = service brake
NFZ = commercial vehicle

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Safety Instructions and Prevention of

Accidents
Please adhere to the regulations given in the Operation Manual in
order to avoid accidents and damage to the equipment.

During the brake test, please mind that no one stays

Teststan
in close proximity to the turning rollers.
in

operation
If necessary, please put up railings or marks on the
floor or a signboard with warning lamps.

Should the brake tester be located in the traffic

routes of the workshop or at a place accessible to
the public, the test stand, if not in use, has to be
covered or equipped with railings.

If the brake tester is not in use, the main switch must

be locked in order to block any unallowed operation.

The test stand is only to be operated by observing the power and

maximum speed given in the technical data sheet (maximum switch-
on time of the electric motors 20%).

Vehicles must be driven slowly onto the test stand in order to avoid
unnecessary strain to both the rollers and the vehicle.

Drive off the test stand only while the

rollers are running.

We recommend to inspect the fastening screws of

the cover plates from time to time in order to avoid
damage to the tyres when driving onto and off the
test stand.

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Access to electrical control devices (e.g. exchange of safety fuses),

not controllable from outside, is only allowed to trained personnel.

Before opening the switch cabinet, the system must be dis-

connected from the electric power supply system.

All parts of the electrical system must be kept dry.

Safety devices of the test stand, in particular

initiators and safety rollers, must be inspected
regularly with regard to proper functioning. The
testing rollers must be provided with step-in safety
devices.

It is obligatory that test stands installed above inspection pits are

equipped with safety devices preventing the public from staying
close to the rotating propeller shafts, wheels or test stand rollers.

Do not use the brake tester for purposes other than originally
intended:

a)The brake tester may not be adjusted while the rollers are
rotating.

b) Do not start vehicle motors with the gear of the brake tester.

c) Do not park any vehicel on the brake tester.

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Product Specifications

Use of Product
The VIDEOIline 2000 enables you to perform vehicle tests with
passenger cars quickly and easily. The equipment has particularly been
constructed for fast vehicle diagnoses in workshops.

Simple operation coupled with a quick test run allows you to carry out
time-saving and efficient vehicle tests in a row - only after a short
training period.

Manufacturer

Richard Langlechner GmbH

Konrad-Zuse-Str. 1

D-84579 Unterneukirchen

CARTEC Telefon (08634) 622 - 0

Telefax (08634) 55 01
A systematic approach
to vehicle safety

Product version: Serial Number:

VIDEOIline 2000 See label inside the switch cabinet

Extent of supply:

Mechanics:

track test plate

suspension tester Eusama
roller brake tester
optionally:
steering geometry tester

Accessories:

IR remote control A4 printer

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1. Initial Operation
Turn on the equipment by pressing the main switch.

Turn on the PC by pressing the power switch.

Switch on the monitor.

Switch on the printer (note the adjustment-printer manual).

Start the installation process: * Insert the disk.
* Switch to disk-drive A.
--> MS-Dos command = A:
* Start the installation
programme.
--> MS-Dos command = install
* Further data appear on the
screen that have to be observed
by all means.

The equipment is in the starting phase. After approximately 10 seconds

the programme stops.
Following text appears on the screen: Current date:
New date (dd.mm.yy.):
When the correct date appears on the screen:
confirm by pressing the return key " ", otherwise change
correspondingly.
Following text appears after this confirmation:
Current time:
New time:
When the correct time appears on the screen:
confirm by pressing the return key ( ), otherwise change
correspondingly.
When the blue field with the text "Vehicles in Test" appears, press the
"Esc" key.
After a short period of time the so-called "standby picture" appears.
VIDEOline 2000 is ready for operation.

Notice: When no command is entered into the test line for

more than 10 minutes, the screen protector is started
automatically. When pressing any key (keyboard or remote
control) or when moving the track plate, the screen save is
switched off again.

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2. Operating Elements
You can either operate the VIDEOline via the infrared remote control or
via the keys on the switch cabinet.

