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MANATEC JUMBO HCV Operating Manual

3d wheel aligner
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3D WHEEL ALIGNER
HCV model
OPERATING MANUAL
(Ver.1.7)

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Summary of Contents for MANATEC JUMBO HCV

  • Page 1 3D WHEEL ALIGNER HCV model OPERATING MANUAL (Ver.1.7)
  • Page 2 Dear Customer, Congratulations, for selecting 3D Wheel aligner as your Wheel alignment computer. Our Wheel aligners are user friendly system which can be used effectively to correct all the alignment angles of four wheelers. We take special care to ensure that every Wheel aligner leaving our Factory is in the best operating condition.
  • Page 3 INDEX Page No. WARRANTY – STATUTORY CLAUSE SAFETY 2.1. INTENDED USE 2.2. SAFETY INSTRUCTIONS FOR COMMISSIONING 2.3. SAFETY INSTRUCTIONS FOR OPERATION 2.4. SAFETY INSTRUCTIONS FOR SERVICING 2.5. SAFETY FEATURES 2.5.1. POWER FAILURE DATA RECOVERY 2.5.2. CONTROL FUSES 2.5.3. HIGH VOLTAGE PROTECTION 2.6.
  • Page 4 OPERATION 7.1. DEFECTS / MALFUNCTIONS 7.2. PRELIMINARY ALIGNMENT PREPARATION 7.3. MAIN MENU 7.4. ALIGNMENT 7.4.1. VEHICLE SELECTION 7.4.2. WHEEL RUNOUT 7.4.2.1. CUSTOMER DATA INPUT 7.4.3. CASTER & KINGPIN SWING 7.4.3.1. TURN LEFT 7.4.3.2. TURN RIGHT 7.4.3.3. STRAIGHT AHEAD 7.4.4. ALIGNMENT PARAMETERS & RESULTS 7.4.4.1.
  • Page 5 7.6. SETTINGS 7.6.1. VEHICLE SPECIFICATIONS 7.6.1.1. INTERNATIONAL HCV DATA 7.6.1.2. INDIAN HCV DATA 7.6.1.3. UNITED STATES HCV DATA 7.6.1.4. INDIAN LCV DATA 7.6.1.5. USER DEFINED VEHICLE DATA 7.6.2. MEASUREMENT UNITS 7.6.3. ALIGNMENT DATA 7.6.4. WORKSHOP INFORMATION 7.6.5. CALIBRATION HISTORY 7.6.6. MULTI-USER 7.6.7.
  • Page 6 WARRANTY – STATUTORY CLAUSE Equipment is provided with one year Warranty from the date of installation or thirteen months from the date of dispatch which ever is earlier (International warranty up to fifteen months from date of dispatch) against any manufacturing defect. Warranty is subject to following conditions: Ensure that proper power supply with protective Earthing is provided to equipment.

  • Page 7: Intended Use

    SAFETY Thoroughly read all Safety labels and Manual instructions before installing, operating and maintaining the Wheel aligner. They are provided to remind the operator to exercise extreme care while performing wheel alignment with this product to prevent personal injury and property damage.

  • Page 8: Safety Instructions For Operation

    2.3. SAFETY INSTRUCTIONS FOR OPERATION Read the Operating manual thoroughly. Only permit qualified personnel to operate, maintain or service the Aligner. The operator should have thorough understanding of the vehicle systems being serviced & sufficient knowledge on the operation & safety features of alignment. Always keep the Aligner and the surrounding work area clean and free of Tools, Parts, Debris, and Grease etc.

  • Page 9: Safety Label Information

    2.5. SAFETY FEATURES 2.5.1. POWER FAILURE DATA RECOVERY During alignment, if the power goes off & resumes, the system has the facility to resume the previous job without redoing the entire alignment again. When the power goes off, system will operate in UPS mode. Press Ctrl+S to save the job and shut down the PC.

  • Page 10: Features And Specifications

    FEATURES & SPECIFICATIONS Description     Features     Suitable for alignment of Buses, Trucks, Dolly, Trailers & Cars     Compatible with Multi-axles (up to 16 wheel vehicles)  Simultaneous alignment of 6 axles using 4 Cameras & 12 Targets ...
  • Page 11 Description     40 Option for selection of Vehicle specifications during alignment     41 Multiple User Log-In Power failure data protection (Resuming of current job in which stage     the power failure happened) ...
  • Page 12 Description     Electrical specification Power supply : Stabilised UPS (AVR Built-in) & CVT (1KVA)     230VAC ±10%, Single phase, 50Hz, +N +PE 110VAC ±10%, Single phase, 60Hz, +N +PE     Power consumption : 250W ...

  • Page 13: Space Requirements

    INSTALLATION 4.1. INSTALLATION REQUIREMENTS Wheel aligner installation should be done only by qualified Service personnel. Provision of handling means such as Forklifts etc. is the owner's responsibility 4.2. LOCATION The Wheel aligner should not be installed outdoors, in moist rooms, at hazardous locations, or in the vicinity of explosives or flammable liquids.
  • Page 14 Ref.: MEL-WA(3D HCV) - OM Ver.1.7...
  • Page 15 Drive Through model Ref.: MEL-WA(3D HCV) - OM Ver.1.7...

