User Manual
Contents
1. There are several different TruckCam adapter types available to make it easier to mount the frame gauges to the frame please check out the accessories list in this manual or contact your local TruckCam supplier for further information 6 Section Product Description cnapter Accessories page 9 18 TruckCam Frame Check System User Manual Software version 2 truckCam a 3 2 Place the reflective targets on the frame gauges Make sure the targets are positioned cor rectly Mount Wheel Adapters The TruckCam Wheel Adapters are made to fit both aluminum and steel rims in sizes 12 to 24 They are mounted by fitting the hooks at the end of the wheel adapter legs either on the inside of the rim or between rim and tire depending on rim make and rotating the knob on the side of the wheel adapter to secure it T9 TruckCam Frame Check System User Manual Software version 2 truckCam Software and hardware startup Start your computer and start the TruckCam software by double clicking the program icon Start up the cameras by pressing the ON OFF button In the TruckCam startup screen choose Continue to start new measurement or Resume to resume the latest measurement Please note A Resume is only possible within 24 hours of the latest measurement When choosing Continue the screen Frame Measure is shown This is the basic scr2. 3195 LON OG es HSINH sm 1550 1984901Q 61121 6 JOUCHAO 8 7 _ 19901 8 022 7 1 _ 9901 1 0c9 1496uoH 69901 UOISUSPF 7151 G qouy 99901 2 2 qouy 9901 qouy 89901 07961 MOS NNN wau 37 JIDIY 91492 AT I 466 01 Sidu 61045 uoydudseg YTE nding VEL HOOS APE 001 LO er E 2 X 5 2 5 5 4 5 E 5 so 2 E38 e Addis y 3 O4 NIKLAS Jequunu Hod TruckCam Frame Check System User Manual Software version 2 truckCam APPENDIX CE DECLARATION EC Declaration of Conformity Model 256 Camera Sensor Brand name TruckCam Manufacturer TruckCam AB H gmossev gen 3 SE 641 39 Katrineholm Sweden Tel 46 150 66 25 40 Fax 46 150 66 25 41 TruckCam AB declares under our sole responsibility that the product identified as TC 258 Camera Sensor to which this declaration relates is in conformity with the B9 338 EEC European Directive The following harmonized standards has been applied EN 61000 6 2 2005 EMC Immunity EN 61000 6 4 2007 Emission The product is C marked
3. in accordance with the EC Declaration of Conformity the product must not be modified without the manufacturer s permission If this occurs this documented EC Declaration of Conformity ceases fo apply and the product s owner is considered be the manufacturer and must verify and draw up an addendum to the EC Declaration of Conforrmity and file technical data for the inspection authority Katrineholm Sweden on the 19th of March 2008 tel 46 0 Thorleif 0398501 fax 46 0 15065 25 41 Managing Director TruckCam AB FruckCam AB Hgmessedgen 3 SE 647 39 Katrineholm Sweden fet 440 0750 852540 Far 46 0150 86 25 47 infodirckeam om temet wii FUCCNTL com 39 TruckCam Frame Check System User Manual Software version 2 40 TruckCam Frame Check System User Manual Software version 2 APPENDIX CONTACT INFORMATION For support please contact the local TruckCam representative in your area or country System Manufacturer TruckCam AB Hogmossevagen 3 SE 641 39 Katrineholm Sweden Tel 46 0 150 66 25 40 Fax 46 0 150 66 25 41 E mail info truckcam com Internet www truckcam com truckCam 41 TruckCam Frame Check System User Manual Software version 2 Printed February 17 2010 TruckCam Part no 19101
4. truckCam TruckCam Frame Check System Volvo FH16 700 1520 ehicle data 20100129 Ci Cain egistration no ABC 123 EN ake type ileage otes TruckCam AB gmosseviigen SE 641 39 Katrineholm Sweden Sign Johansson Twist Tilt 4 3 Vertical Bending in mm O TruckCam AB User Manual Software version 2 X X IruckCam AB Hogmossevagen 3 5 641 39 Katrineholm Sweden lel 46 01150 66 25 40 Fax 46 01150 66 25 41 E mail info truckcam com Internet www truckcam com TruckCam Frame Check System User Manual Software version 2 INDEX 1 PRODUCT DESCRIPTION 2 SOFTWARE INSTALLATION AND SETUP 3 MEASUREMENT PREPARATION 4 CALIBRATION OF EQUIPMENT 5 MEASUREMENT PROCEDURES 6 MEASUREMENT DOCUMENTATION 7 SYSTEM MAINTENANCE APPENDIX A SYSTEM SPARE PARTS APPENDIX CE DECLARATION APPENDIX C CONTACT INFORMATION truckCam 10 18 21 21 32 33 34 39 41 TruckCam Frame Check System User Manual Software version 2 TruckCam Frame Check System User Manual Software version 2 x x truckCam 1 PRODUGT DESGRIPTION Agreed Functionality e The TruckCam Frame Check System is designed for measuring of frames and chassis of commercial vehicles e The TruckCam Frame Check System provides measurement of side sway vertical bend tilt and twist e The TruckCam Frame C
