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Service Manual - Prier Tire Supply

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1. manufacturing use reproduction and sales rights are reserved by Snap on Tools and the information contained herein shall not Strobe an Strobe a Strobe aa be used in whole or in part without the d os des PIERRE express written consent of Snap on Tools Strobe4 Strobe4 Strobe Strobe lt Strobe lt Strobe lt gt D EAWO235J48A Motor D EAWO235J48A Motor r g lt 2 2 440664 IN 55 55 Front Calibration Front Ultra Camera p4 Ultra Camera Ultra Camera pi ges II EAPO238J20A T EAPO2BJ2OA 21 EAPO238 20A P BLACK BLACK BLACK FAWO235J48A 2 52 FAW0235J48A N switch PRE Switch 2 01763 2 01763 E MEN SET ID To 2 DOnnec LO CE Jltra Camera SET 0101 u 1 5 1 5 28 b Umi Switch ss LA switch T AN I SW EAW0235J48A P2
2. POINTING DEVICE KEYB PRINTER 21 3141516 7 819 E PT Imi e 3 4 s e 7 8 9 10
3. PE ll ect n T TT E IOD De P4 6 Cul Camera Camera AE Connections Connection Strobe Connection RIGHT CAMERA S
4. Page left blank intentionally CHAPTER 2 THEORY OF OPERATION GENERAL The SD Image Aligner is a revolutionary concept in performing wheel alignments The system uses a camera based machine vision technology that provides many benefits to the shop owner and alignment technicians Itis the fastest most accurate and easiest to use aligner ever made One of the benefits to new technologies is the use of state of the art components and computer programming that makes the task of servicing this product easier than previous generations of alignment equipment One of the most obvious differences is the lack of an electronic measuring head the source of many of the failures and inaccuracies on conventional products There is not much about this aligner that is conventional Shop owners and alignment technicians easily recognize the many strengths of this system compared to conventional measuring head systems As the 3D Aligner was prepared for introduction into other International markets such as Asia and Latin America it became evident that the tasks of developing language translations and market specific vehicle specification databases was overwhelming with DOS The decision was made in 1998 to develop a Windows based user interface for the 3D aligner in parallel with efforts to do the same for the company s conventional wheel alignment system In the fall of 1998 the Windows environment was introduced The Windows com
5. tte di 5 STROBE BOARD HEPLEAGENMENBNK CL UE ELE 5 8 BOTIOMJ TOP SWITGHREPEAGENMIENT cott uten b necu event aca 5 8 LOWER MINIEUB REPLACEMENTS uyu Z conste dame tie Meet esame DES 5 9 UPPER MINI HUB REPLAGEMEDIT ectetur pipe u u 5 9 BIO Qi CC RR 5 10 POWER SUPPLY ADJUSTIVIBNT u uuu k uu dui ee ee ea eels 5 10 MOTOR GONTROLEER PGB JUMPER reda 5 10 CALIBRATING CAMERA uuu ca rdum Ds u 5 11 CALIBRAIE POD MOTORS 5 11 SELEG RNG THE WHEEL GLAMP TYPE 5 12 CAMERA POD a a Ev oo detiene ats 5 13 Effective 04 2005 TABLE OF CONTENTS Effective 04 2005 INTRODUCTION GENERAL The contents of this service manual does not outline and explain the entire functions and use of the aligner In order for the Service Technician to properly troubleshoot and diagnose problems with this system he she must have an understanding of the proper operation of this unit and indicators The 3D Image Aligner is a revolu tionary concept in performing wheel alignments The system uses a camera based machine vision t
6. 3 49 CHAPTER 4 SECURITY GENERA P cS 4 1 SECURITY KEY QUE LS EC A a 4 1 BRAND SPECIF 4 1 de Neon outta 4 1 SOEFTWABE FEATURES iit ott tusun un ect a a baad Trete co a han s a 4 2 DESIGNATED GAME BRS nana ane same aa ane can tar De ei 4 2 Effective 04 2005 TABLE OF CONTENTS CHAPTER 5 ULTRA ARAGO 3 ae ia ice crags vce ees eas pun P PEE 5 1 COMPONENT IDENTIFICATION 5 2 COMMON POD ASSEMBLY SIDE VIEW uu uuu u un unn aaa 5 3 L EEFT OANIERAASSENIBIY niii yu Z Cove putet 5 4 ma e MER zm EET 5 4 mimi za AE m PE uc Tn 5 4 RIGHT GAMERA ASSEMBLY satriane at ayusqa 5 5 FERONT VIEW cT 5 5 REAR yE de a a OT 5 5 MAINTAINING THE ULTRAARAGO cerota ei teen elie 5 6 REMOVING POD GOVERS in uq i en 5 6 uuu 5 6 CAMERA REPLACEMEN Wi eitel a aha avi aaa 5 7 MOTOR DRIVE REPA C RME N T