  • Page 16: Power Requirement

    Fig. 1 4.4. POWER REQUIREMENT 230VAC, Single Phase, 50/60Hz +N +PE (or) 110VAC, Single Phase, 50/60Hz +N +PE Supply should be connected only through a CVT of 1KVA capacity and then through an UPS of minimum 1KVA capacity with AVR (Automatic Voltage Regulator) circuit using a CE certified Two Pole, Type C, 6A MCB.
  • Page 17 WHEEL ALIGNMENT PARAMETERS WHEEL ALIGNMENT refers to a set of wheel angles which are responsible to distribute the weight of the automobile over the suspension system and the four wheels uniformly when the vehicle is in motion. Proper distribution of the weight results in uniform tyre wear and effective steering control.
  • Page 18 NEGATIVE CAMBER is the inward tilt of the tyre at the top. Fig. 3 If a tyre was absolutely vertical, the degree of camber would be zero. Unlike the Caster angle, Camber will change with vehicle load and ride height. With the weight of the driver in the vehicle, front left Camber will increase and front right Camber will decrease and vise versa for left hand steering vehicle.
  • Page 19 5.2. Unlike Caster and Camber, which are measured in degrees, Toe is most frequently measured in fractional Inches, Millimeters or Decimal degrees. An incorrect Toe setting is one of the main alignment factors that cause excessive tyre wear. Front and rear Toe are the same in definition, with the adjustment capabilities and procedures being the only actual difference.
  • Page 20 5.3. CASTER CASTER is the angle between an imaginary line drawn through the upper and lower steering pivots and a line perpendicular to the road surface (viewed from side of vehicle). If the top of the line tilts rearward, the vehicle is said to have POSITIVE CASTER.
  • Page 21 5.4. KINGPIN INCLINATION (Steering axis inclination) Fig. 8 KINGPIN Inclination (also referred to as the ball joint angle or Steering Axis Inclination- SAI) can be a difficult angle to understand. The easiest way to understand Kingpin Inclination is to first define Steering axis. The steering axis is an imaginary line intersecting the spindle support.
  • Page 22 5.5. THRUST ANGLE Fig. 9 THRUST ANGLE is the line that divides the total angle of the rear wheels. The rear tyres are not just following the front tyres, they are actually establishing direction of the vehicle. In doing so, a direction of thrust is developed. The Thrust angle created by the rear wheels is used as a reference for aligning the front wheels.
  • Page 23 5.6. SCRUB ANGLE (HCV) Fig. 10 SCRUB ANGLE is the angle formed at the intersection of the thrust lines of both the Drive axle and Tandem/Dummy axle in a Multi-Axle vehicle. 5.7. PARALLELISM (HCV) Fig. 11 PARALLELISM is the perpendicularity of the twin steerable axle‟s centre with respect to the Geometric centre line of the vehicle Axles are determined to be parallel, thus minimizing tire wear, if measurements between twin steerable axles are equal at both ends of the axle.
  • Page 24 5.8. FRONT WHEEL SETBACK FRONT WHEEL SETBACK or front end squareness is a condition in which one wheel is rearward of the other. If Setback is present the turning radius will not be correct when the vehicle turns. With this condition, the tyres will wear very much in the same manner as if they were under inflated.
  • Page 25 5.9. REAR WHEEL SETBACK It is the condition of Rear axle with respect to the Geometric centre line ie., one of the Rear wheel is rearward or forward with respect to the other wheel. The Rear Wheel Setback is the angle between a line drawn through both the wheel resting points. A line perpendicular to the vehicle geometrical line (thrust line) will be measured in angles.

  • Page 26: Wheel Runout

    5.10. WHEEL RUNOUT Fig. 16 RUNOUT is one of the important factor which affects a good wheel alignment. Hence Runout compensation is a critical parameter in wheel alignment. Runout is the wobbling of wheel with respect to neutral axis ie., vertical axis of Camber and the axis parallel to Geometric centre line in case of Toe.
  • Page 27 Due to the above adjustments, Camber variations will be equally distributed in the vehicle (in motion) at any point of time. The process of bringing the Camber to average Runout position is called Runout compensation. The equipment does the Runout compensation automatically without the knowledge of technician.
  • Page 28 5.12. TRACK WIDTH DIFFERENCE Track width difference is the angle between Front Left wheel resting point to Rear Left wheel resting point & Front Right wheel resting point to Rear Right wheel resting point. Fig. 20 The measured angle will be displayed as Positive angle, if the Rear Track width is more than the Front Track width.
  • Page 29 5.13. LOCK ANGLE Fig. 21 LOCK ANGLE is the angle measured in degrees by which the front wheels of a vehicle move to the extreme left or right from the straight ahead position when steered. Left wheel Lock Angle : The maximum degrees to which the left front wheel can (Internal) turn when the wheels are steered to the left side.
  • Page 30 5.14. TOE OUT ON TURNS When the front wheels of a vehicle are steered to left or right, the angle turned by each wheel at any instant is not equal. When the left wheel is turned towards left side by 20° from the Straight ahead position the right side wheel would have turned lesser than 20°.

  • Page 31: Description Of Main Parts

    DESCRIPTION OF MAIN PARTS The equipment consists of a pair of Vertical columns (Left & Right) with Camera systems, Interface box & Target plates. A Main cabinet is provided to hold the Interface box, Computer & Peripherals. Movable Wheel bracket holding posts are provided to hold the Integrated Wheel bracket &...

