WHEEL ALIGNMENT Operation Manual Model No.: JA1001WH
We have made every attempt to ensure that the information in this document is accurate and complete. However, We assume no liability for any damages that result from the use of this document or the equipment which it accompanies. We reserve the right to make changes to this document without notice at any time. Safety Precautions It would be damage the machine and dangerous to the user and other people around, if users don t abide by the safety precautions in this chapter or the safety precautions in other chapter of this manual Please don t switch on the power if you didn t finish reading the safe precaution, or didn t totally understand the safety precaution in this manual. The operator of the aligner machine must be the person who trained by our company. Due to the reason that the difference of the use method, tools, the spare parts of the vehicle and the difference technical level of the operators, this manual couldn t to provide to the user all the suggestion and the safety information in every side. Therefore, based on the aware of the repairing technique of the testing vehicle, the operator must actually understood the alignment principle. Before using UNITE alignment machine, the operator must be aware of the system of the vehicle which to be tested, also be aware of the requirement of the operating and safety of the other equipment which use together with the alignment machine, such as the shelf and the lift. Before using this machine, please refer and abide by the safety information and the repairing procedure provided by the vehicle maker. Important! Keep this instruction information, don t throw away! Power safety: Important! Please save this information
In case the machine is failure to work, please ask the professional technician to repair and then operate. The power supply voltage must be equal to the equipment s rated voltage. Keep the equipment dry. If don t use the equipment, please pull off the power cable. Please catch the plug when pull off the cable, don t pull the cable directly. Keep cable earth connect well. It s dangerous to be approach to the high voltage power!! Danger! Electricity! High voltage in cabinet There are key board, printer, charger and switches in the cabinet. The maintenance of the main cabinet must be done by the professional service technician. Please don t open any part outside of the marks. Please switch off the power of the main cabinet before the repairing. Protect eyes. Please take the safety goggle during the working. Be careful the crash from the equipment and the vehicle. Correct setting of the gear(automatic and manual). Except for the requirement of the operator s manual. Keep the vehicle brake, unless the manual require the wheel running. Please use edge to stop the wheel while the vehicle on the lift. Please refer the safety precaution provided by the manufacturer when the vehicle will be lift. Please be careful while using the jack lift the vehicle. Incorrect using and maintenance will cause the injury or death to the person. The irrelative people must be told don t enter into the equipment working area. Be careful of scalding! Don t touch the hot exhaust system, engine and the radiator. Please take the gloves while work near the high temperature system.
Incorrect using of the tools will cause the broken of the tolls and cause the injury to the person.
Contents 1 Introduction 3 1.1 Safety precautions... 5 1.2 Power interruption... 7 2 The basics 6 2.1 Starting the program... 6 2.2 Exploring the screen... 8 2.3 Start measurement... 9 3 Quick tour 8 3.1 Customer data... 8 3.2 Load car form database......9 3.3 Vehicle information... 10 3.4 Ready Run-out compensation... 11 3.5 Start Run-out compensation... 12 3.6 Caster measurement... 14 3.7 Measurements... 16 3.8 Adjust rear... 21 Additional adjust..18 3.9 Adjust front... 19 3.10 Measurements... 22 3.11 Main menu... 23 4 Alignment setup 25 5 CCD calibration 27 6 Increment vehicle data 28 6.1 Load vehicle... 28 6.2 Modify vehicle specification... 29 6.3 Delete vehicle parameter 30 7 Radio communication 31 7.1 Charging the measuring units... 31 7.2 Power down mode... 31 7.3 Communication problems of low battery... 31 7.4 When to use the cables... 32 7.5 About battery... 32 8 System components 33 8.1 Machine cabinet... 33 8.2 Accessories... 33 8.3 Measuring unit... 34 8.4 Cable connections... 35
1.Introduction This manual provides operating instructions and information required to operate the CCD wheel alignment computer equipped with the dsdemo.exe graphical alignment software. It is recommended to read the manual in the order presented. The Quick tour chapter will provide the basic information needed to operate the aligner through a total four wheel alignment. Notation: All actions are printed as bold type so it is easily understood which action is required by the operator. Between the bold type items are illustrations and explanatory information to guide you through the operation. The manual assumes customers are already familiar with the basics of wheel alignment. When reading the Quick tour chapter, minimum information is provided about how to operate the aligner. More detailed information can be found by reading the sections referenced to in italics. These references should be read as needed for additional information to the instructions presented. 