5. Joh Twist Tilt 4 3 20100129 Choose Vehicle data to enter data about the measured vehicle Save to save the current measurement Print to print the report sheet and Done to return to the Frame measurement window When clicking Save a dialog box will open to allow you to choose file name and where to save the measureemnt data The data will be saved in the form of a jpg image a picture of the printed report 32 TruckCam Frame Check System User Manual Software version 2 x x truckCam 7 SYSTEM MAINTENANCE Well kept and well maintained system parts will greatly increase and secure the reliability and life time of the system Cameras In order to maintain the measurement system make sure the cameras are kept in order and store them in the charging cradle when not in use to avoid damage The protective front glass of the cameras may be cleaned using a dry soft cloth if necessary If a camera is dropped on the floor please do a calibration of the unit If that calibration fails please send the unit for repair accompanied by necessary fault descriptions Reflective targets The reflective targets should be kept clean at all times Clean them when necessary using a mixture of 50 alcohol and 50 water and dry them with a soft cloth Please be aware that grease or oil on the reflective wave will affect the functionality of the syst
6. TruckCam Frame Check System User Manual Software version 2 truckCam Frame gauge calibration In order to perform a proper and correct measurement it is not only important to check if the cameras are calibrated but also very important to check whether the hardware frame gauges you are using is in perfect order This checking of hardware can be done by use of the software and cameras under Frame Gauge Calibration In the Frame measure measurement window please click on Frame gauge calibration Mount two wheel adapters with cameras on one of the vehicle axles Hang the self centring gauge you are about to calibrate as square as possible to the frame either in the front of the vehicle or at the position on the frame where it is easiest to end turn the frame gauge by 180 Place the front markers in the correct positions on the frame gauge 24 TruckCam Frame Check System User Manual Software version 2 truckCam Please follow the steps presented by the help texts in the yellow square on the computer screen 18 Position 1 1 Aim one camera with the securing screw up at one the markers and press OK 2 Aim the camera on the other side of the vehicle with the securing screw up at the other marker and press OK Position 2 3 End turn the frame gauge by rotating it 180 and hang it on the same spot in the frame as before 4 Move the markers to the correct positions and make sure the
7. shown on the computer screen are in mm 3 Measure the width of the frame in the rear Enter the data into the screen as described above 27 TruckCam Frame Check System User Manual Software version 2 truckCam 4 Measure the inside distance between the left and right marker Enter the data into the screen as described above The program needs this distance in order to calculate the twist value for the frame width you entered KT TS dannes ep 331415 spo GETS agde 5 Click on Store 28 TruckCam Frame Check System User Manual Software version 2 truckCar Please follow the steps presented by the help texts in the yellow square on the computer screen 1 Aim camera with the securing screw up at the closest marker and press OK Take the first camera from the spindle and place the second camera on the same wheel adapter Aim this second camera with the securing screw up at the same marker and press OK The two cameras have both taken a picture of the same target in order to let the computer combine both pictures to calculate the correct values Stay on the same side and remove the camera from the spindle turn it 180 and remount it on the spin dle Aim the camera with the securing screw up at the far marker and press OK Go to the other side w
8. specific location Click Next 10 TruckCam Frame Check System User Manual Software version 2 Foi nu Hard ary nd Fiene chose your 15 nanc fer locare Via Pe ther kn below rd Fri dp io teen oe nata meas Tha bar deer ond si bue Li Search remavabie media CD ROM 7 include this konen in peach PT v Dont choom Chien __ 12 _ dte frasi in RM cher yoa caosa wil Es bas mech for pour haer Cr Jer Cass Choose to search removable media for the device driver or choose to specify a location and browse to the TruckCam Software CD Click Next Truck am __ B noi gen jemg ro vety Click Continue Anyway The device driver for the TruckCam Wireless Server is perfectly Windows 2000 XP Vista compatible although this warning might occur during installation Found Hev Hardware Wizard Completing the Found New Hardware Wizard Tha acad hae nud plug the aane Lar cam Wireless P Firash keg Pa Click Finish when the device driver has been completely installed 11 TruckCam Frame Check System User Manual Software version 2 truckCam PC software Load the TruckCam Software CD and choose the folder for the applica