2.1 Infrared Remote Control

in combination with SHIFT

function: license weight input
in combination with SHIFT
function: delete license weight
store RAX
in combination with SHIFT
function: input axle weight

store FSB

store FAX
delete axle weight

kg kg
store track RAX no function with COMBIline

7 8 9
drop plates RAX free

in combination with SHIFT func

store track FAX tion: gs and list printout

start normal printout

plates up FAX 4 DATA 055 6
ovality test with running rollers

in combination with SHIFT function:

weight input by 500kg steps
in combination with SHIFT function
500 kg 100 kg weight input by 100kg steps

stop test stand or SDW measurement stop test stand or SDW measurement
delete automatic mode STOP STOP 3 delete automatic mode
0 1 02

put test stand in operation (semi-auto mode)

SHIFT function before driving onto the test stand (autom. mode)

00

SDW display repetition lock and unlock SDW plates

d l

right test stand ON

left test stand ON

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2.2 Operating Elements on the PC Keyboard

Key Function
F1 = store braking values of front axle
F2 = store braking values of rear axle
F3 = store braking values of hand brake
F4 = total weight input
F5 = start FWT VDA
F6 = start FWT HIA
F7 = start steering geometry
F8 = delete all data
F9 = automatic operation mode
F10 = semi-automatic operation mode
0 = printer sheet feed
1 = input customers data
2 = data bank
3 = result printout
[Alt][3] = result printout + coloured graphic representation
4 = call up reference curves
5 = store reference curves
6 = call up FWT VDA measuring results
7 = call up FWT HIA measuring results
8 = list the stored reference curves
9 = repeat SDW display
[Alt][X] = exit test programme
Enter = call up BDE results or end data input
[Strg][T] = call up service routine
[Shift][K] = new image build-up or new identification
= back space

= start screen save

Esc F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 Pause

Strg Alt Alt Strg

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3. Test Sequence Semi-Automatic

Before each new test sequence delete the preceding

test data with the key shown opposite.
The Info-line shown on the right side of the screen is
1 marked grey.

The Beginning of a Complete Test Run:

Drive the vehicle straight and without moving the

steering wheel across the track test plate onto the FWT.
Drive the vehicle with the front axle into the hollow and
switch off the engine.

Start the FWT with the key shown opposite.

The test stand starts to operate first on the right and
then on the left.

Remain seated in the vehicle and await the build-up of

the diagram.

The measured data are automatically related to the

front axle.
Performance curves appear on the screen. In the Info-
line the front part of the "bottom part" of the car is
backed in green colour. Track value and weight of the
front axle are stored as well.

Drive onto the brake tester.

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The roller set starts to operate.

The screen flashes with red background. Wait until

2 flashing is over, then slowly increase the braking
pressure.
The braking imbalance is permanently indicated in the
three-coloured scale shown on the right side.
The maximum recording time of the braking diagram is
15 seconds.

permanent imbalance determination

of the braking forces per axle at any
braking force;
Error diagnosis from "zero to blocking
4
limit"
*green field: braking imbalance ok. Ovality of the brake in percent
*yellow field: brak. imbal. critical
*red field: brak. imbal. too high 3 at any braking force;
Error diagnosis from "zero to
Repair brake system
blocking limit."

kN

Tendency of the braking effect

left-right from "zero to
blocking limit"
display of max. braking force
imbalance during the whole brake
testing process

When blocking one side, one of the measuring beams will turn blue.

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Shall the ovality be measured ?

If yes, press the key shown opposite.

2 (The ovality shall be tested at approximately 2/3 of the
braking force.)
Keep the braking force constant (approx. 7sec.). Then
the right scale, 0 to 60, is coloured (up to 20%: green,
more than 20%: red).

The ovality test is completed.

Increase the braking pressure of the vehicle until the

roller set is stopped through the slippage of one wheel.
The blue colouring of the left or right measuring scale
shows which wheel has triggered off the slippage.

The braking data are related to the front axle.

kg
In the Info-line the front part of the "upper part" of the
car is backed in green colour. The braking diagram
appears in green colour.

Attention!
The brake tester must be put into operation when
leaving it.
2 Wait until flashing is over, then drive the vehicle
from the test stand.

Drive the vehicle with the rear axle into the hollow, then
switch off the engine.

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Start the FWT with the key shown opposite.

Remain seated in the vehicle and await the build-up of

4 the diagram.

Measured data are automatically related to the rear

axle. Performance curves appear on the screen. In the
Info-line the rear part of the "bottom part" of the car is
backed in blue colour. The track value and the weight of
the rear axle are stored as well.

Attention!
The FWT only starts to operate when the weight of
the car is higher than 200 kg.