1.1 Safety precautions Read and follow all cautions and warnings printed in this manual and on the equipment. Misuse of this equipment can cause personal injury and shorten the life of the equipment. This unit must be plugged in to properly ground outlet. Do not cut off the grounding prong on the AC power cord. If using a ground adapter, be sure the pigtail is grounded to the power receptacle. If an extension cord is needed, use a three-wire type with the grounding circuit in good condition. Grounding this equipment is essential for its safe and correct operation Use a separate outlet for the mains supply suited for computer equipment. Do not connect lifts, tire-changers, welding-machines etc. to the same outlet since this may cause the aligner to malfunction or cause seriously damage to the aligner. Turn off the power before moving the system cabinet. The aligner is equipped with a hard disk which may be damaged by vibration. When the power is off the read/write heads are parked and the unit may be moved safely. The equipment should be stored and kept in a dry condition. The equipment is not weatherproof and should not be used outside in rain or snow. Always use wheel chocks in front of and behind the left rear wheel after positioning a vehicle on the rack.
1.2 Power interruption The equipment constantly stores the state of the measurement and the values recorded. If AC power to the system is interrupted, or if the unit is turned off, any measured alignment information will not be lost. When power is restored and the program is restarted, operation will resume from the point at which the power failed.
2.The basics This chapter will familiarize you with the main components of the dsdemo.exe screen and beach you a few basic skills you will use every time you work with the program. You will learn how to: Start the alignment program. Interpret the contents of the standard screen layout. Use the keyboard and push-buttons to select an item. Initiate a guided tour through the alignment procedure. 2.1 Starting the program Turn on the power of the machine. After the computer was started, input the password of WINDOWS and entered into the WINDOWS system, double click the desdomo.exe icon on the Desktop, and entered into the desdomo.exe wheel alignment program. See the picture as the main menu, remember this appearance is a diagraph that main menu, because we adjust in hereafter the process want to use this main menu many times single. 2.2 Exploring the screen The following section describes the main components of the main menu 2.2.1 The screen header The screen header displays the icon related to the header text, the text display, minimize and close button. 2.2.2 The display area In this area the information related to the specific page and push-buttons linked to the application of the page are displayed. 2.2.3 Button area(the screen footer) The button area contains the push-buttons with icons related to the currently selected screen, and the operation of the related selected screen. 2.2.4 Shortcut menu When the mouse is moved to the shortcut menu icon, which will appear it s a shortcut menu, click the icon, the shortcut menu window will be opened.
Button operation 2.2.5 Push-buttons:The push-buttons can be selected by the use of the mouse. The buttons on the screen footer can also be activated by pushing the function keys on the keyboard. F1, F2, F3 corresponds to the first three keys, F5, F6, F7 to the next three. In all alignment screens (except the main menu) this will lead you to the previous or next screen in the natural order of the alignment procedure. Notation: The Header Text will tell us the main function of this screen. 2.3 Start measurement Choose the Start a new measurement button by use of the mouse. This will initiate a guided measurement of the alignment angles. Notation: If have completed to measure once, this button will delete the result measurement of the last time. The customer can keep the result measurement of the last time according to the demand. Run as follow the diagram after pressing:
The button icon and the header text is very clear, hereby no more repeat.
3 Quick tour The following chapter describes a typical four wheel alignment procedure. The flow-diagram shows how a complete measurement and adjustment is performed. Begin new measurement Edit customer data Load car form database Run-out compensation Caster measurement Adjust front and rear Print and Save measurement The dotted line arrow of the diagram means if the Caster is adjusted, then it s need to be measured again. Press Begin new measurement in the main menu,the screen will change to the Customer data screen. 3.1 Custom data
Move the cursor to the desired input field. Press and write the required information using the keyboard. If a customer has been entered previously, the stored data can be retrieved by selecting from the scroll lists After complete the input of the customer information, press Page Down on the keyboard or press next step button (it is the third one from the left side); Notation: If a customer has been retrieved from the list, it is possible to retrieve the latest stored measurements for this customer, it could be retrieved by activating the push-button Load measurement. At this time the screen will be change to the Load measurement screen;it could be retrieved as per time.