9. ON OMG OL L3IVOS HOEM WTI Jejdopo eeuM OG O1 60 10 8002 2n SUDJSIQ 683701 66 OCX 444 OcXe deld 82 SMD D ZE M S 901 92 QOUY GCOOL SC COIS 9X9W SS9S vC amp 8 61 J9Uso 99CV 08 EG J9USDM L6CV OC 84501 IC SASS VSEOL OG 1915049 S 0l 61 C000 CO CO NO ION CN NOD 00 0 lt JOYUSOM 8 461 49 50 MOIOSOWUOG OZXO LW 59 M S LW S94W JAN SW INN 4D0T 9155 OVX8W S9OW 932649 Buuds 9 9 ISUSPMISISS O 444 02 444 NU 7201 9 10 3 01 9155 SOX9W S9 OW 631 WI soq 668401 ALO NOLLAINDS3G N38WN 13 Vd EN 18 e vo GAddV ov NMV3G JYNLYNDIS 3WVN 5144 8976 OSI S3ONV 38ITIOL XX D3 HSINIJ 3593415 SB3I3WITIIW NI 34 SNOISNAWIG HSINIH 13412345 ASIMYAHLO 859131 L EIVIS P i 36 TruckCam Frame Check System User Manual Software version 2 Frame Gauge 102 0595 ON OMA WINALL vo spod mm QUDIJ CO 0 FT 22 10 9005 ov EH AUU 892T OSI SJONVAITOL 8
10. ble language TruckCam Frame Measurement System Waai Settes 21 0 Frams Choose to install the TruckCam program in different folder by clicking Browse or con tinue the installation by clicking Next 12 TruckCam Frame Check System User Manual Software version 2 truckCam 44111 em E _ Click Finish when installation is complete If the above Restart dialog shows please click Restart to restart the computer before starting to use your TruckCam system in order for the software to work properly 13 TruckCam Frame Check System User Manual Software version 2 truckCar Setup Framerieasure ment Double click on the TruckCam program icon to start the TruckCam program Start up the cameras by pressing the ON OFF button on the units respectively Click Setup to enter the program setup Before using the system for the first time it is required to enter the setup area to configure the program settings These settings will then be stored in the program when you click Next in the setup window 14 TruckCam Frame Check System User Manual Software version 2 truckCam hhyrorimkmn 1 SE ELT 15 EEE FRA IS aisle ihm a mpm nb EM Communication setup It is vital to the functionality of the system that you enter the correct radio numbers of the cameras here in order for the wireless co
11. ble when measuring and fits aluminum as well as steel rims in sizes 12 24 Frame gauges TC 102 The TruckCam Frame Gauges work according to a self centering prin ciple When mounted to a vehicle they determine the vehicle center line which is the basis for all TruckCam wheel angle calculations The reflective targets are placed at the end of each frame gauge to make up a square of known points for each measurement Needed for measurements how ever not included in the TC 2007 TruckCam Upgrade System for Frame Measurement Needed for measurements how ever not included in the TC 2007 TruckCam Upgrade System for Frame Measurement Needed for measurements how ever not included in the TC 2007 TruckCam Upgrade System for Frame Measurement TruckCam Frame Check System User Manual Software version 2 truckCam TruckCam Accessories TruckCam offers a wide range of accessories to enhance and ease the frame measurement procedures even further Magnet Adapter TC 1029 2 This adapter can be used when ever needed to make the fitting of the frame gauges to the vehicle easier Chassis Extender TC 1026 2 This adapter is used when mounting the frame gauges to a vehicle with a very short overhang in the rear Frame Gauge Extender TC 102 30 2 The frame gauge extenders are used when mounting the frame gauge to vehicles with wide frames where the maximum width of 130cm between frame gauge hangers is not en
12. ecially designed to measure angles and distance relative to a reflective target It has a strong housing with rubber protection at both ends The camera lens and built in flasher is protected by a hardened front glass camera is equipped with an infra red IR flasher sending out short flashes of IR light a few times per second When this light hits a reflective target the light will reflect back to the camera lens The lens is equipped with an IR filter only permitting IR light to pass through The result is a picture having a reflec tive target depicted against a black background Thus the camera can operate in complete darkness or in sunshine since it only uses the light from the IR