  • Page 32: Interface Box

    6.1. VERTICAL COLUMN (Left & Right) Both the Left side & Right side Vertical Columns contain a pair of High performance SI (Scientific Imaging) Camera system positioned to illuminate the respective patterned Targets mounted on the Wheels and capture the reflected incident rays. A LED Driver board &...
  • Page 33 6.3. TARGET PLATE Fig. 25 The Target plates contain patterned IR reflecting media to reflect the incident rays from the Camera assembly. A Spirit level is provided in each Target plates to ensure its horizontality while mounting it on the wheel bracket. Handle the Target plates carefully.
  • Page 34 Press “Continue” button. Following screen will appear prompting the user to enter the previous Owner details: Fig. 27 Key-in the below details and press “Continue” button: Company Name : MANATEC ELECTRONICS PVT LTD Country : India Pin Code : 605007...
  • Page 35 Select “Commercial/Office” option from the Drop down menu of “Intended use” as shown below and press “Continue” button: Fig. 28 Now enter the user‟s Owner details and press “Continue” button: Fig. 29 Go through the instructions displayed and click “Continue” button. Fig.
  • Page 36 Fig. 32 NOTE: Typically Dell will take 15 business days for international transfers. Hence is advisable to convert the details at the time of installation itself. DISPLAY UNIT – Primary & Secondary (refer scope of supply) 6.6. The Display unit is a High resolution Color Monitor to display the alignment screens and functions.
  • Page 37 6.9. STANDARD ACCESSORIES (refer scope of supply) Use only the Accessories recommended by the manufacturer and handle it carefully. Failure to comply may cause injury to Operator Frequently inspect the accessories and clean and lubricate WHEEL BRACKET (HCV) – 12” to 24” 6.9.1.
  • Page 38 6.9.2. ROTARY PLATE (7 ton) Fig. 35 The Rotary plate consists of a freely rotating plate with load capacity of 7 ton in each Rotary plate suitable for HCVs. The front wheels of the vehicle being aligned should rest on these plates. The Rotary plate helps to free up the wheels from the friction and relaxing the ball joint to its original condition.
  • Page 39 6.9.6. LCV STEERING LOCK Fig. 39 Steering lock is used to arrest the movement / rotation of Steering wheel, while performing Runout measurement & Toe adjustment. Do not keep your head nearer to the Steering while locking with Steering lock to avoid get hit due to the spring tension 6.9.7.
  • Page 40 6.9.10. WHEEL BRACKET HOLDING POST, 3 HOLDER Movable Post provided to hold 3 Nos. of Integrated Wheel bracket & Target plate units near the respective left & right side Wheels under alignment, when not in use and for quick access during alignment. Fig.
  • Page 41 6.9.13. RATCHET WITH CHAIN BLOCK This accessory is provided for adjusting the Thrust angle in HCV vehicles with single rear axle. Fig. 46 6.9.14. PLASTIC TOOL BOX & ORGANIZER A box is provided to store the Rim locking pins and adapters safely without damaging it when not in use.
  • Page 42 6.10.5. RIM LOCKING PIN – Double sided (for Run flat tyre rims & Fancy disc) This Rim locking pin of 64mm Lg. is developed for clamping different kind of LCV Run flat tyre rim profiles, compatible with 24" Wheel bracket. Fig.
  • Page 43 6.10.11. FRAME REFERENCE GAUGE FOR TRUCKS & BUSES This is a reference gauge used for computing the wheel alignment parameters by adjusting the position of axles either with reference to the geometric center line or Frame (Chassis) center line in a longitudinal direction. The frame center line will be calculated by taking input at four positions on the chassis sequentially in the order of Front Left, Front Right, Rear Left &...
  • Page 44 Calibration kit is a simplified tool meant for calibrating the all the Target plates simultaneously and if necessary to correct it. Calibration is a very important function. During this process, the Calibration stand should not be jerked or moved during calibration process 6.10.14.
  • Page 45 The steel rope will be tied to any of the rear axle (ideally drive axle) and the winch will be operated. The winch will pull the vehicle backward. To move the vehicle forward direction, a pulley with shaft mechanism installed on the pit (next to the F2 Rotary plate) will push the vehicle forward.