7. 32 E 2 25 3 PH Ius ind 85 32 1 Opens the Hmain txt file for viewing Page 3 38 sex LD 4 E visualiner 32 3 Exelosng ione CAM 5 Runs the stored Diagnostic file in a visual Playback mode Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE Stored Diagnostic Analysis Continued By clicking on the Playback button the aligner accesses the Hmain diag file and starts to playback all of the data that was captured The screen will open up in the Data Examination mode with easy visuals for the technician to see and help diagnosis problems The technician can easily pause the data playback by clicking on the Pause Play button To exit the Data Examination mode the technician needs to simply click on the Cancel button after which the aligner will revert back to the Stored Diagnostic File Analysis screen Diagnostic Data Analysis Playback progress bar 8 Yisualiner Pro32 Data Examination Mode 0 04 Target Blobs Blobs 2552 Back Subtract Off Distance 117 9 Target Angle 32 1 Number of Planes 2 Target Blobs Blobs Back Subtract Distance 118 1 Target Angle 36 2 Number of Planes 147 Number of Images 149 Number of Images 115 LR sood target measure it _RR Good target measureme nt 04 RMS Target Blobs Blobs 32 32 Target Blobs Blobs Buttons not active
8. OEM Wizard Always Use Standard Wizard 7 Always Use OEM Wizard Prompt When OEM Wizard Tire ee Thresholds Automatic Screen Avance 2 5 4 Front Diefence Enable Advance 2 595 J5 ont to Rear Difference EJ seconds 227 2 Rear Difference r Display Out Of Specification Indicator On Pripfout Automatic Caster Swing F Enable Automatic Caster 7 2 Initiation Angle security cs W BUICK 1991 PARK AVENUE ORE Effective Page 3 14 04 2005 4 From the Security Menu select the KEY DISK radio button Insert the PLATINUM KEY DISK into the floppy drive and select lt APPLY gt Once the Key Disk has been loaded the disk is branded rendering it useless for installations on other units Store the disk in the cabinet for future installations for this unit only PLATINUM INSTALLATION COMPLETED Effective 04 2005 HSE CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE US MES CCE security a Prod User nimi aton Key AAQAA0D000 Select One Rack A 4 Optical heads toe sensors Installed Features Specifications 000000 Menu Mode Page 3 15 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE VOICEALIGN SOFTWARE INSTALLATION 1 Choose the PREFERENCES tab from the main menu of the alignment software Preferences Rack
9. zz vk k i d Left Motor ID is set on ID 1 Right Motor ID is set on ID 2 Effective Page 5 10 04 2005 CHAPTER 5 ULTRA ARAGO 3 CALIBRATING CAMERA PODS CALIBRATE POD MOTORS The motor needs to know how far it has moved each time it looks for the targets We can only judge distance by the speed of the motor times the length of time it was moving Calibration gives us this speed usually a few inches a second We need an accurate distance to get an accurate speed The result of an inaccurate motor may be a jerky target search where either the motor moves too far each search increment or too little Before beginning the calibration process the camera pods must be adjusted to the very botton or the very top of their travel 1 From the Main Menu select the Maintenance tab 2 From the Maintenance tab select Aligner Diag nostics 3 From the Aligner Diagnostic select Camera View NOTE ITIS NOT NECESSARY THAT THE CAM ERAS SEE WHEEL TARGETS AT THIS x Target Search Mode TI M E CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg ExtiCrew Cab ES 4 Using the mouse select Manual Mode then Go to the bottom The motors should power up and move both cameras to the bottom of their travel bot tom shut off switch 5 Exit by clicking on the Home key in the toolbar 6 From the Main Menu select the Preference tab 7 From the Preference tab select the System Con figuration Icon
10. CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE DATA EXAMINATION e his mode allows the operator to look at raw plane generation data as it arrives e Allows easy display of pacifier data without having to look at text files e Displays the number of proto blobs potential target blobs as well as measured blobs e Translates error codes into text explanations that may aid in diagnostics The data examination mode displays a myriad of information without having to open and change the cmd file and turn on the mpacifier command The information is updated on going and can be used by the operator if a failure in the alignment mode occurs This test has two pages of information By clicking on the small respec tive target identification in the upper left hand corner the operator receives the second page of information This is only available when you JPRB J Le 819 RMS i Target Blobs Blobs Off access this screen form the Menu mode and not from the camera view toolbar button RMS Background noise should be 06 or less 15 is maximum Target Blobs Blobs Number of Blobs dots identi fied The number in parenthesis is the number of poten tial dots Back Subtract Subtract background noise Unit is set to autocontrol Normal working mode should be on Distance Distance from the camera to the respec tive target in inches Target Angle Angle of target Number of Planes Number of target plan
11. ob 5 n jP2 CELL eG Lp ee E EEEEEEEEVN DDDDDDDDD Connection DDDDDDDDDD 67452301C TEEN Camera 67452301C m LEFT Camera RIGHT T n Strobe STROBE 4 DIDI Connections STROBE Connection PCB 1 2 3 4 5 6 PCB AAA QE PRE MOTER 29 CUNNEC 1 5V Red BEAM D o He e SO RETANA ous RO 2 ETO Ret g 12V 3 Shield 4 shielo 4 Lower Limit NC 5 RIDGE 1 HsOn 6 12V Return Green 6 CSpare 12 J 12V Gsolateo 8 Lew g ce Seem MAIN LEP POWER 11 2 Hs n SOURCE De ONC qe Rocker Switch a il Ty 5V GND s gt e ay OS fe MM 3 n 2 E Mt 12V m E AAA Sede 1 ui jb 61115114 42 16 P ML RIA Liev GND GN di ULTRA 1 POWER le V DC Cable ome ole SUPPLY Ground 2 IMUC MOD REV 04 2004 REV A USB DWG BY i CHK BY Eric Bryan Rod Harrison y PRINTER amp MOD CHK BY 000000000000 ALIGNER CABINET ULTRA Block Diagram DWG PAGE 1 7 8
12. Always Use Standard Wizard Always Use Wizard MKS Prompt When OEM Wizard Available Enable MKS I Tire Diameter Thresholds Automatic Screen Advance 25 3 Front Difference 3 Enable Screen Advance 2 5 2 Front to Rear Difference i Timeout seconds 2 5 4 Rear Difference r Display Out Of Specification Indicator On Printout Automatic Caster Swing F Enable Automatic Caster 7 3 Initiation Angle Extreme Weather Mode BUICK 1991 PARK AVENUE i Effective Page 3 10 04 2005 4 From the Security Menu select the KEY DISK radio button Insert the SPECIFICATION KEY DISK into the floppy drive and select lt APPLY gt Once the Key Disk has been loaded the disk is branded rendering it useless for installations on other units Store the disk in the cabinet for future installations for this unit only 5 Jump back to the Main Alignment menu by clicking on the HOME key in the upper left hand corner 6 Choose the Maintenances tab from the Main Menu Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE eras als Displays BI FI Security Installed Features Specifications 000000 ll HE UE Feat EES Installed Features Platinum Specifications 000000 Key Select One Key Codes Fr Key Disk Enter Co
13. Page 3 42 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 9 Verify Power and ground to unit is acceptable 115 volts 10 e Is this a dedicated circuit e Verify polarity correct orientation of hot neutral and ground e Verify ground Aligner must be properly grounded Resistance from Aligner to earth ground should be less 0 5 Ohms 10 Check for mechanical issues Clamps cables damage to unit 11 Check and review for any service bulletins that may be available www Equiserv com CSR PREFERENCES There should be no reason for the preferences of the aligner to be changed Changes made in the preferences can ultimately affect the aligners accuracy Listed are the preferences and a brief explanation of it s use This feature should be used with extreme caution STEPS FOR CHANGING PRAMETERS 1 From the Main Menu click on the Preference tab and then click on the Log In Out button s 1 5 Maintenant Preferences 2 Login as CSR using the 20 digit code given from technical User Looe support User Login Identification CSR Password 3 Click on the CSR Preferences icon in the Preference menu om 8 0 Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 4 The Main Preference screen has 3 option tabs CSR Preferences TID Preferences and Param eters Radio buttons are provided for changing CSR Preferences Parameters from factory defaults
