Snap-On Ultra Service Manual
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Snap-On Ultra Service Manual

Wheel aligner
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Service Manual
Ultra, UHR Ultra and V3400
WHEEL ALIGNER
May 2014

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Summary of Contents for Snap-On Ultra

  • Page 1 Service Manual Ultra, UHR Ultra and V3400 WHEEL ALIGNER May 2014...
  • Page 2 Snap-on Tools Company. All manufacturing, use, reproduc- tion, and sales rights are reserved by Snap-on Tools Company and the information contained herein shall not be used in whole or in part without the express...

  • Page 3: Table Of Contents

    D.C.THEORY OF OPERATION ..........................5 POWER SUPPLY ............................5 HUB BOARD ..............................6 ULTRA CAMERA POD ASSEMBLY ........................ 7 ULTRA UHR CAMERA / STROBE ASSEMBLY 3D SYSTEM ................. 8 CHAPTER 2 THEORY OF OPERATION GENERAL ................................13 CAMERAS ..............................13 TARGETS 2D ..............................
  • Page 4 STORED IMAGE ANALYSIS ..........................46 RACK CHECK ..............................47 DATA EXAMINATION ............................48 CAMERA DIAGNOSTIC ..........................49 TARGET RTP ..............................50 ALIGNER DIAGNOSTIC ..........................52 CAMERA VIEW ..............................52 CAMERA TEST ............................. 53 STORED DIAGNOSTIC FILE ANALYSIS ......................54 EXPORT DIAGOSTIC FILES ..........................54 INTRODUCTION NEW FOR V3400 ...............................
  • Page 5 IMPORTANT SAFETY INSTRUCTIONS When using this equipment, basic safety precautions should always be followed, including the following 1. Read all instructions. 2. Do not operate equipment with a damaged power cord or if the equipment has been dam- aged until it has been examined by a qualified authorized service technician. 3.

  • Page 6: Chapter 1 Ac/Dc Power Distribution

    CHAPTER 1 AC/DC POWER DISTRIBUTION ELECTRICAL SAFETY PRECAUTIONS Make sure the aligner is unplugged before disconnecting any wires in preparation for replacing any boards, cables or other items within the unit. Use the “Lockout and/or Tagout” procedure. When working on this aligner, keep three points in mind: THIS UNIT MUST BE PLUGGED IN TO A PROPER AC OUTLET FOR THE UNIT TO OPERATE CORRECTLY.

  • Page 7: Service Guidelines

    AC/DC POWER DISTRIBUTION When inserting PCB’s: • Place boards on a grounded static mat after removal. • Remove the new PCB from the original package onto a grounded static mat. Save packaging to use when returning defective boards. • Remove power from the machine (un-plug from wall) before installing the PCB. •...

  • Page 8: Ac Theory Of Operation

    AC/DC POWER DISTRIBUTION AC THEORY OF OPERATION Always use “one hand rule” when working with AC voltages by keeping one hand in your pocket or behind your back. Before removing any wires on the equipment, always verify that the equipment is turned “OFF”. Turn off the Main Power switch in the back of the unit and unplug the AC power cord from the AC outlet.

  • Page 9: Hub Board

    AC/DC POWER DISTRIBUTION The DC output of the Camera Power supply feeds through a harness on the back of the cabinet. Both the 5V and 12V power is fused at this location. Should a camera stop working checks should be made to both fuses for proper continuity and both the 5V and 12V be checked for proper power using a VOM.

  • Page 10: Ultra Camera Pod Assembly

    AC/DC POWER DISTRIBUTION ULTRA CAMERA POD ASSEMBLY When ordered the camera pod comes as an assembly however should a strobe board fail it can be ordered and replaced separately. The camera pod is supplied with both 5VDC to power the “Acquired target indica- tors”...