3.2 Load car from database This screen is used for loading the alignment specifications for a specific vehicle. Choose manufacturer, model and year represented in the three columns. As picture above, the car we selected as follows: manufacturer: TOYOTA, Model: T-100, Year:98-. Notation: Load car from the database. 1.Choose the model from : a. total model, b. import model, c. domestic model, which the car belong to. And then input the initial letter of the model to search the model. 2.Imput the keyword directly to search the model. 3.The icon modify add and delete, which can be pressed to modify add or delete the standard specification of the vehicle model. Press Next Step, when the vehicle has been loaded. The screen will change to the Vehicle information screen. 3.3 Vehicle information This screen shows different information regarding the correct setup of the vehicle for alignment measurement as per different vehicle model. See the picture below, which ask the operator to check the air compress of four tyre.
Position the vehicle on the alignment rack with the front wheels centered on the turntables and the rear wheels on the slip-plates and apply the parking brake. Notation: In order to avoid flushing of elec. turntables and slide- plates with the floor or the platforms of the lift, it is recommended to place the slid-plates and turntables after the run-out compensation has been performed and then lower the vehicle. Otherwise damage to the elec. turntables may occur. Before lower the vehicle, take out the lock pin of the elec. turntables, and push the elec. turntable inward for 1-2cm, in this way, the wheel will be posited in the center of the elec. turntable after lower the wheel. Lift the vehicle to the alignment height. Notation: In order to ensure correct alignment, the alignment rack must be in level in transverse and longitudinal directions. In left and right the level difference is not allowed over 2 mm, in front and back the difference is not allowed over 3 mm. Check for correct tire size and pressure. Check for weakened coil springs (vehicle may be leaning to one side). Turn the steering wheel from side to side and feel for excessive play. Check control arms and tie rods for possible wear or damage. Check ball joints and bearings for wear or damage. Visually inspect rims for signs of damage or excessive run-out. Badly damaged rims must be replaced. Press Next Sept when the vehicle has been set up correctly. The screen will change to the Run-out compensation screen.
3.4 Ready for run-out compensation This screen initiates the actual measurement of the vehicle. Before performing the run-out compensation the measurement must be prepared in accordance with the following procedures: Attach the clamps to the rims and check that the clamps are secure. The clamps can be fastened to the rim either from the inside to the outside or vice versa by turning the star grip. For alloy rims special adaptors are available. Level the units according go the electrical levels and tighten the locking pins. Check for infra red beam are shaded. Connect the electronic turntables. When the run-out compensation procedure has been initiated, the lamps on all four units should light continuously red. If this is not the case you should either initiate a new measurement from the main menu, or you should push the ZERO button on a measuring unit or on the screen to reset the current compensation values. Lift the vehicle. The compensation may be started with any wheel. If all four wheels cannot be jacked during compensation, it can be preferable to start with the wheels held by the handbrake, in this way ensuring that the vehicle will not roll away when lowered. Lift the vehicle 3cm off the ground of the lift. When compensating one of the drive wheels beware that the other wheel does not rotate. It may be necessary to chock the wheel to prevent it from rotating. If a measuring unit is removed from any wheel this wheel must be compensated again when remounted.
3.5 Start Run-out compensation The compensation may be started with any wheel. The process is as follows: 1.Loose the locking screw on the unit and turn the wheel until the clamp is in vertical position and the star-grip in upper position. 2.Set the unit go horizontal position. (See the picture above, the line around the yellow lamp will turned into green.)the arrow at the 90 degrees position will change the position. Simply click on the picture above, it will turn clockwise, we will complete a repair of wheel four times like this and again and again. 3.Turn the wheel 90 degrees clockwise until the clamp is in the horizontal position with the star-grip to the right. 4.Press the compensation button. The arrow at the 91 degree position disappear, appear at the 180 degrees position. 5. Turn the wheel 90 degrees clockwise until the clamp is in the vertical position with the star-grip in the lower position. Press the compensation button.