14. 7 Read the License Agreement if you agree click on YES Clicking on NO will abort the installa License tion process Please read the following license agreement SNAP ON INCORPORATED Hereinafter referred to as Company grants you non exclusive nontransferable license to use this software on one Alignment machine This is legal agreement between you either an individual or an entity the end user and The Company You may install this copy of the software for use on one Aligner GRANT OF LICENSE This Software License Agreement License permits you to use one copy of a specified version of The Company Aligner Software product SOFTWARE on any single Computer Aligner provided the SOFTWARE is in use Do you accept all the terms of the preceding license agreement If so click on the Yes push button If you select No Setup will close eee 8 The default designation for the alignment software is C Program Files Snap on Technologies Inc Aligner click on lt NEXT gt to proceed with Select folder where Setup will install files software installation Setup will install Aligner in the following folder To install to this folder click Next To install to a different folder click Browse and select another folder NOTE THE INSTALLER SHOULD ALWAYS USE THE SOFTWARE DEFAULT DESIGNATED PATH Destination Folder 9 The next scree
15. Connector PCB REAR VIEW Motor Drive Assembly Right Camera Pod Assembly CAM TARGET Effective 04 2005 Page 5 5 CHAPTER 5 ULTRA ARAGO 3 MAINTAINING THE ULTRA ARAGO REMOVING POD COVERS 1 Remove the 4 screws securing the pod covers from the camera assembly 2 Make note of the threaded hole for each side The threaded holes used for mounting the left covers are marked with an L circled in yellow other threaded holes are used for mounting the right pod covers illustrations shows the threaded holes for mounting the left cover Failure to install the covers correctly will result with the LED s being mis aligned with the LED faceplate on the outside of the cover FACEPLATE ALIGNMENT The faceplate insert in the the pod covers must be aligned properly with the LED s on the Strobe PCB b n D97 pee ES e he R17 ERA rio kas k a DB E 2 La BACK SIDE LED s must fit inside Effective Page 5 6 04 2005 CHAPTER 5 ULTRA ARAGO 3 CAMERA REPLACEMENT 1 Power down the unit by toggling the switch to the Power Supply to the lt OFF gt position 2 Un plug the power cable from the power source 3 Remove the screws from the bottom of the Pod Covers and gently remove the pod covers 4 From the front of the Pod locate the two screws securing the camera assembly to the pod car Make note of the location of the holes being used The index h
16. From the calibration menu click on the RCP icon to begin the process Slide the turntables to the outboard position Place the calibration bar on the right rack rail with the small target on the outside of the front turntable and the large target towards the rear center of the rail Click on lt OK gt when done Two images should appear in the upper left hand portion of the screen The images will alternately change colors from clear pink green the aligner is sampling the images and will automati cally prompt the technician for advancement Effective Page 3 24 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 8 After a period of time a message is displayed to raise the plunger on the double leg bracket This will cause the images to rotate on the screen Click on OK when one 9 the 1 5 plunger Place the cal bar with the small target on the right rail the large target on the left rail with the feet centered front to rear on the turntables Slide the turntables inboard if necessary Click on lt OK gt when done 10 Move the cal bar back on the rack approximately 2 feet on the 4 rack Click lt OK gt when done 11 Move the cal bar back again approximately 2 feet on the rack Click on lt gt when done Effective 04 2005 Page 3 25 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 12 Move the cal bar back again to the front turntables Pla