  • Page 11: Ultra Uhr Camera / Strobe Assembly 3D System

    Acquired Indicators ULTRA UHR CAMERA / STROBE ASSEMBLY 3D SYSTEM The UHR Camera / Strobe PCB is all integrated onto one PCB. The camera pod is supplied with both 5VDC to power the “Acquired target indicators” and directional LED’s and 12VDC to power the strobe.
  • Page 12 AC/DC POWER DISTRIBUTION By viewing the LED’s on the strobe board the technician should be able to quickly identify if both the 5VDC and 12VDC are present. There are no test points available. In the figure below all Target Indicators and Directional Indicators are lit up.
  • Page 13 AC/DC POWER DISTRIBUTION...
  • Page 14 AC/DC POWER DISTRIBUTION...

  • Page 15: Chapter 2 Theory Of Operation

    2010 Pro42 was introduced. Pro42 added the versatility of added features plus it also opened up the area of using a higher resolution camera system Ultra High Resolution(UHR). The UHR system also incorporates a true 3D target. This target is much smaller and lighter.
  • Page 16 Theory of Operation Side Field of View Figure1 Top Field of View Figure 2...

  • Page 17: Targets 2D

    Theory of Operation TARGETS 2D The target’s visual surface is a series of circles or “dots” made of a retroreflective material. This material returns any light that hits its surface at a 180-degree angle directly back towards the source. If we are look- ing at the reflected light, it is brightest at the center of the light source.

  • Page 18: Targets 3D

    Theory of Operation TARGETS 3D The new 3D targets are unique for each wheel. The rotation of the sub targets defines the wheel position. A quick glance at the targets the operator may think that both left targets are identical and both right targets are identical.
  • Page 19 Theory of Operation Configuration using single pole wheel clamp...

  • Page 20: Target Acquistion

    Theory of Operation TARGET ACQUISTION When we begin a new alignment the program has no idea where the targets are located. The software turns on the cameras and goes into a “search mode”, looking throughout the cameras’ field of view for any targets. We see this on the screen in the form of 4 red targets away from the wheels.
  • Page 21 Theory of Operation First, we must find the angle r by applying formulas from basic trigonometry: tan r = (A/2) = (P/2) Since we know A,F,P and Z can be calculated and the angle can be found using trigonometric tables. Once the angle is known, we can use it in another trigonometry formula to find D: D = (P/2) tan r...

  • Page 22: Foreshortening

    Theory of Operation FORESHORTENING The discussion earlier about perspective and the screwdriver example assumed that the screwdriver (or target) was “normal” to your eye. Normal means the object is being viewed straight on (perpendicular or at 90 degrees), so its full length is observed. 90 o Look what happens to the observed size of the screwdriver when it is rotated away from 90 degrees to your eye–...

  • Page 23: The Circle

    Theory of Operation Focal Length (fixed by lens) Pen (known length fixed) In this example, the camera is at a fixed point in space. All fixed camera lenses have a fixed focal point. The distance from the camera to the focal point is a known value F, created by the designers of the lens.
  • Page 24 Theory of Operation Now look what happens as the circle is rotated about the X-axis – in two dimensions it appears to be an el- liptical shape. Rotated The more we rotate the circle about the x-axis, the smaller the y-axis diameter appears. In fact, a mathemati- cal relationship exists that says if you can measure the length of the y-axis line and the length of the x-axis (the circle’s true diameter), you can determine the angle of rotation.

  • Page 25: Positioning Sequence

    Theory of Operation POSITIONING SEQUENCE The 3D Aligner knows where the targets are, but it does not yet know where the vehicle is. Of course, the targets are attached to the vehicle’s wheels, and this provides the link to the vehicle’s alignment angles. The term “wheel alignment”...

  • Page 26: Side-To-Side Determination

    Theory of Operation When the vehicle is rolled, the 3D software directly locates the spindles and now knows 4 distinct points in space with respect to the cameras that are part of the vehicle. Since the vehicle is now off the rack turn- tables, it is necessary to roll it to is start position to perform any corrections.