Drive onto the brake tester.

For the test sequence see front axle.

Store the braking data.

kg

In the Info-line the rear part of the "upper part " of the
7 car is backed in blue.

The roller set starts to operate.

Now the parking brake or the hand brake can be

2 checked.

Store the data of parking brake or hand brake.

In the Info-line the hand brake symbol is underlayed

with yellow colour.
8 No diagram appears.

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The inspection of the vehicle is now completed.

Start the printout

or:

Press "Key 1" (on the PC keyboard)

Customers and vehicle data as well as remarks or advertising text
are changed or fed into the computer.

Start the printout.

Attention!
By means of the PC key combination [Alt][3] the
corresponding diagram will be printed out in colour
when the PC is connected to a colour printer.

(For further possibilities please see "Operating Elements

of the PC Keyboard" of this manual.)

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4. Test Sequence Automatic Operation

Mode

This test sequence is completely identical with the one operated

manually.

Single difference: Before driving onto the brake tester

press the key shown opposite.

2
In this part of the programme the roller set switches
automatically on again and again as long as a vehicle is
on it.

By pressing this key the automatic operation is stopped.

500 kg The equipment changes to manual operation.

STOP

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5. Brake Tester Emergency Operation

VIDEOline 2000 disposes of an emergency running programme.
In other words, if the safety switch is defective, the roller set can be put
into operation via a certain key sequence of the infrared remote control.

Press the key sequence shown opposite; keep the last

key pressed.

As long as this key is being pressed braking tests can

be performed.

Attention!
Always direct the remote control towards the receiver.

It is possible to store the braking values.

Attention!
The test stand starts to operate even if no vehicle is on
the roller set. The slip control is also out of function.

Caution! Tyre damage!

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6. Single-Wheel Operation
In case of light vehicles it is often necessary to test the rear axle via
single-wheel operation. The left or right side are tested separately.

Press the key shown opposite.

As long as the testing process is going on the left roller

0 set is in operation (slip function is active).

Press the key shown opposite.

Same function as left-hand side.

When both wheels are tested, the corresponding axle

can be stored via the infrared remote control.

Start the desired printout.

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7. Repetition of Display

"Key 6" on the PC keyboard:

The result for "vehicle front axle FWT" appears on
the screen.

"Key 7" on the PC keyboard:

The result for "vehicle rear axle FWT" appears on
the screen.

"Key on the PC keyboard:

The total analysis of the braking tests repeatedly
appears on the screen.

"Key 9" on the PC keyboard:

The steering geometry data appear on the screen.

on the remote control:

Calling of steering geometry-measurement data.

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8. Storing Reference Curves

Up to 15 000 vehicles and their axles can be stored in the PC for a long
period of time.
The storage of the reference curves must be completed before the
beginning of the next test sequence or the deletion of the test
sequence.
The data are stored via the desired axle.

"Key 6" on the PC keyboard:

The front axle is to be stored as reference curve.

"Key 5" on the PC keyboard:

Put in, for example, the license number of the
vehicle as file name (max.8 bits). Capital or small
letters are of no importance.

"Key " on the PC keyboard:

The file name is stored.
Now it is possible to store additional information of
up to 70 signs.

"Key " on the PC keyboard:

The complete data set is stored.

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9. Calling of Reference Curves

"Key 4" The curves stored in chapter 8 of this manual can

be called up by means of the PC keyboard for the
sake of comparison between the new and the old
curve (overlapping).

Attention!
When calling up reference curves, the same file name of
the curve as stored under "key 5" must be used.

In order to avoid false diagnoses make sure that the desired axle, which
is to be used for comparison purposes, is really being called up.
In other words, the reference curve of the front axle must be chosen as
the tested front axle of the vehicle.

In order to avoid the printout of the called-up reference curve -for

whatever reason- please feed the computer via the PC keyboard with
the following information:
- put in the number "0" (zero) and the term "ref" without pressing the
spacebar after "0".

(In order to delete the reference curve it is necessary to be inside the

programme part as described under "key 4".)

"Key on the PC keyboard:

The preceding command will be confirmed.

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10. List of File Names

If a stored file cannot be found, it is possible to print out all stored

reference curves by pressing

"Key 8" on the PC keyboard.

Only the files and file names appear on this printout.