17. 45 z ULTRA Camera ULTRA Camera FRS amp USB Motor USE Root Hub USB Root Hub 6 USB Root Hub e USB Root Hub USB Root Hub Check the Obvious Before you start troubleshooting a USB problem double check your fundamentals Check to make sure that the Generic USB hub is loaded check to ensure that the two Ultra Cameras are loaded check to ensure USB cables are physically connected Confirm that any USB hubs are properly connected and plugged in to pow ered electrical outlets Many failures can be traced to unplugged equipment or devices that are plugged into outlets that aren t receiving power The Ultra Aligner has a dedicated Power Supply for the cameras For troubleshooting you should have an extra Ultra Camera that has tested OK on another computer You can try using the device on the PC experiencing the problems to verify that the USB port not a faulty device or cord is causing the trouble This can be easily accomplished by plugging an extra Ultra Camera directly into the PC s USB port on the back of the PC Effective Page 3 48 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE CAMERA TROUBLESHOOTING Scenario 1 One camera never works Check the device manager to make sure that it recognizes two cameras If it does you can assume that the PC Camera Power Supply Cable from the console to the Hub and 12 of the Hub is good Unplug both cameras from the Hub and pl
18. Imaging System Type Two Camera System Three Camera maging System Three Cameras Two Camera with Remote Camera PRECES Motorized Pods Three Camera with Remote Camera Pod Motors Available Enable Motor Target Search 87 0 Distance between limit switches inches Calibrate Pod Motors Up 4 After gaining access to the camera identification look closely at the illustration of the two camera beams The DMS EP E E upper camera beam illustrates the left directional arrows illuminated and the lower camera beam illustrates the right directional arrows illuminated If a3 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 identi fied Use the pointing device and click on the illustrated camera beam that matches the camera beam that is being serviced After selecting the correct illustration the iluminated directional arrows should swap from one camera to the other Again using the pointing device click on the camera beam that matches the beam being worked on NOTE IF THEINCORRECT CAMERA INDENTIFICATION IS SELECTED THE CAMERA IMAGES WILL BE SWAPPED FROM LEFT TO RIGHT AND ALL IMAGES WILL APPEAR IN THE CAMERA VIEW AS UPSIDE DOWN A T gt i Effective 04 2005 Page 3 29 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE CALIBRATION AND PR
19. Parameter Group Standard Features Parameter Group r OEM Standard ore CSR Edited e OEM Allow Positioning Wobble Show Allow Caster Roll r Allow Individual Toe Editing e CSR Edited Purge Log File Allow Positioning Wobble Default checked _ SHEWROLET TRUCKS 2002 2500 PICKUP K25 HD TEE Allows the operator to by pass Wheel Wobble if box is unchecked the operator must redo and pass wheel positioning on all 4 wheels IO Allow Caster Roll Default checked Allows the operator to by pass Wheel Roll during caster sweep If the box is unchecked the operator must redo and pass a successful caster sweep without wheel roll IO Allow Individual Toe Editing Default unchecked This allows for individual toe specification edit during specification editing procedures 5 Click onthe TID Preferences tab to access and view TID Preferences Click on lt OK gt to save changes and exit TID PREFERENCES These values are used when performing a Target ID TID These preferences are found in the CSR Preferences by clicking on the TID Preferences tab Measurement Angle Default 90 Total rotation of the target from the forward position back Forward Bias Angle Default 25 Maximum BENE Preferences TID Preferences amount of forward rotation for TID TID Parameters 90 ij Measurement Angle Wobble tolerance Default 10 The maximum 28 4 Forwa
20. 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 Note the conditions in great detail I E e Weather Temperature e ime of day e Sun position e Heater locations CRT under the camera e CPU speed and type e Motherboard type e Installed memory e Printer type e Software revision e Machine serial e Modification Status e Hardware configuration isthe machine using the latest files I E software version level e Additional software that has been added e Additional Hardware that may have been added Is the condition repeatable If yes what sequence makes the condition occur Where is the machine located in the shop Distance from cameras to Turn plate centerline and distance between the camera pods 15 the unit within the proscribed installation parameter What type of equipment is used near it Possible interference Check camera view e Ensure Cal Target is visible and un obscured e Clean the targets e Clean camera lens To clean camera use canned air don t touch lens with fingers Verify TID and RCP File dates are valid VCD PLD The RCP and TID dates should be no older then the installation date of the unit NOTE RCCP PLD AND RCTP PLD TYPICALLY WILL HAVE DATES OLDER THAN THE INSTALL DATE THIS IS NORMAL Effective