  • Page 27: Relative Camera Positioning (Rcp)

    Theory of Operation RELATIVE CAMERA POSITIONING (RCP) It would be easy to say that we know the distance between the cameras because we designed and manufac- ture the Camera Beam and cameras. However, the knowledge the aligner must have about the relationship of one camera to another is critical and must be known to high level of precision –...
  • Page 28 Theory of Operation To determine Relative Camera Position we need to take the fixture of a length we know and place it across the runways, placing one target in the left camera’s vision and one target in the right camera’s vision. ...

  • Page 29: Modeling The Vehicle In 3-Dimensional Space

    Theory of Operation We do this by placing the fixture on the left runway so that both targets are in the visual field of the left cam- era. If we measure with one camera, then measure with a different camera and get the same values we can be sure the fixture has remained stable and our RCP is valid.

  • Page 30: Measuring Steering Angles

    Theory of Operation MEASURING STEERING ANGLES The steering angles caster and SAI are defined by physical components of the vehicle suspension, those that define the steering axis (such as upper and lower ball joints on a short-arm long-arm suspension). Conven- tional aligners measure these angles using gravity gauges and the toe system by monitoring the affect these angles have on those angles as the wheels turn.

  • Page 31: Chapter 3 Checkout, Calibration And Maintenance

    In using this guide always start with ba- sics regardless of the complaint. Some of the screen captures in this Chapter were taken using a two camera system. Servicing an Ultra Arago or V3400 will only add an additional camera view. The troubleshooting is handled the same.

  • Page 32: Calibration Utilities

    CALIBRATION CALIBRATION UTILITIES The Calibration Utilities are special utilities designed to calibrate different parts of the alignment system. It also includes a utility used to back up the calibration data and to aid a technician in the proper troubleshooting of the V3D system Utility used for performing ISO calibration.
  • Page 33 CALIBRATION SYSTEM CONFIGURATION After a camera has been installed it will be necessary to train the alignment system which side the new camera has been installed. NOTE: failuRE TO fOllOw This pROcEduRE afTER a NEw camERa iN- sTallaTiON will REsulT iN iN-accuRaTE aligNmENT REsulTs. 1.
  • Page 34 CALIBRATION After gaining access to the camera identification, look closely at the illustration of the two camera beams. The upper camera beam illustrates the right (passengers side) directional arrows illuminated and the lower camera beam illustrates the left (drivers side) directional arrows illuminated. If a 3 Camera system was chosen in the previous screen the user will also need to identify the calibration camera or if a remote camera is present it will also need to be identified.
  • Page 35 CALIBRATION viEw as upsidE dOwN There is also three additional selection buttons available once the Imaging system has been determined. 1. Less than 2.3 Meters (90 Inches) • This button should be set to the ON (up) position if the cameras are less than 90 inches from the turnplates.
  • Page 36 CALIBRATION In order to maximize the Arago 3™ alignment system, the cameras have been mounted on a swivel pod assembly. This swivel pod allows the right and left cameras to rotate in order to see the targets in all field of views (Narrow, Normal and Wide).

  • Page 37: Target Id Process

    CALIBRATION The customer has several different options of the types of wheel clamps being used. Depending on which market the Aligner is sold in the most common clamp used will be the AC200 and/or AC400 wheel clamp. If additional wheel clamps are used the customer must enable them using the “Wheel Clamp Types”.
  • Page 38 CALIBRATION 4. Once the system acquires the target an arrow indicates the direction to rotate the target/wheel. The initial rotation is 25º forward. 5. If the tire and wheel is rotated past the 25º point the meter will change to red letting the operator know to rotate back. 6.

  • Page 39: Camera View

    CALIBRATION 9. After the completion of a successful target ID the screen indi- cates to lower the wheel. This is not necessary if the opposite side target is needing to be ID, click on the <OK> button and select the next target. Lower the wheels after all four targets have been ID’d.