  • Page 46: Operation

    OPERATION Only permit qualified & trained personnel to operate, maintain or repair the Aligner Ensure the Top plate of Rotary plates are locked with Locking pins before parking the vehicle. Always use rotary plate spacer for proper Runout measurement. Always comply with the applicable accident prevention regulations Avoid exhaust smoke directly falling on the Target plates Do not hammers or hit any part of the equipment with service Tools Do not operate the equipment under direct sunlight.
  • Page 47 Using Frame reference gauge, the centre line of Truck chassis is identified (Refer blue line) by capturing the readings at all 4 positions. The mis-aligned Drive axle (B2) is indicated in Red line Adjust the Drive axle (B2) towards the chassis centre line (Blue line). Followed by this, adjust the remaining axles also with reference to the chassis centre line as per on-screen guidance.
  • Page 48  For Trucks with 1 Front axle & 1 Rear axle having Wheel base less than 4mtr, park the Front steer axle at 2 Rotary plate. Fig. 65 NOTE: Use F1 Target plates for Front axle wheels & B1 Target plates for Rear axle wheels.
  • Page 49 NOTE: Use F1 Target plates for Front axle wheels & B1 Target plates for Rear axle wheels.  For Buses with 1 Front axle & 1 Rear axle having Wheel base less than 4mtr, park the Front steer axle at 2 Rotary plate.
  • Page 50 NOTE: Use F1 Target plates for Front wheels & F2 Target plates for Rear wheels. Using any other Target plates may cause error in measurements.  For F1B3 Tag axle and F2B3 Tag axle Trucks, use Wheel bracket rim pin adaptor while fixing wheel brackets in B1 tag axle for target plates visibility.
  • Page 51 SCREEN BUTTONS & ITS FUNCTIONS To go to previous To redo Caster screen To view additional To go to next screen parameter of Rear wheels To view additional To skip the current parameter of Front operation wheels To go to Welcome To view Vehicle screen specifications...
  • Page 52 7.3. MAIN MENU When the equipment is switched ON, Windows Operating System will boot up and then the system will initialize all the devices. Execute the Aligner software from the desktop. A Welcome screen will be displayed with following options: Fig.
  • Page 53 7.4. ALIGNMENT Keep hands & other body parts away from jacking surfaces. Follow jack manufacturer‟s safety recommendations during tyre location change. Failure to comply may lead to injury The Target plates are configured with an exclusive identification name (F1, F2, B4, B3, B2, &...
  • Page 54 Select the required User & key-in the password to enter into Vehicle selection screen. NOTE: If user ID is not created, use Default user for further operation. 7.4.1. VEHICLE SELECTION Select the required Vehicle databank from the following options in the screen: Fig.
  • Page 55 User can also search & select the required vehicle quickly by pressing VEHICLE SEARCH button by providing the Vehicle Make, Model & Database as input, instead of going through standard selection process Vehicle specifications can be selected at Initial stage and "Alignment completed"...
  • Page 56 (iv) B2 Axle specification: Fig. 82 (V) B3 Axle specification: Fig. 83 Check the condition of each parameters of the Vehicle and select the required data to record in the Alignment report. In case of HCVs with Multi-axles, Check & ensure the Frame gap of both Left &...
  • Page 57 Place Wheel stoppers 0.5metre before the Front wheels and 0.5metre behind the Rear wheels to arrest excessive movement of vehicle while carrying out the Push-Pull Runout Level all the Target plates & lock knobs before Runout measurement Make the Gear lever to Neutral position if the vehicle being aligned is Rear wheel drive The pushes axle or Tag axle should be disabled from lifting function (load sensor) in the vehicle for carrying out the Push-Pull runout...
  • Page 58 CUSTOMER DATA INPUT 7.4.2.1. After Vehicle selection, following screen will be displayed: Fig. 85 Enter required input. All the above data will be recorded in the Alignment report which can be printed after completing alignment. While feeding the customer data, the machine will be searching the targets in the background of the program.
  • Page 59 Car with 1 Front axle & 1 Rear axle Fig. 87 Press RUNOUT button to carryout Push-Pull Runout measurement. The following screen will be displayed. Drive the vehicle backwards until the ball matches the green region in screen. Truck with Truck / Bus with 2 Front axles &...
  • Page 60 The stop display will prompted at 30° of roll. Apply brake gently and wait for the reading acquisition and till STOP symbol goes off. Fig. 89 Now drive the vehicle forward and to reach the home position. Then Stop the engine.
  • Page 61 If any of the wheels have abnormal value ie, above 1°30‟, a warning message will be displayed. Press REDO RUNOUT to redo Runout after ensuring the proper mounting of Wheel bracket. Otherwise proceed further. Fig. 93 Remove the Locking pins from the Rotary plates and apply Brake pedal lock once the Runout is completed 7.4.3.
  • Page 62 Steer the wheels to left until the moving BALL fully matches the left GREEN region. After reaching the Left Green region, the system will display "Stop " icon and measures the parameters. Fig. 95 After data acquisition, system will automatically go to Turn Right screen.
  • Page 63 Now adjust the Steering wheel straight manually for fine adjustment till the Red ball in the Green region reaches the centre white region, followed by a "Stop" symbol and then goes to next screen. Fig. 98 Lock the Steering wheel in straight position visually and then press NEXT SCREEN button as shown below to record Initial measurements of all parameters for prinout: Fig.
  • Page 64 7.4.4. ALIGNMENT PARAMETERS & RESULTS Following procedure needs to be carried out for the adjustments as per vehicle Manufacturer‟s specification. TWO COLOR REPRESENTATION While doing Caster, Camber & Toe correction, the pointing Arrow sliding over the Horizontal bar indicates specification range using different colors as indicated below: Color Indication...