Now it is possible to check under which sign or name the reference

curve was stored.

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11. Data Input and Advertising Text

"Key 1" on the PC keyboard:

Feed the PC with personal customers or vehicle
data.

"Key " on the PC keyboard:

Keep this key pressed until you are asked the
following:
"Please select: (W) = advertising text, (E) = error or
(L) = braking limit.

Or press any key to end the data input.

When pressing the letter "W", company related

data can be fed into the PC.

Please note that the address of the company is entered into the upper
three lines. Thus it is made sure that the address of the company
appears in the headline of every test certificate. The three lines at the
bottom are intended for advertising texts, etc. These three lines appear
as footline in the test certificate.
These six lines (head- and footlines) cannot be deleted. The text can be
overwritten in case of a desired change.

11.1 Optical Detection of Faults

It is possible to call up a list of error messages by pressing the key "E"

in the window "W" for advertising texts. This list can be changed or
supplemented (max. 15 lines with 60 signs each) at any time.

How to Change the Text?

Choose the corresponding line by pressing the cursor

+ key.

Press the key shown opposite and the line is marked

red. The text can be now changed correspondingly and
then confirmed by pressing the return key.

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How to Select the Detected Errors?

The errors which are to appear on a second sheet are confirmed by

means of the return key (line background turns black). Leave this part of
the programme by pressing the key "Esc".

Start the test printout.

Note:
If such error messages are required on an additional
printout, this programme part has to be selected as
described above. If no selection appears on the menu
"Optical detection of faults", the normal printout
appears.

11.2 Meaning of the Key "L"

With this key it is possible to select a certain minimum braking force, i.e.
select, for example, 900 N.

If this braking force is reached, the braking beams turn green from
these 900 N onwards. This means that the braking forces are all right.

Note:
If the VIDEO line was made dead, the requested value
has to be fed into the PC again.

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12. Delete Functions

Two keys in the whole testing equipment are intended for the deletion of
data.

on the infrared remote control

"Key F8" on the PC keyboard

By pressing these two keys all variable data such as customers and
vehicle data as well as remarks and all of the values that were
determined with one of the testing devices will be deleted.
In order to avoid wrong testing the memory must be deleted before
each new testing process (with a different vehicle).

Key combination [0][ref] on the PC keyboard:

By means of this key combination the reference curve of the colour
"velvet" will be deleted from the analysis in the FWT testing programme.

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13. Weight Input

If the roller brake tester is to be used as a single unit, the total weight is
necessary for the determination of the total deceleration.

Press these two keys on the infrared remote control.

1
All blue fields of the remote control are now active, and
the weight can be entered.
kg

The input will be confirmed.

In case of a typing error the last entered number

kg can be deleted.

A further possibility of how to enter the total weight:

"Key F4" on the PC keyboard:

The weight must be entered with a four-digit
figure.

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14. Service Routine

The service routine serves to check the individual closed-circuit of force
transducers and initiators. In this case the track plate is also checked.

The following three steps are necessary for check-up:

"Key Strg T" on the PC keyboard:

Following message appears:

"Track calibrating y/n"

If you wish to calibrate the track:

Press "Key J" of the track plate 5mm in one
direction, keep pressing and confirm with "Key Y".

If you do not wish to calibrate the track:

When pressing "Key N" following message
appears:
"Test FWT (1) -- Test BDE (2) Please select!"

"Key 1" FWT When selecting this key the zero points are
represented in mA. The scale sensor represents
them in left and right-hand position, the track plate
represents them in the form of beams.

Example:

See next page.

Press any key to exit. The CARTEC-standby

picture appears.

Now you have to wait for about 30 sec until you can
switch over to the next point of the programme.

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Example:

mA mA mA mA

9 9 9 9

8 8 8 8

7 7 7 7

6 6 6 6

5 5 5 5

4 4 4 4

3 3 3 3

2 2 2 2

1 1 1 1

0 0 0 0
1.0 1.1 0.0 0.0 mA
FWT Force Transducer FWT Force Transducer As with the Eusama principle these
left right two scales are at 0.0 mA.

If the cursors are within the green field, the zero points are all right. If necessary provide new adjustment.

mA

9
Press the spacebar:

8
The scale for the check-up of the track plate appears.

7
When the plate is in central position, the cursor must be in
the green field. 6

Press the track plate to the right, and the cursor moves upwards.
5
Press the track plate to the left, and the cursor moves downwards.
4

0
0.0

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If the values of the BDE are to be checked, press the following keys:

"Key Strg T"

"Key N"

"Key 2"

All zero points are being listed up:

Example:
See next page.