  • Page 40: Relative Camera Positioning (Rcp)

    CALIBRATION 1. Raise the lift to the alignment working height with no vehicle. Set the lift down on the locks. 2. The RCP fixture must be assembled prior to use. The components consist of: • Aluminum bar • Large and Small Target 3.
  • Page 41 CALIBRATION 8. Two images should appear in the upper left hand portion of the screen. The aligner will sample the images and will automati- cally prompt the technician for advance- ment. Click on the <NEXT> button when prompted. 9. The aligner will sample and process the im- ages.
  • Page 42 CALIBRATION 12. Move the cal bar back on the rack approxi- mately 2 feet on the rack. Click on <NEXT> when done. 13. Move the cal bar back again approximately 2 feet on the rack. Click on <NEXT> when done. 14.

  • Page 43: Activate And Calibrate The Ride Height Measuring Device

    CALIBRATION 16. Extend the plunger under the rear foot. Click on <NEXT> when done. congratulations! You have successfully com- pleted calibration. ACTIVATE AND CALIBRATE THE RIDE HEIGHT MEASURING DEVICE From the calibration menu, click on the system Configuration icon and click on Ride height Target switch to activate the Ride Height Target feature.
  • Page 44 CALIBRATION 6. The <NEXT> button will illuminate once the target has been acquired. Click on the <NEXT> button, a check mark will appear prompting the user to proceed to step 2. 7. Proceed with calibration, until all three steps have been completed. 8.

  • Page 45: Calibration Backup / Restore

    CALIBRATION CALIBRATION BACKUP / RESTORE Calibration and Preference backup offers the user or technician a way of backing up all customized options and alignment calibration to a flash drive. Should an alignment machine require a hard drive replacement the user or technician can simply restore all data from a saved flash drive back on to the newly installed hard drive.
  • Page 46 NOTES...

  • Page 47: Chapter 4 Diagnostics

    CHAPTER 4 DIAGNOSTICS The Diagnostics menu offers the technicians tools to troubleshoot and diagnose problems with the aligner only. These diagnostic routines will not diagnose all problems that could arise. The technician should also become familiar with the proper hookup and voltage that is supplied to this unit.

  • Page 48: Stored Image Analysis

    Diagnostics From the Main Menu select the Diagnostic Icon at the top of the Carousel. STORED IMAGE ANALYSIS Allows the user to view and zoom into stored images (stored using Ctrl Alt P). This feature is available any time that the system has target view on the screen. The system is set to acquire images for every 2 seconds for a known time after which it will switch to 4 seconds and then 20 sec-...

  • Page 49: Rack Check

    Diagnostics RACK CHECK This test checks how coplanar (parallel) the rack is. Even though we are very resistant to rack problems, non copla- nar racks can introduce some error to our system. The image aligner is designed to perform a perfect alignment every time.

  • Page 50: Data Examination

    • This mode allows the operator to look at raw plane generation data as it arrives. This information de- pends on the camera being used (Ultra or Ultra UHR or V3400) • Displays the number of proto-blobs (dot like object in the cameras FOV. Could be a reflector on a car or a dot on a target) as well as measured blobs.
  • Page 51 Retrieve additional data by clicking on the target identification icon. The information displayed depends on the type of camera being used (Ultra or Ultra UHR) Threshold - All pixels received by the cameras have a brightness level of 0 to 255.

  • Page 52: Camera Diagnostic

    Diagnostics CAMERA DIAGNOSTIC By switching from Left to Right the techni- cian can compare camera characteristics. Both the Left and the Right camera should run parrallel information. • Temperature • V3.3 • Vaa • Vdd • Vio • Software Version (Camera) •...
  • Page 53 Diagnostics The information in target RTP is the “X” “Y” and “Z” coordinates of the targets relative to the axix of rotation (Spindle). As described in the Theory of Operation chapter all the targets are identical however each target is rotated differently to properly identify the location (LF, RF, LR, RR).

  • Page 54: Aligner Diagnostic

    Diagnostics ALIGNER DIAGNOSTIC The information from this screen is used for both field service and engineering. CAMERA VIEW This screen shows the view as seen by the camera. This is a good tool to use to verify live images. The user can also use the <CTRL-ALT-P>...