  • Page 65 THRUST ANGLE ADJUSTMENT 7.4.4.1. Press NEXT button to view & adjust the Thrust angle & the tilt direction of Axle. By feeding the distance of the Spring plates or Track width, the amount of the movement towards the direction will be indicated.
  • Page 66 REAR WHEEL PARAMETERS 7.4.4.2. By pressing REDO ALIGNMENT button, complete alignment sequence from Wheel runout screen can be repeated Truck with Truck / Bus with 2 Front axles & 3 Rear axles 1 Front axle & 1 Rear axle Car with 1 Front axle &...
  • Page 67 Fig. 108 Adjust the front wheel Toe for F1 axle as per specification & lock the tie rod. Pres NEXT button to view all other parameters of front axle. Truck / Bus Car / LCV Fig. 109 This screen displays the Live readings of Caster, Camber and Toe. Effect the corrections in the Front wheels until the GREEN color at the Horizontal bar with the Arrow point to that region.
  • Page 68  After achieving the F2 Toe, adjust the Drag link to make adjustment of differential Toe as guided by the screen. After achieving the differential toe to zero, now tighten the Drag link pinch clamps. Fig. 111  After adjustment of F2 Total toe & Differential toe, press NEXT button go to Parallelism Adjustment screen.
  • Page 69  After adjustment of F2 toe & parallelism, press next button to read F2 axle other parameters. Fig. 114 Press NEXT button to carryout Toe adjustment of Pusher axle. PUSHER AXLE ADJUSTMENT (Single Tie rod) 7.4.4.6. Following procedure should be carried out to adjust Pusher Axle Toe: ...
  • Page 70 SCRUB ANGLE ADJUSTMENT 7.4.4.7. Press NEXT button to view & adjust Scrub angle & the tilt direction of Axle. By feeding the distance of the Spring plates or Track width, the amount of the movement towards the direction will be indicated. Now adjust the Scrub angle to 0°...
  • Page 71 TAG AXLE ADJUSTMENT 7.4.4.8. Following procedure should be carried out to adjust Toe of Tag Axle: Fig. 122  Adjust the Axle (B1) to zero.  In this condition, adjust the Tag axle tie rods to achieve the required Toe and lock it. Fig.
  • Page 72  Select the Vehicle Make and Model of car using the Drop down menu and click NEXT button: Fig. 125 If required, the Make of CAM / Bush can be selected from the Drop down menu  System will prompt the user to choose the adjustment methods and the sequence for adjustment as shown below: Fig.
  • Page 73 Fig. 128 Fig. 129 ADJUSTABLE BUSHING In this method, User can adjust the Bush online to achieve the required Camber & Caster instead of replacing the new Bush, so that the user can save time: Fig. 130 Fig. 131 Ref.: MEL-WA(3D HCV) - OM Ver.1.7...
  • Page 74 CAMBER / CASTER SHIMS In this method, System guides the user to perform online adjustment for Caster & Camber. User can select the required shim size for replacement and perform adjustment to achieve the Camber & Caster within specified value: Fig.
  • Page 75 REAR ADJUSTMENTS In this method, user can select the required shims for rear wheel and perform adjustment to achieve the Camber & Toe within the specification: Fig. 136 Fig. 137 DEFAULT In this option, user can select the required Bush for the replacement in upper control arm and perform adjustment to achieve the Camber within specification: Fig.
  • Page 76 7.4.5. MULTI-AXLE CONFIGURATIONS & APPLICABLE SEQUENCE (Drive Axle Reference) CARs and LCVs (6A/5A/4A) 7.4.5.1. Mount Front F1 labeled Target plates with Front axle (F1) Mount Front F2 labled Target plates with Rear axle (B1) Carryout Push-Pull Runout by driving vehicle (Ref. Chapter 7.4.3) Carryout Caster / KP swing for F1 (Ref.
  • Page 77 HEAVY TRUCK – 1 Front Axle & 3 Rear Axles (6A/5A/4A) 7.4.5.4. Mount Front Target plates with Front axle (F1) Mount Rear Target plates with Rear axles (B3, B2 & B1). For 4A model use F2/B3 labeled Target plates Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 78 HEAVY TRUCK – 2 Front Axles & 3 Rear Axles (6A/5A) 7.4.5.7. Mount Front Target plates with Front axles (F1 & F2) Mount Rear Target plates with Rear axles (B3, B2 & B1) Carryout Push-Pull Runout by driving vehicle (Ref. Chapter 7.4.3) Carryout Caster / KP swing for F1 &...
  • Page 79 HEAVY TRUCK – 2 Front Axles & 3 Rear Axles (including 1 7.4.5.10. Pusher 3rd Axle) (6A/5A) Mount Front Target plates with Front axles (F1 & F2) Mount Rear Target plates with Rear axles (B3, B2 & B1) Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 80 HEAVY TRUCK – 2 Front Axles & 4 Rear Axles (including 1 7.4.5.12. Pusher & 1 Tag Axle) (6A) Mount Front Target plates with Front axles (F1 & F2) Mount Rear Target plates with Rear axles (B4,B3, B2 & B1) Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 81 BUS – 1 Front Axle & 2 Rear Axles (including 1 Tag Axle) 7.4.5.15. (6A/5A/4A) Mount Front Target plates with Front axle (F1) Mount Rear Target plates with Rear axles (B2 & B1) Carryout Push-Pull Runout by driving vehicle (Ref. Chapter 7.4.3) Carryout Caster / KP swing for F1 (Ref.
  • Page 82 BUS – 2 Front Axles & 2 Rear Axles (including 1 Pusher Axle) 7.4.5.18. (6A/5A/4A) Mount Front Target plates with Front axles (F1 & F2) Mount Rear Target plates with Rear axles (B2 & B1) Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 83 TRAILER (Forward parking) – 2 Rear Axles (6A/5A/4A) 7.4.5.21. Mount Rear Target plates with Rear axle (B1) Mount Rear Target plates with Rear axle (B2) Carryout Push-Pull Runout by driving vehicle (Ref. Chapter 7.4.3) Carryout measurement as guided by the screen Adjust Rear 2 axle (B2) Adjust Rear 1...
  • Page 84 TRAILER (Forward parking) – 5 Rear Axles (6A/5A/4A) 7.4.5.24. Mount Rear (B1) Target plates with Rear 3 axle (B3) Mount Rear (B2) Target plates with Rear 4 axle (B4) Mount Rear (B3) Target plates with Rear 5 axle (B5). For 4A model use F2/B3 labeled Target plates Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 85 TRAILER (Reverse parking) – 1 Rear Axle (6A/5A/4A) 7.4.5.25. For reverse parking, select the Settings icon from Welcome screen and select required Trailer parking options as shown below: Ensure the B1 axle is parked at 7mtr from the Camera reference line Mount Rear Target plates with Rear axle (B1) Carryout Push-Pull Runout by driving...