6. Turn the wheel 90 degrees clockwise until the clamp is in the horizontal position with the star-grip to the left. Press the compensation button. 7.Turn the wheel 90 degrees clockwise until the clamp is in the vertical position with the star-grip in the upper position. Press the compensation button. The screen shows a green circle to indicate, that the run-out compensation has been completed for this wheel. Notation: Fig. 3.5-1
If the screen shows a red value, it indicates, that the wheel has excessive run-out. The angle shown is the run-out, while the line indicates the direction of the maximum run-out. The maximum run-out accepted without warning can be changed in the program setup. Although the aligner will calculate the correct alignment angles even though the wheel has excessive run-out, it should be checked if all claws on the clamp are mounted correctly or if the rim is damaged. Repeat this procedure for the remaining wheels. Notation: Secure the installation of the clamp. When the wheel has been compensated, the wheel may be rotated to any position without any influence on the measuring accuracy. The compensation procedure can be repeated for any wheel by pressing the compensation button on the corresponding unit. The lamps on the unit turn red and the procedure can be repeated for this wheel. To restart the compensation procedure for all wheels press the ZERO-button on a measuring unit or on the screen. Lock the brakes with the brake pedal depressor. Notation: If the handbrake has been pulled during the compensation, it should be released during the measurement, to ensure the highest possible accuracy. Pull the locking pins on the turntables, loosen the locking screws on the sliding plates and push the plates inwards 1-2cm. Lower and bounce the vehicle. Level and lock the units. Press Next Step when the run-out procedure has been completed. The screen will change to the Caster measurement. 3.6 Caster measurement This screen is used for initiating the measurement of caster, kingpin, toe out on turns and max. lock angle. When the ZERO-button is pressed, the progress bar at the right down corner show the progress, the camber and toe values are stored as the before adjustment values. In the following picture, we will continue to measure:
The bar graph shows the vehicle driving direction. When steering straight ahead, it always check that the measuring heads are in level. Steer the front wheels until the bar graph turns green and the arrow is in the centre position. Notation: If using mechanical turntables remember to reset the scales on the turntables before pressing the ZERO-button. Press the ZERO-button. Turn the steering wheel to -10 o position, see the picture.
When the ZERO-button has been pressed, turn the steering left or right to measure caster and max turning angle. When you turn steering wheel the screen will appear the ray blocked. You take no notice of it,and still turn steering wheel. The steering scale on the screen showing the present steering position. Turn the steering wheel to right to finish reading the data, you also need to turn the steering wheel to left to read another half data. During the swing, the caster, KPI, toe-out-on-turn, inclusive angle, max. lock angle can be measured. After the caster measurement has been completed, all measured angles are stored as the before adjustment values. These values cannot be changed until New measurement button is selected. When the wheels have been set to the straight ahead position the screen automatically changes to the Measurements screen. 3.7Measurement before adjustment The screen Measurements shows the result of the wheel alignment before the vehicle is adjusted. The left column shows the stored measurements for the front and rear axle while the right column shows the vehicle manufacturer specifications loaded from the database.
Press Continue when the run-out procedure has been completed. The screen will change to the Adjust rear. Adjust the sequence:rear Camber Rear Toe Front Caster Front Camber Front Toe 3.8 Adjust rear Normal adjustment start from rear wheel. All stored values inside tolerance are shown in green, values outside tolerance are shown in red, while values without manufacturer specifications are shown in actual. Values not measured are not shown. See the fig. 3.8-1, we only measure the camber, toe of the real wheel, and retain the total toe and the thrust angle.