  • Page 55: Camera Test

    Diagnostics CAMERA TEST Test both the strobe and the gain of the camera and it’s ability to recognize images with gain and strobe changes. All adjust- ment from this location are manual adjust- ments, when exiting this test the camera assembly will return to auto function.

  • Page 56: Stored Diagnostic File Analysis

    Diagnostics STORED DIAGNOSTIC FILE ANALYSIS This allows the operator to examine a stored hmain.diag file (stored using Ctrl Alt P) without having to search the hard drive. This information can be used to troubleshoot a possible problem at a later time. If a unit is experiencing problems, the customer can simply press <CNTRL-ALT-P>.
  • Page 57 Diagnostics COVERING THE BASICS These procedures must be followed before placing a call to tech support. Failure to have these answers when asked result in longer customer down time and additional calls to TECHNICAL SUPPORT. 1. Verify complaint. (Remember, operator error requires proper training, no service tools or service parts are needed.) 2.
  • Page 58 Diagnostics CSR PREFERENCES There should be no reason for the preferences of the aligner to be changed. Changes made in the preferences can ultimately af- fect the aligners accuracy. Listed are the preferences and a brief explanation of it’s use. This feature should be used with extreme caution.
  • Page 59 Diagnostics TID PARAMETERS These values are used when performing a Target ID (TID). These preferences are found in the CSR Prefer- ences by clicking on the TID Preferences tab. • Measurement Angle (Default 90) - Total rota- tion of the target from the forward position back.
  • Page 60 PC may have an add-on PCI or EISA controller card that provides USB service. The Ultra Aligner has a Hub PCB that relays information to and from the cameras to the PC and passes power from the power supply to the cameras.
  • Page 61 Plug a spare power/usb cable and camera into the back of the console and check to see if the Device man- ager recognizes an Ultra camera. If so we can assume that the PC and USB root hub and Universal host controller and power supply are working correctly.
  • Page 62 If a system is experiencing constant controller failure, make sure the OS in use supports USB; verify that the devices are supported by the controller; and check the controller’s settings and drivers. The Ultra cameras use a generic controller. Integrated controllers will likely require you to enter the BIOS to make changes, while add-on cards will require traditional troubleshooting according to the manufacturer’s directions.
  • Page 63 Should you experience this issue, move the working devices to another root hub to see if the problem is in a particular root hub or with the devices themselves. If an Ultra camera is moved to a hub that has not loaded the device drivers the Operating system will prompt the user to load these drivers.
  • Page 64 Diagnostics Managing the USB Hubs Change USB Root Hub settings as follows: Click START. Right click on COMPUTER. Click PROPERTIES. Verify Windows Service Pack 1 (Blue Arrow) is installed. If not this update can be found on Mi- crosofts website. Click DEVICE MANAGER.
  • Page 65 Diagnostics USB Device Drivers The ability to hot swap USB devices is a great feature, but it relies on a somewhat oversimplified set of general-purpose drivers. Some devices may appear to be general-purpose devices when in fact they are not. This means that you must install the drivers before you connect the device to the PC. Sometimes you need to reboot to give the new drivers priority over the general-purpose drivers.
  • Page 66 Diagnostics Disabling “Windows Presentation Foundation Font Cache 3.0.0.0”: Click Start Right Click Computer Left Click Manage Left Click Services and Applications Double Click Services Double Click “Windows Presentation Foundation Font Cache 3.0.0.0” Change “Startup Type” to Disabled Click Apply Click Ok 10.
  • Page 67 Diagnostics...
  • Page 68 NOTES...

  • Page 69: Introduction

    Snap-on V3400/Geo 790 INTRODUCTION The Snap-on V3400 Aligner Platform is similar to the legacy imaging aligner with some unique features we need to point out. There are three main differences to focus service and operation issues: 1. The use of Blue Tooth for cameras to PC communications.