21. e Target angle greater then 48 degrees e Distance to front target greater then 160 inches 4 064 meters e Distance to rear target greater then 240 inches 6 096 meters e Target RMS greater then 0 10 Number of target blobs less then 29 e Number of images is 0 for a particular camera e Number of planes is for a particular wheel e If the strobe is gt 4000 or the gain is gt 75 CODES LIKELY TO APPEAR ON AN DATA EXAMINATION SCREEN loo m any possbE bbbs m the cam era view to abw m any piotob bbs us to sortand geta target 102 119 No bbbs found No tagets bbbs visibb the cam era 103 120 122 138 Num bbbs Ess then numberof Found some bbbs but nsufficrentnum bera visibb 110 astersk fds to wcognize a taget The ntensiy is notata conect bvelto enabb us to 112 htensity notn range caLubte vales ee Ole W n have c ahli the ROI Region of ntestb and w 1llsoon be geting targetdata h The RMS i too huge much enorm seeng the target vibiaton ordmty tagets are possbE cause No asterekbhbs see whatitis as we cannotsee the astersk bbbs sk bbe loo m any asterisk bbbs visibb dentty this target ck To hana l asterisk bbbs visbe identify this fvaldate umed see a taigetbut t Valdate target aibd 1 not conectorentaton refbctons orother algneis cam era vew possbE cause loo few bbbs visibb laigetnot uly vis
22. in playback mode Back Subtract Back Subtract Distance 224 0 Distance 223 6 Target Angle 36 2 Target Angle 36 7 Number of Planes 137 Number of Images 141 5 33 Number of Planes 140 Number of Images 143 12 48 29 IUS fidsUsed 32 12 48 29 PH IUS protBlob 34 32 33 33 33 12 48 29 PH IUS Aims 6 0346 1 5561 6 6382 8 0522 6 6497 12 48 29 PH acqCount 1 46 1 2 1 12 48 29 PH 105 distMeas 118 1486 117 9128 223 9616 223 6773 96 8682 12 48 29 IUS thetMeas 36 1983 32 1643 36 1970 36 7469 39 2964 12 48529 PH IUS 297 3274 251 3558 295 7918 237 9518 182 4426 12 8 29 PH IUS alphHeas 241 4498 158 6189 328 3145 199 7546 5 5243 zi 5 PI ayb ack Data CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg Ext Crew Cab Pause Play button NOTE IF THE DIAGNOSTIC SOFTWARE HAS BEEN ENABLED BE SURE TO RESET THE ALIGNER BY CLICKING ON THE HOME ICON AND THEN THE BEGIN ALIGNMENT ICON FAILURE TO DO SO WILL CONTINUOUSLY WRITE DATA TO THE DIAGNOSTIC FILE Effective 04 2005 Page 3 39 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE EXPORT DIAGNOSTIC FILES 3 3 OR GREATER The diagnostic file export icon allows the technician to easily find and export all potential diagnostic information to a floppy disk or to any other location The following files can be exported e Hmain txtis the normal logging file Hma
23. 8 Make sure that the Imaging System Type is set to Three Cameras 10 Check both the Pod Motors Available and En able Motor Target Search boxes 11 Using a tape measure measure the distance be tween the two limit blocks Input this value into the Wisualinar Pred Dern Meds LIENS nup rr rame F QE as System Imaging System Type Three Cameras distance section Ride height target 12 Using the mouse pointer click on Calibrate Pod Motorized Pods Motors gt Pod Motors Available Enable Motor Target Search 13 The calilbration process will require the camera pods ee to travel up and then back down TWICE After the T Calibrate Pod Motors P cameras travel the distance the unit should auto Wa matically enter both the Up and Down distance usually the distance would be couple of inches second CHEVROLET TRUCKS 2002 K2500 PICKUP 25 HD Reg Ext Crew Cab Ei 14 If the up or Down speed is greater than 3 0 in sec the speed is not calibrated correctly Go back to Step 4 and repeat the pod motor calibration Effective 04 2005 Page 5 11 CHAPTER 5 ULTRA ARAGO 3 SELECTING THE WHEEL CLAMP TYPE There are two differenct standard wheel clamps available for the aligner It is very importany that the correct wheel clamp is selected NOTE SHOULD THE INCORRECT WHEEL CLAMP GET SELECTED THE GENER ATED VEHICLE DEMINSION DATA WILL BE INCORRECT 1