  • Page 86 TRAILER (Reverse parking) – 4 Rear Axles (6A/5A/4A) 7.4.5.28. Ensure the B1 axle is parked at 5.5mtr from the Camera reference line Mount Rear (F1) Target plates with Rear 1 axle (B1) Mount Rear (B1) Target plates with Rear 2 axle (B2) Mount Rear (B2) Target plates with Rear 3...
  • Page 87 TRAILER (Reverse parking) – 6 Rear Axles (6A/5A/4A) 7.4.5.30. Ensure the B1 axle is parked at 4mtr from the Camera Mount Rear (F1) Target plates with Rear 1 axle (B1) Mount Rear (B1) Target plates with Rear 3 axle (B3) Mount Rear (B2) Target plates with Rear 4 axle (B4)
  • Page 88 TRAILER (Reverse parking) – 7 Rear Axles 7.4.5.31. Ensure the B1 axle is parked at 4mtr from the Camera Mount Rear (F1) Target plates with Rear 1 axle (B1) Mount Rear (B1) Target plates with Rear 3 axle (B3) Mount Rear (B2) Target plates with Rear 4 axle (B4) Mount Rear (B3) Target plates with...
  • Page 89 TRAILER (Reverse parking) – 8 Rear Axles 7.4.5.32. Ensure the B1 axle is parked at 4mtr from the Camera Mount Rear (F1) Target plates with Rear 1 axle (B1) Mount Rear (B1) Target plates with Rear 3 axle (B3) Mount Rear (B2) Target plates with Rear 4 axle (B4) Mount Rear (B3) Target plates with...
  • Page 90 FULL TRAILER (Forward parking) – 1 Front Axle & 1 Rear Axle 7.4.5.33. (6A/5A/4A) Ensure the B1 axle is parked from 7mtr from Camera Mount (B1) Target plates with Rear 1 axle (B1) Mount Front (F2) Target plates with Rear 2 axle (B2) Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 91 5. Fix drawbar gauge and mount the Front (F1) Target plates 6. Adjust Rear 1 axle (B1) 7. Swivel the Dolly as guided to center. 8. Adjust Rear 2 axle (B2) 9. Adjust Rear 3 axle (B3) and also ensure the Drawbar gauge values are within specification.
  • Page 92 FULL TRAILER (Forward parking) – 2 Front Axles & 1 Rear Axle 7.4.5.36. (6A/5A/4A) Ensure the B1 axle is parked at 7mtr from Camera 1. Mount Rear (B1) Target plates with Rear 1 axle (B1) 2. Mount Front (B4) Target plates with Rear 2 axle (B2) 3.
  • Page 93 6. Fix drawbar gauge and mount the Front (F1) Target plates 7. Adjust Rear 1 axle (B1) 8. Swivel the Dolly as guided to center. 9. Adjust Rear 2 axle (B2) 10. Adjust Rear 3 axle (B3) 11. Adjust Rear 4 axle (B4) and also ensure the Drawbar gauge values are within specification.
  • Page 94 FULL TRAILER (Reverse parking) – 1 Front Axle & 1 Rear Axle 7.4.5.39. (6A/5A/4A) Ensure the B1 axle is parked at 4.5mtr from Camera Mount Front (F1) Target plates with Rear 1 axle (B1) Mount Rear (B1) Target plates with Rear 2 axle (B2) Carryout Push-Pull Runout by driving...
  • Page 95 Fix drawbar gauge and mount the Rear (B2) Target plates Adjust Rear 1 axle (B1) Swivel the Dolly as guided to center. Adjust Rear 2 axle (B2) Adjust Rear 3 axle (B3) and also ensure the Drawbar gauge values are within specification.
  • Page 96 FULL TRAILER (Reverse parking) – 2 Front Axles & 1 Rear Axle 7.4.5.42. (6A/5A/4A) Ensure the B1 axle is parked at 4.5mtr from Camera Mount Front (F1) Target plates with Rear 1 axle (B1) Mount Rear (B1) Target plates with Rear 2 axle (B2) Mount Rear (B2) Target plates with...
  • Page 97 Fix drawbar gauge and mount the Rear (B3) Target plates Adjust Rear 1 axle (B1) Swivel the Dolly as guided to center. Adjust Rear 2 axle (B2) 10. Adjust Rear 3 axle (B3) 11. Adjust Rear 4 axle (B4) and also ensure the Drawbar gauge values are within specification.
  • Page 98 FULL TRAILER FORWARD PARKING ALIGNMENT PROCEDURE 7.4.5.45. (6A Model) Select the Full Trailer Configuration button in the Vehicle type selection screen: Select the required model configuration of the Full trailer. (Forward Parking) Fig. 139 Park the Full trailer in Forward parking as shown below in such a way that the B1 axle is at a distance above 7 meter from Camera and press NEXT button.
  • Page 99 The system will identify the Target plates mounted on the wheels as shown below: Fig. 142 Press RUNOUT button to carryout Push-Pull Runout measurement. The following screen will be displayed: Fig. 143 Push the Full trailer backwards by 30° away from Camera by driving the vehicle or pushing manually, until the ball matches the green region in screen.
  • Page 100 Now drive the vehicle forward to reach the home position. Then Stop the engine. Fig. 146 Once the Stop symbol is displayed, the system will proceed to next screen automatically. Fig. 147 Runout values will be displayed. Press NEXT button to proceed further.
  • Page 101 Initial values will be displayed as shown below: Fig. 150 Adjust the B1 axle (Thrust angle) as per screen guidance and press NEXT button after completion: Fig. 151 Individual parameters of B1 axle will be displayed. Press NEXT button to proceed: Fig.
  • Page 102 Adjust the B2 axle and press NEXT button. Fig. 154 Individual parameters of B2 axle will be displayed. Press NEXT button to proceed: Fig. 155 Adjust the B3 axle and press NEXT button. Fig. 156 Individual parameters of B3 axle will be displayed. Press NEXT button to proceed: Fig.
  • Page 103 Adjust the B4 axle and press NEXT button. Fig. 158 Individual parameters of B4 axle will be displayed. Press NEXT button. Fig. 159 Both the B5 axle‟s Scrub angle and Drawbar‟s straight ahead will be displayed simultaneously. Adjust both the parameters to achieve the target values and press NEXT Button Fig.
  • Page 104 Alignment report will be generated and displayed: Fig. 162 Press HOME button to save the job. FULL TRAILER REVERSE PARKING ALIGNMENT PROCEDURE 7.4.5.46. Select the Full Trailer Configuration button in the Vehicle type selection screen: Select the required model configuration of the Full trailer. Fig.
  • Page 105 Fix the Wheel brackets (with Target plate) as shown in the Attention screen. Ensure the targets are visible in the preview screen. The Target plate ID is shown within brackets (ID). Fig. 165 Note: Do not interchange the Target IDs with Axle IDs Enter required input in the Vehicle details screen and press NEXT button.
  • Page 106 The stop display will prompted at 30° of roll. Apply brake gently and wait for the reading acquisition and till STOP symbol goes off. Fig. 169 Now drive the vehicle forward to reach the home position. Then Stop the engine. Fig.