  • Page 70: Establishing Communications With The Cameras

    V3400 Service ESTABLISHING COMMUNICATIONS WITH THE CAMERAS When the camera towers are first powered up you will note one green LED that indicates DC power supplied to the pods. Once the pods boot up you will note a slow “rotating strobe”. The “rotating strobe” are the LEDs in each camera board that flash in a circle indicting the level of connection.

  • Page 71: Identification Of The Cameras

    V3400 Service IDENTIFICATION OF THE CAMERAS If the cameras are not identified or when replacing a camera, you must perform the identification process. There are two ways to identify the cameras, automatic and manual. The manual entry requires the camera ID be known. When shipped from the factory there is a label that identifies the camera on the face of the camera board and on the bottom of each pod.

  • Page 72: Checking The Firmware

    V3400 Service If replacing a target, or clamp, TID or single bar calibration will be required. It is recommended that single bar be performed, however if a customer is doing the work TID will suffice. NOTE: NEvER pERfORm Tid afTER dOiNg a siNglE baR calibRaTiON. dOiNg sO will dElETE ThE OffsETs fOR TOTal TOE aNd cambER.
  • Page 73 V3400 Service Also the measurement data screen indicates the relative signal strength and ID of the cameras as well. DISCONNECTED CAMERA In the event a camera loses communication with the PC during a live screen such as rollback, readings or adjust.

  • Page 74: Servicing Pod Components

    V3400 Service SERVICING POD COMPONENTS Pod covers are constructed in three pieces allowing the technician to only remove the section covering the component to be serviced. Each pod cover section is secured with two phillips screws on the top and two on the bottom.

  • Page 75: Replacement Of Pod Components

    V3400 Service REPLACEMENT OF POD COMPONENTS CAMERA REPLACEMENT To remove pod components, first identify the part in question and remove that section of pod cover. To remove a camera board, first disconnect the power and control cables. Only the measurement cameras will have motor control cables, the calibration camera has only a power cable connected.

  • Page 76: Single Bar Calibration

    SINGLE BAR CALIBRATION Introduction With the release of 7.4 Pro42 software, a new Single Bar calibration feature is now available. This new Cali- bration procedure will execute TID, RTP, and apply Total Toe and Camber offsets to maximize accuracy. This single bar calibration is applicable to all X-CEL (UHR) Imaging Aligners with 7.4 and up software.
  • Page 77 Single Bar Calibration Select the wheel clamp(s) being used. The procedure used is the same for all wheel clamps with the exception of the degree rotations and the mounting of the AC400 wheel clamps. (See Below). This pro- cedure must be done using all wheel clamps on site as each set of clamps has it’s own calibration factors.
  • Page 78 Single Bar Calibration Place the calibration bar and stands in front of the turnplates if possible and mount the paddle assembly to the bar. Mount the front selected wheel clamps and target assembly to the calibration paddles. NOTE: The wheel clamp and tar- get assembly must be mounted vertical before continuing.
  • Page 79 Single Bar Calibration With the front clamps and targets mounted vertical, a stop sign will appear. Be patient as the system is re- cording data and may take several minutes to complete. This is the wheel clamp and targets initial position (Vertical) for the entire single bar calibration procedure.
  • Page 80 Single Bar Calibration Rotate the bar rearward and lock it using one of the locking knobs on the stands until a stop sign appears. Rotate the bar forward and lock it using one of the locking knobs on the stands until a stop sign appears. Rotate the bar back and lock it using one of the locking knobs on the stands until a stop sign appears.
  • Page 81 Single Bar Calibration After the rear target assembly has been measured on the front of the rack the software will prompt the user to move the bar and stand assembly to the rear of the alignment rack. Again make sure that the bar and stands are on a solid surface.
  • Page 82 Single Bar Calibration Rotate the calibration bar rearward and lock it using one of the locking knobs on the stands until a stop sign appears. Rotate the bar forward and lock it using one of the locking knobs on the stands until a stop sign appears. Repeat steps 20 thru 21.
  • Page 84 309 Exchange Avenue Conway, AR 72032  05.07.2014 2014 Impreso en U.S.A. TEEWA546P4 (Rev C)

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