In general, the values are classified into three colour fields:

Green field = all right

Red field = too low (adjust), in respect to the track plate it is all
right
Blue field = too high (adjust)

Press " " in order to leave the service routine.

VIDEOline 2000 is ready for operation after approximately 30 seconds.

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Example: Service Routine BDE (Force Transducer, Pedal Pressure

Transducer, Track Plate)

mA mA mA mA

9 9 9 9

8 8 8 8

7 7 7 7

6 6 6 6

5 5 5 5

4 4 4 4

3 3 3 3

2 2 2 2

1 1 1 1

0 0 0 0
0 0 N 0 kg 0 .0
BDE Force Transducer BDE Force Transducer Pedal Pressure Track Plate
left right Transducer

If the cursors are within the green field, the zero points are all right. If necessary provide new
adjustment.

Example: Service Routine BDE (Limit Switch for Auto Start, Overspeed
Monitor)
Press spacebar:

mA mA mA mA

9 9 9 9

8 8 8 8

7 7 7 7

6 6 6 6

5 5 5 5

4 4 4 4

3 3 3 3

2 2 2 2

1 1 1 1

0 0 0 0
Limit Switch for Auto start Limit Switch for Auto Start Overspeed Monitor Overspeed
left right left right

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15. Steering Geometry Testing

15.1 Test Sequence
Drive with the front wheels right before the rotary plates.
Position the SDW measuring plates centrically to the front wheels.
Remove the guide pins from both rotary plates.
Drive slowly to the middle of the rotary plates and pull the parking
brake.
Switch off the engine.

Press the opposite key.

The test plates are unlocked pneumatically, and the

DATA
SDW testing programme is put into operation.
5 The SDW diagram appears on the screen.

Turn the steering wheel to the left if the cursor on the

screen is pointing to the left and the steering wheel is
moving on the screen.

The measured value appears on the screen

(degree/minute).

Turn the steering wheel to the right only if both cursor

and steering wheel are turning to the right on the
screen.

If the steering wheel is moved earlier, a measuring fault

is inevitable.

The measured values are automatically stored.

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Operation Manual VIDEOline 2000 with
Suspension Tester FWT 2005 KS-Eusama

Attention!
Drive the vehicle off the plates only after the measuring
plates have been pneumatically locked.
(The locking process automatically takes place after the
measurement.)

Both rotary plates must be fixed with the safety pins in order to
avoid twisting (Caution! Danger of accident!).

15.2 Calling of SDW Data

The measured values appear.

Press alternatively

"Key 9" on the PC keyboard: the measured values appear.

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Operation Manual VIDEOline 2000 with
Suspension Tester FWT 2005 KS-Eusama

16. Technical Data

GENERAL
max. axle weight BDE (t) 3 temperature range (C) -20 up
max. braking ratio (kN) 6 without heating to +70
max. axle weight FWT (t) 2 test speed (km/h) 5.5
coefficient dry/wet 0.9/0.7

MONITOR 14
height (mm) 360 colour monitor 16 col.
width (mm) 365 weight (kg) 6
depth (mm) 430 resolution (image spots) 1024x768

CABINET
width (mm) 850 depth (mm) 600
height (mm) 1250 weight (kg) 35

POWER SUPPLY
(V) 380 (kW) 9.5
(Hz) 50 fuse rating slow blow (A) 3 x 25

SENSORY
force transducer BB005KN accuracy at 20 (%) +/- 2
BB010KN

MECHANICS

Brake tester:: FWT - Eusama:

max. test width (mm) 2240 length (mm) 2020
min. test width (mm) 860 height (mm) 250
length (mm) 2340 width (mm) 600
height (mm) 250 weight (kg) 460
width (mm) 700 engine power (kW) 2x3
weight (kg) 370
roller diameter (mm) 200 Track test plate:
roller length (mm) 700 length (mm) 1000
roller displaced height (mm) 25 height (mm) 50
engine power (kN) 2 x 3.7 width (mm) 600
weight (kg) 55

Version 02/94 RW/CS. Technical data subject to change. 34