  • Page 107 Fix the Drawbar in such a way that its Pointer is perpendicular to the axle as shown below. Fix the Target plate & press NEXT button. Fig. 173 Initial values will be displayed as shown below: Fig. 174 Adjust the B1 axle (Thrust angle) as per screen guidance and press NEXT button after completion: Fig.
  • Page 108 Adjust the Dolly by swiveling it as per the arrow indicated on screen. After achieving the value within range, press NEXT button. Fig. 177 Adjust the B2 axle and press NEXT button. Fig. 178 Individual parameters of B2 axle will be displayed. Press NEXT button to proceed: Fig.
  • Page 109 Individual parameters of B3 axle will be displayed. Press NEXT button to proceed: Fig. 181 Both the B4 axle‟s Scrub angle and Drawbar‟s straight ahead will be displayed simultaneously. Fig. 182 Adjust both the parameters to achieve the target values and press NEXT button.
  • Page 110 ARTICULATED BUS – 1 Front Axle & 2 Rear Axles 7.4.5.47. Reverse parking alignment is not possible for Articulated buses & can be done only in Drive through model Park the Bus on a straight line by ensuring the Front (F1) axle is at 2.8mtr from Camera in 1 Rotary plate 7 MTR...
  • Page 111 ARTICULATED BUS – 1 Front Axle & 3 Rear Axles 7.4.5.48. Park the Bus on a straight line by ensuring the Front (F1) axle is at 2.8mtr from Camera in 1 Rotary plate 7 MTR 2.8 MTR Mount Front (F1) Target plates with Front 1 axle (F1) Mount Rear (B1) Target plates with...
  • Page 112 Remove Front (F1) Target plates from Front 1 axle (F1) and mount it with Rear 2 axle (B2) 10. Remove Rear (B1) Target plates from Rear 3 axle (B3) and mount it with Rear 1 axle (B1) 11. Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 113 7MTR 2.8MTR Remove Front (F1) Target plates from Front 1 axle (F1) and mount it with Rear 3 axle (B3) 10. Remove Rear (B1) Target plates from Rear 4 axle (B4) and mount it with Rear 2 axle (B2) 11. Carryout Push-Pull Runout by driving vehicle (Ref.
  • Page 114 7.5. DATA MANAGER This software will work only on Wheel aligner machine Data from alignment results are forwarded to the Wheel aligner Data Manager only at the end of wheel alignment in the Alignment completed screen Data Manager is smart software developed for the purpose of managing alignment results which are generated by Wheel aligner.
  • Page 115 Fig. 188 The list of alignments conducted within the provided date will be displayed Job number wise. By selecting tab of respective axle in the screen, results of respective wheel parameters can be viewed. Press VIEW button to view the Date based reports as shown below: Fig.
  • Page 116 Select the required Vehicle Registration number and press NEXT SCREEN button. Following screen will be displayed: Fig. 191 Fig. 192 The list of alignments conducted for the selected Vehicle registration number will be displayed based on Job number. By selecting tab of respective axle in the screen, results of respective wheel parameters can be viewed.
  • Page 117 Select the required Year and press NEXT SCREEN button. Press VIEW button to view the Year based alignment report as shown below which helps the user in getting the No. of alignments achieved in a year (Month wise): Fig. 195 Press PRINT button to print the report.
  • Page 118 7.5.5. CUSTOMER DATABASE Upon selection of Customer database icon, a Date window will be displayed. Select the required “From” and “To” date and press NEXT SCREEN button: Fig. 198 Press VIEW button to view the date based Customer details as shown below: Fig.
  • Page 119 DELETE DATA button is provided in the Data Manager program to delete the data with following options: Within a period Job number wise All the data Press HOME button and then select TICK mark to exit from Data Manager program and return to Welcome screen as shown below: Fig.
  • Page 120 7.6. SETTINGS You can enter into this Option by clicking SETTINGS in the Welcome Screen and by providing the Password. Fig. 202 The following Menu will be displayed: Vehicle Measurement units Alignment data Workshop Calibration history specifications information Ref. Chapter 7.6.1 Ref.
  • Page 121 INDIAN HCV DATA 7.6.1.2. The Indian data contains specifications of known vehicles collected by Manufacturer with update available at the time of dispatch. However Manufacturer is not responsible for any incorrect or incomplete vehicle specifications available in the Indian data. UNITED STATES HCV DATA 7.6.1.3.
  • Page 122 By selecting this option, screen displays the following Data sheet in which the details of specifications are to be filled: The user has to keep ready all these information before starting to add any Vehicle specifications. VEHICLE MAKE Type Vehicle makes and press ENTER to go to the next window.
  • Page 123 7.6.2. MEASUREMENT UNITS This option is used to change the measurement units like “degree min" / “degree” / “mm" / “inch” and other angles in “degree” / “degree min”, “kg” “lb”. Fig. 206 7.6.3. ALIGNMENT DATA This option is provided to view the results of a particular job to analyse / trouble shoot.
  • Page 124 Now choose “Save as” from the File menu and provide a relevant name and then select “JPEG” as file type. Adding Logo After providing the Workshop information, click on the Logo box provided at the bottom. System will prompt to choose the Logo file from the PC. Choose the relevant JPEG file and press SAVE button in the screen to include the Work shop Information &...
  • Page 125 Following are the options provided: Fig. 211 BACKUP CALIB DATA FROM PC TO OTHER LOCATION 7.6.7.1. This option is used to backup the Calibration data from Desktop Computer to other locations. Also a backup is stored in local HDD of Personal computer. Choose the location in which the data is to be saved and click SAVE button.
  • Page 126 7.6.8. RESET JOB NUMBER The Job Number is a Serial number which is automatically generated by the system for each alignment job. This option is useful to reset the Job number to 0001. If this option is selected, confirmation will be requested to reset the Job Number.
  • Page 127 For enabling LCV Vehicle data Fig. 216 For upgrading to 6A alignment Fig. 217 For enabling Software lock Fig. 218 RESET PASSWORD 7.6.9.2. On selecting this option, the operator will be prompted to enter the current password. If entered password is not correct "Invalid Password"...