flasher The picture is analyzed by a microprocessor within the camera sensor itself and information is sent to the computer by wireless communication The computer finishes the calculations giving the three angles a alfa B beta and camber as well as the distance to the target as a result These parameters are then used by the computer software to calculate the wheel angles and frame deformations camera is equipped with three electronic inclinometers as well as a gyroscope The signals from these sensors are combined with the data from the camera to produce a very powerful tool to be used for wheel alignment The gyroscope is used to extend the angle range to handle max turn angles for steerable axles The electronic inclinometers are used t
13. een from where both measurement and calibration functions are started 20 TruckCam Frame Check System User Manual Software version 2 truckCam 4 CALIBRATION OF EQUIPMENT Camera Calibration The TruckCam software has a built in functionality for checking and calibrating the cameras This calibration is carried out on the vehicle to be measured using the standard measure ment equipment If necessary start up the unit itself by pressing the ON OFF button on the back of the camera Start the program and continue by clicking Continue In the Frame measure measurement window click Camera Calibration 21 TruckCam Frame Check System User Manual Software version 2 truckCam Follow the steps presented by the help texts in the yellow square on the computer screen 1 Aim the camera slightly upwards and press the OK button 2 Aim the camera slightly downwards and press the OK button 3 Aim the camera horizontally and press the OK button 22 TruckCam Frame Check System User Manual Software version 2 truckCam 4 End turn the camera by taking it off of the wheel adapter spindle turning it upside down and putting it back on the wheel adapter spindle again 5 Aim the camera at the same marker and press the OK button The screen will display the calibrated values Click Print to print a calibration report Click End to continue 23
14. em and might influ ence measurement results and or the working speed of the cameras Other equipment Please check on regular basis the functionality of all other hardware like wheel adapters and frame gauges in order to avoid faulty measurements 33 TruckCam Frame Check System User Manual Software version 2 APPENDIX A SYSTEM SPARE PARTS Camera Sensor TC 256 ev 6020 vo E nag AW B89 Z OSI SAONVAFIOL 288 01 DUUSJUV 01661 SIPUDH 01 052 21 Alo siivd 3494 NOLLdIMOSIG Lid ON Wal 9 8 1 9 G 34 TruckCam Frame Check System User Manual Software version 2 truckCam Frame Markers TC 207 10 20 30 40 Front Left 1 Sticker 2 Plate ITEM PRODUCT PART PRODUCT PART NO TC 207 10 1 Frame marker reflex sticker FL TC 207 01 2 Frame marker FL RR sheet TC 207 FL RR TC 207 20 1 Frame marker reflex sticker FR TC 207 02 2 Frame marker FR RL sheet TC 207 FR RL TC 207 30 1 Frame marker reflex sticker RL TC 207 03 2 Frame marker FR RL sheet TC 207 FR RL TC 207 40 1 Frame marker reflex sticker RR TC 207 04 2 Frame marker FL RR sheet TC 207 FL RR 35 TruckCam Frame Check System User Manual Software version 2 Wheel Adapter 12 24 TC 150 130 1 133HS 01961
15. heck System enables dynamic measurement while in driving position No lifting of frame or chassis is required during the measurement e The TruckCam Frame Check System enables measurements to be performed fast and reliable on all tyoes of commercial vehicles e The TruckCam Frame Check System uses wireless communication technology for transmission of information between camera sensors and computer TruckCam Frame Check System User Manual Software version 2 Technical Data Operating time with fully charged batteries Charging unit operating voltage Operating temperature System Requirements Recommended Central Processing Unit CPU Memory RAM Available hard disk space Ports Minimum Central Processing Unit CPU Memory RAM Available hard disk space Ports Required operating system Microsoft Windows 2000 SP3 XP SP2 Vista truckCam gt 16h 100 240V 50 60Hz 5 to 40 centigrade Intel Pentium IV 1 8GHz or equal 2GB 1GB 1xUSB2 0 Intel Pentium IV 1GHz or equal 1GB 1GB IXJSB2 Additional system requirements might apply to get the above mentioned operating systems fully functional please check with your operating systems supplier TruckCam Frame Check System User Manual Software version 2 x x truckCam Component Description For component spare parts see Appendix Spare Parts Camera Sensor TC 256 The TruckCam Camera Sensor is a rugged high precision sensor sp