Fig.3.8-1 Rise wheel to adjust Camber: Press the button in figure 3.8-1, the screen will change to Adjust Camber. Such as figure3.8-2. Fig. 3.8-2 When the wheel has been raised, Press the Adjust Camber. Such as Fig. 3.8-3. button. The screen will change to the
Fig.3.8-3 We can only to adjust Camber in this screen. There will be difference as per difference vehicle model When the wheel has been adjusted, Press the button. Press button, the screen will change to the Adjust Camber. Additional adjust In additional, we can do the additional adjust to the vehicle (usual to the accidental vehicle)press the button. The screen will change to the Additional adjust. Such as Fig. 3.8-4. Fig. 3.8-4
Side offset. Axle offset. Press the button. The screen will change to the Second page of Additional adjust. Such as Fig. 3.8-5. Fig.3.8-5 Wheel base difference. Track width difference. Rear wheel set-back. Press button to quit the Additional adjust screen. Press button, the screen will change to the Adjust front. 3.9 Adjust front The screen Adjust front shows all angles related to the front axle. To adjust caster it is necessary to initiate the correct measuring conditions as described on the screen.
Fig. 3.9-1. Fig. 3.9-1 Press button, to adjust the vehicle with one adjustable tie-rods. Adjust the vehicle with one adjustable tie-rods, see the following picture. Fig.3.9-2 Lift wheel to adjust camber/caster: press the button in screen in case need lift the vehicle,the screen see the fig.3.9-3 as follow Confirmed that the vehicle was lift, then press button, the screen show as the Fig. 3.9-4 The screen remind us do not to adjust toe at this time.
Fig. 3.9-3 Fig. 3.9-4 After the adjustment, press button,then press button to lower
the wheel, and return back to the screen of adjust vehicle with one tie-rod. Press button to adjust toe, see the fig. 3.9-5. Fig. 3.9-5 This screen is used for selecting adjustment of toe, if need adjust toe constant, you can enter into toe constant adjustment screen. Press button to complete the left work. 3.10 Measurement after adjustment Fig. 3.10-1
This screen shows the result of the wheel alignment before and after the vehicle is adjusted. See the Fig. 3.10-1. The left column shows the stored measurements for the front and rear axle before the adjustment, while the right column shows the actual measurements after the adjustment. Press the to return back to the screen of adjust front wheel, or press button to finish the measurement adjustment. obtain a printed summary of the values before and after adjustment. 3.11 Finish measurement This screen is used for printing, storing and terminating the current measurement, and for initiating a new. Fig.3.11-1 1. If the measurements have not been printed, they can be printed by activating Print measurements on this screen. See Fig.3.11-1. 2. To save the measurements in a database for later retrieval activate Save measurements. See Fig.3.11-2. 3. Select Print, save and start new measurement, will erase all current customer data, vehicle specifications, inspection notices and measurement values. See Fig.3.11-3.
Fig.3.11-2 Fig. 3.11-3
4 Alignment setup To change the user setting of the equipment, choose the Setup button in the main menu or press F5 on key board, and then enter password, see Fig.4-0. Fig.4-0 Enter password(the initial password is 888888 ), then the screen will be changed into alignment setup screen. See Fig.4-1. 1 Toe unit: 2 options, unless special requirement of the client, our system unit is degree and minute. 2 Obliquity Unit: 2 options, unless special requirement of the client, our system unit is degree and minute. 3 Run-out compensation:2 options. 1.Elide not allowed, the run-out compensation must be done; 2.Elide allowed, the compensation could be done as per the situation of the vehicle. It s suggested to do the run-out compensation to whatever the new, old or accident vehicle. 4 Compensation method:4 options. 2 point method:run-out compensation ask for 2 point. 4 point method:run-out compensation ask for 4 point. 5 SATA setup:it s already setup by the factory default setting. 6 Password setup: the password of the function setup screen and CCD alignment screen are set here. 7 Repair factory info.: you may input the information related to the repair factory, those information will be printed out together with the report to the client.
Fig.4-1
5 CCD calibration Press button in the main menu screen, or press F5 on keyboard, the screen will be changed to the screen as following fig. 5-0: Fig.5-0 Enter password (initial password is:123456), then enter into following screen, see Fig.5-1. Fig.5-1 The information related to the CCD will be setup in this screen, it s not suggested to do any change in this screen, the brief instruction is as follows:
1 Goniometer clearance: it will show the situation of the goniometer. 2 The status of the cell: it will show the status of the cell. 3 CCD clearance:it will show the status of the CCD. You may click the relative button to clear or recover the factory default setting.