  • Page 128: Language Settings

    7.7. LANGUAGE SETTINGS The User can select the preferred language out of the available options so as to display the alignment screens and Voice prompts in their regional languages. Press LANGUAGE button in the Welcome screen and select the language as shown below: Fig.

  • Page 129: Maintenance

    MAINTENANCE The equipment requires only minor maintenance to keep the equipment operating properly. We recommend attention to the following points for getting maximum benefit out of the equipment. Keep the area around the Aligner clean. Remove any tools or other items that are leaning against the Aligner.

  • Page 130: Troubleshooting

    TROUBLE SHOOTING The common troubles and error messages which can be attended by the users are listed in the table given below. For Troubles and Error messages other than that are listed in the table contact the Service Engineer for Trouble shooting. The Service Engineer may ask for information to help in diagnosing the service concern.
  • Page 131 Trouble Causes Remedies Ensure wheel bracket rim locking pins are clamped properly All the Wheel brackets should be clamped uniformly either at inner or Wheel bracket not fixed outer side of Rim properly Ensure the wheel bracket is fixed on the rim at 12 o clock position (While the wheel bracket center block is slide down).
  • Page 132 9.2. ALIGNMENT HCV Trouble Causes Remedies Misaligned Rear axle (ie., unequal Rear Toe). Check the Rear suspension Rear axle is not perpendicular to Geometric Centre Line Setback Check the position of Front wheels are in line Uneven tyre pressure. Car pulls sideway with low Check both tyres are with same pressure inflation Mismatched tyre sizes.
  • Page 133 Trouble Causes Remedies Tyre squeal on turns due to wrong Toe Out on Turn angle Align the Tie rod and adjust the Lock angle from misaligned Tie rod, or and check the tyre pressure bent Steering arm. Low or uneven tyre inflation Unstable at high Speed due to Adjust the Toe or replace the worn out incorrect Front or Rear Toe or...
  • Page 134 9.3. DESKTOP COMPUTER & PERIPHERALS Trouble Causes Remedies Insert the equipment’s Power When System is switched Power socket problem or cord to another Plug point’s ON, no beep sound and loose connection in the No display Power socket plug point power socket &...
  • Page 135 Manufactured by All rights reserved. Any reproductions of this document, partial or complete, are not allowed without prior consent of Manufacturer All information, illustrations and specifications contained in this Manual are based on the latest information available at the time of publication. Manufacturer reserves the right to make changes at any time without further notice to any of its products to improve reliability, functions, design or whatever can be thought suitable...

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