16. ith the free camera Mount that camera on the spindle and aim the camera with the securing screw up at the closest marker and press OK Remove the camera from the spindle turn it 180 and remount it on the spindle Aim the camera with the securing screw up at the far marker and press OK 29 TruckCam Frame Check System User Manual Software version 2 truckCam The program has taken four reference points of the frame the data of which is now dis played on the computer screen The screen displays the distance between the scales in the front and the back of the frame On the left side you can see the twist of the frame which in this example is 4mm and the tilt leaning which in the example is 3mm If you are using more than two frame gauges and you have placed for instance three more gauges between the front and the rear gauges you are now able to move the targets which are placed on the gauges on the far side to the next frame gauge in order to take a ard a 4th and 5th measuring point When you are using two frame gauges you need to move the frame gauge on the far side including the markers to the next point of the frame you want to measure Please note You are not allowed to touch or move the cameras as they are now in meas urement position Any movement will result in measurement errors and the measurement will need to be started over again 30 TruckCam Frame Check System User Manual Software ver
17. nnections to work properly The system is shipped with the entire wireless communication interface between the units fully set up and func tional However when experiencing problems with wireless communication you might need to Pair the system units Instructions on how to do this can be found in Section Pairing on page 16 System standby This is where you set the time of system inactivity before the system enters standby mode A O value indicates that the standby mode is inactivated Report header and preview Enter company details to be printed on each measurement report sheet Also specify the path to the logo you want to use on each measuring report In case you would prefer to use the TruckCam logo this logo can be found in the Support subfolder of the TruckCam folder Please note that a logo needs to be specified in order for the system to print a measurement report 15 TruckCam Frame Check System User Manual Software version 2 x x truckCam Pairing Enter the Pairing function of the TruckCam system by clicking Pairing in the Setup window Follow the steps presented by the help texts in the yellow square on the computer screen 2 GITT 1 Press and hold both OK buttons on each camera for 7 seconds to activate the service channel This is indicated by the blue LEDs on the cameras which start to blink once the camera has entered service channel 2 Wait until the red squares
18. o calculate camber caster and KPI directly on the wheel itself The camera sensor is powered by a built in battery pack and the batteries are recharged every time the camera is placed in the charging cradle The operating time of the batteries is gt 16 hours depending on the way of use of the system The camera has a standby mode where it consumes only 1596 of the power In standby mode the wireless connection is still active while the camera part itself is switched off The software in the computer automati cally switches the camera from standby mode to operation mode as needed Needed for measurements how ever not included in the TC 2007 TruckCam Upgrade System for Frame Measurement TruckCam Frame Check System User Manual Software version 2 x x truckCam Frame Markers TC 207 The Frame Markers are markers that the camera sensor uses to determine angles and distances These markers need to be kept clean to maintain high measurement accuracy and long life time of the TruckCam system For cleaning recommendations please see Chapter 8 System Maintenance page 30 Wireless Server TC 305 The Wireless Server is connected to a PC and powered via a USB cable It permits the cam era to communicate with the PC software Wheel Adapter 150 The TruckCam Wheel Adapter is used to mount the cameras to the wheels of the vehicle The wheel adapter is designed according to a tripod principle to enable the best accuracy possi