6 Vehicle data 6.1 Load car from database Press Start a new measurement button in the main menu. Press Next step in the Customer data screen. Select any car in the Load car screen from database. Press the button in the screen, it will change to the screen of add vehicle alignment technical standard, see the picture as follows:
Input vehicle parameter in the screen of add vehicle alignment technical standard, press button. 6.2 Modify vehicle specification Press button, the screen will change to Modify vehicle technical spec.
In this screen, you can change the data of this model of vehicle. For example, we modify a car: maker: TOYOTA, vehicle model: VICHI T-100, Date: 98-, modify it s data, and then press button. Please remember use + symbolize positive sign, - symbolize negative sign. Don t delete and which separately symbolize degree and minute. When you input the data, it not necessary to input +, >, which will automatically generated when you move the mouse to the other place. 6.3 Delete vehicle parameter
Press button, if you only select the maker, the dialogue box will pop up as follows, click yes, the maker and all vehicle model data will be deleted. If you select maker and model, a dialogue box will pop up as follows: If you select maker, model and date, a dialogue box will pop up as follows: Notation: please don t delete the data easily, if it s necessary to delete, you must clear the maker, model and the date.
7 Radio communication 7.1Charging the measuring units To recharge the units, they must be mounted on the clamps.the current for charging the batteries, is transferred to the measuring unit through the hanger. During the charging of the batteries, the led-lamps on the measuring head will be flashing in a clockwise rotation. This also indicates that the unit is mounted correctly on the cabinet. The flashing stops when the batteries are fully recharged. 7.2 Power-down mode In order to keep the machine stand by for long time, a red button switch was installed on the measure unit s outer covering. Push four button, the battery supply the power to the measure unit, push again to release the button, stop power supply. Usually before running the program, push four button, battery supply the power to the measure unit. If long time don t use the machine, release the button, switch off the power. Power-down mode is used to save power in the batteries, when the machine has not been used for an amount of time. The software will go into power down automatically after inactive period of app. 20 seconds and when the equipment is activated, the measuring units will be active again. The measuring heads will not go into power down mode while doing run out compensation, caster swing or adjustment. During the power down mode there is no radio transmission. 7.3 Communication problems or low battery If a communication error to one of the measuring units occurs during the operation of the wheel aligner the program will show a picture as the one in the figure 6.3-1. To diagnose the problem: Case 1: If the small green lamp in the level indicator is flashing, the measuring unit is in the power-down condition. The battery is ok, but the communication is not working. Attach the cables to all of the units to continue working with the machine. Case 2: If the battery is in a low condition. You must to attach a cable to this unit to begin recharging and continue to work with the machine. The screen will show the yellow pop up screen as shown on figure 7.3-1.
Fig. 7.3-1 7.4 When to use the cable 1 Battery is low 2 If there is a communication problem 3 Cables must always be used by the service-technicians When doing service on the measuring units, they MUST all be connected by cables. Some of the functions in the service programs require that they are connected 7.5 About battery All types of batteries are subject to a chemical reaction. To extend the lifetime of a battery it is very important to charge the battery before using it.
8 System components 8.1 Mobile Cabinet 1. Color screen with high resolution. 2. Drawer with keyboard for editing and entering data. 3. Drawer with A-4 printer. 4. Closet with PC. 5. Mains switch and power cable inlet. 6,7. Connectors for measuring units. 8.2 Accessories Measuring unit 1 Accessories:
2 3 4 5 1 4x measuring heads-for each wheel. 2 4x self centring clamps for 12-19 wheels. 3 1x steering wheel holder. 4 1x brake pedal depressor. 5 Two turntable. 8.3 Measuring unit 1~2 Program selector. Increment stepwise forward or backward in the vehicle
adjustment program. 3 Push Button for Run-out compensation. 5 Push Button for Zero setting. 6 Spirit level for horizontal position of measuring heads 7~8 Connector for rear measuring unit or cabinet. 9 Connector for electronic turntable. 8.4 Cable connection