19. on the screen has turned green for both cameras FET zi Pani Camara 1 180 95 85 16 TruckCam Frame Check System User Manual Software version 2 truckCar 3 Click Pair to automatically change the wireless channel to a randomly selected channel number or click Advanced to set the wireless channel to a manually selected number between 1 and 60 4 The squares on the screen will change from green to red and back to green again as the changing of communication channel is performed on all units Please wait during this procedure 5 The system will tell you when the pairing of the units is done by a message in the yellow help text square Now the units should communicate with each other 17 TruckCam Frame Check System User Manual Software version 2 truckCam 3 MEASUREMENT PREPARATION Before you start measuring the vehicle please complete the below mentioned steps e Check tire pressure tire size and inflate the tires to the specified pressure e Check if the floor or other surface that you re measuring on is reasonably flat Mount Frame Gauges Mount the self centering frame gauges as square as possible to the frame of the vehicle one in the front the other in the rear When using more than two frame gauges please hang the extra frame gauges on the positions of the frame or chassis which you want to measure a x pi
20. ough The total width between the hangers is with these units extended to 180cm TruckCam Frame Check System User Manual Software version 2 truckCam 2 SOFTWARE INSTALLATION AND SETUP Installation Start your computer and insert the TruckCam Software CD Plug the TruckCam Wireless Server into a USB port Windows will find the server and ask you to install its device driver Wireless Server Found Howe Hardware Wizard Welcome lo the Found New Hardware Wizard Vrak will paach lar Gren acd fee By boking pn your pn ites hardware EL er on he Virus Web ete bath vor aur perry Cups Vier bo 10 pagoh tee C yas Sin time CT Yes om ard every nene conis a rece Cr Pin rms Click hid batras Choose not to connect to Windows Update since the Server device driver can be found on the TruckCam Software CD Click Next Found Hew Hardware Wizard Tha pins Var Wireless ca 1 pou hardware came with an CO GJ or Boppy dusk de pi fee gard to de oO al Eus acie aee automatically Pesermanded 5 or pee lena Bebo Click batra Back Choose to install the device driver from a
21. sion 2 x x For the third and following measurement points the live value will appear on the computer screen Side bending Werticel bending In this example you can see that in this particular point of the frame 5 31m there is a side bend of 1mm and a vertical bend of 3mm Click on Store Value in order to save the measured values in this point To remove the value click on Delete Move your targets or the complete frame gauge with targets to the next point you want to measure and save the values Side bending Vertical bending Distance 1 3 5 31 mm mim m 11 j Tw gt al mm Lergh All values in the screen are now shown and calculated with reference points in the front and in the rear of the chassis The software allows you to change the reference points by clicking on the squares under Reference When changing the reference points the software automatically calculates the values for side bending and vertical bend In this case no new measurement 1 required truckCam 31 TruckCam Frame Check System User Manual Software version 2 truckCam 6 MEASUREMENT DOCUMENTATION Printed and saved report To print and or save a report of the measurement click Report Vehicle data tru Registration no 123 1 Make type Volvo FH16 700 Mileage 1520 Notes TruckCam AB H gmossev gen 3 SE 641 39 Katrineholm Sweden
22. y are faced at the cam eras 5 Press OK on one of the cameras Please note The cameras should not be touched during the frame gauge rotation as this will influence the calibration result 25 TruckCam Frame Check System User Manual Software version 2 truckCam The bar graphs on the screen will now show the error of the frame gauge in vertical as well as side position Adjust the frame gauge hangers until the bar graphs on the computer screen shows zero or turn into green The frame gauge is now calibrated and ready for use Click on End to return to the screen Frame Measure Please note In order to get perfect measurement results please calibrate all frame gauges before measuring a frame 26 TruckCam Frame Check System User Manual Software version 2 truckCam 5 MEASUREMENT PROCEDURES Start the TruckCam software by double clicking on the program icon Follow the necessary steps for preparation as described in Chapter 3 Measurement prepa ration and Chapter 4 Calibration of equipment To start measuring a frame the software first needs some parameters from the frame and frame gauges 1 Measure the width of the frame with a tape measure the front 2 Enter the data into the software in the Frame Measure measurement screen either by clicking with the mouse on the green or red arrows or by entering the numbers from the computer keyboard Please note The values
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