24. Assmbly Cam Target Lower Limit Stops lo o vf o lt old Cable Cover WS o E I Mini Hub Not Shown Mini Hub Not Shown 5 0 Effective age 5 04 2005 CHAPTER 5 ULTRA ARAGO 3 COMMON POD ASSEMBLY SIDE VIEW Motor Control PCB Connector PCB Pod Lever Camera Pod Motor Effective 04 2005 Page 5 3 CHAPTER 5 ULTRA ARAGO 3 LEFT CAMERA ASSEMBLY Common Pod Assembly FRONT VIEW Er 2 Petty uat e 1 j ULCUS Left Camera Pod Assembly CAM CAM Includes 2 cameras strobes Mini Hub Connector PCB amp Motor Cntrl PCB Not Shown REAR VIEW Motor Drive Assembly Effective Page 5 4 04 2005 CHAPTER 5 ULTRA ARAGO 3 RIGHT CAMERA ASSEMBLY Common Pod Assembly FRONT VIEW Right Camera Pod Assembly CAM TARGET Common Pod Assembly Motor Cntrl PCB amp
25. Attach the new switch and check for proper operation Both switches should be wired Normally Open NOTE MAY BE NECESSARY TO SLIGHTLY BEND THE PIVOT ARM ON THE LOWER SWITCH SO THAT IT DOES NOT COME IN CONTACT WITH THE POD LEVER MECHANISM Effective Page 5 8 04 2005 CHAPTER 5 ULTRA ARAGO 3 LOWER MINI HUB REPLACEMENT NOTE THE ULTRA ARAGO HAS 3 MINI HUBS EACH COLUMN HAS ONE ATTACHED AT EH BOT TOM AND THE 3RD RESIDES INSIDE THE LEFT CAMERA POD ASSEMBLY 1 Remove the column guard protecting the column and mini hub 2 Un plug all cables from the mini hub 3 Remove the upper and lower screws securing the mini hub protection box 4 Remove the 4 screws that secure the hub to the protection cover the screws are indexed for orientation 5 Reverse procedures for installation and test the aligner and return to service UPPER MINI HUB REPLACEMENT 1 Power down the unit by toggling the switch to the Power Supply to the lt OFF gt position 2 Un plug the power cable from the power source 3 Remove the screws from the bottom of the Left Pod Covers and gently remove the pod covers 4 From the back of the pod assembly remove all USB and Power cables from the Mini Hub 5 Remove the 4 standoffs securing the mini hub 6 Reverse procedure for installation Use the Data Examination mode to check the operation and return to service Effective 04 2005 Page 5 9 CHAPTER 5 ULTRA ARAGO 3 NORMAL WEAR Over
26. IVS system has 3 different types of wheel clamps available to the end user Figure 3 116 Each clamp has a specific use The Conventional Clamp comes standard with the aligner Each target clamp must be ID d before using them in the alignment process Once these targets have been ID d the customer will then have to choose which clamp assembly he she will be using for each alignment Conventional Clamp Used to perform Target Identification on EN qra P Conventional Wheel clamps 21 E These clamps and target come standard with the aligner See Target earlier in this chapter I for procedures I 55 Universal Clamp Used to perform TID using the universal clamp Procedure is the same as Conventional Clamps Select Clamp Hub Pin Clamp Used to CHEVROLET TRUCKS 2002 K2500 PICKUP 25 HD Reg Ext Crew Cab perform TID using the Hub Pin Clamp Procedure is the same as Conventional Clamps TARGET ID PROCESS 1 Click on any of the target ID icons to begin the process Make sure that the process chosen 4 AGS xs E 85 is for the correct target and wheel clamps For illustration purposes the Conventional Clamps are used Select Clamp A DU I CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg Ext Crew Cab Effective Page 3 20 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 2 Move the box around the screen using the arrow keys an
27. Software Components required Alignment Software CD Brand Key Disk floppy e Platinum Options Key Disk floppy e VoiceAlign M Key Disk floppy Specification CD Specification Key Disk floppy 2 Bootthe aligner to the Windows desktop 3 Insertthe CD labeled Alignment software If Auto insert is turned on the alignment software will automatically begin the installation process 4 Theinstall program will first install the EZ Shim software After EZ Shim has been installed the unit will automatically re boot 5 After re booting the unit will install Acrobat Reader After Acrobat has been loaded the unit will once again re boot NOTE IF THE UNIT DOES NOT RE BOOT AFTER THE INSTALLATION OF ACROBAT THE UNIT WILL NEED TO BE RESTARTED BY REINSERTING THE ALIGNMENT PRO GRAM BACK INTO THE CD DRIVE 6 Afterrebooting the alignment program will run and begin to load the alignment software The install Wizard is the first screen to appear Press lt NEXT gt to begin the installation Page 3 6 gue 8221 icrobat Reader 4 05 giant pen Z y tte eee ci EU sare ester Aligner Setup Welcome to the InstallShield Wizard for Aligner The InstallShield Wizard will install Aligner on your computer To continue click Next lt Back Cancel Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE
28. below show s PC access for each of the cabinets Remove the philip screws where indicated and remove the back panel S O O O O T LH e amp n 4 Philips Screws S 7 ne loar Page 3 2 Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE BACK PANEL Main Power Incoming D car remove 3amp Switch Power Fuses Readout Fuse AN gt d gt 21 L Ga EO ks 7 J 7 E D D O O O O 5V O O 5 EH sv eu FEX S s wCamera 5 d Connection lt HOOKUP The
29. detail In many cases the problem is not the equipment it s an operator error e Never make more than one change at a time on a defective machine This could result in extended repair times and unnecessary parts replacements e Ifthe replacement part did not fix a problem reinstall the original component Before trying something else e If the replacement part appears to fix the machine take a few minutes to reinstall the defective part and verify the repair and diagnosis Verification always ensures that the problem has been resolved and usually prevents a return service call e When sending a defective part back for repair a detailed description of the failure should be included with it Failure to follow this procedure may result in a failed part getting returned to the field un fixed Every Technician should keep a notebook with descriptions of errors and fixes he has encountered on the aligner It s easier to repair future problems based on known good experiences instead of guessing what was done the last time this problem was seen e Always have current software on hand Current software revision levels can be found at http Www equiserv com techsupport ServiceSoftware SoftwareMatrix AlignerMatrix htm Effective 04 2005 Page 3 1 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE PC ACCESS There are two different cabinets available fo the alignment system The back Panel and PC hookups for both are identical The illustrations
30. fingers and all parts of the body away from moving parts Adequate ventilation should be provided when working on operating internal combustion engines To reduce the risk of electric shock do not use on wet surfaces or expose to rain Do not allow unauthorized personnel to operate the equipment Use only as described in this manual Use only manufacturer s recommended attachments ALWAYS WEAR SAFETY GLASSES Everyday eyeglasses only have impact resistant lenses they are NOT safety glasses SAVE THESE INSTRUCTIONS Effective Page vi 04 2005 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 CAUTION THIS UNIT MUST BE PLUGGED IN TO PROPER AC OUTLET FOR THE UNIT TO OPERATE CORRECTLY REFER TO THE UNIT ID PLATE LO CATED ON THE BACK OF THE UNIT EXTENSION CORDS ARE NOT RECOMMENDED BUT IF AN EXTENSION CORD MUST BE USED USE A CORD THAT IS LESS THAN 50 FEET WITH A 16 AWG OR ABOVE 50 FEET AND LESS THAN 100 WITHA 14 AWG 1 Aligner voltages refer to the return white side of the AC line Yet sometimes outlet wiring is reversed In that case electrical neutral connects to the hot side of the line The aligner operates normally but the PC board floats
31. incoming 7225 P3 incoming 2 5 Ret a 22 my 27017854 x 2 D 5 12 12 ie Motor Control 5 Motor Control gyan qu N gt S 6 4 12V Ret 6 12V Ret lt lt P2 USB COMMUNICATION lt Motor Lontrol uus 1 1 P6 onnector oar Zone or oar J1 incoming 1 Lower Limit lal HUL Apoa 2 Limit die P N e M N 3 Motor Alarm Los ee mo 4 GND incoming i 5 Bridge 1 HsOn a R C 9 P4 outgoing 4 1 l E nant NC EAWO2 35J49A mE e pe 39119 6 12V RAD TON 9 12V GND g P2 USB COMMUNICATION Lie otor Enable fi E B ve 75 USB COMMUNICATION ridge 2 HsOn 5 fi I A GND USB COMMUNICATION lt x EAW0235J50A lt gt EAW0235J50A 5 12 24 D IT amp amp J2 1 Lower Limit a EE DE do Upper 2 GND 1 o p P 1e P25 P2t MiniHub MiniHub EAPO2 38J70A EAPO2 38J70A e POWER STRIP M A CN WIRING SHELF _ 0 TYPICAL COMPONENTS SHOWN EAWO235J54A f at back White F 12V of console FO rH 10A SLO 250V Red F2 5v FAW0235J54A E d omes 10A SLO 250V ponen een FA Bz g I EAW0235J45B MODEL EEWA550A REV 02 2005 Rev A 510 250V co gt OWG BY Rod Harrison CHK BY Eric Bryan H shield tied MOD BY CHK BY Mis mU G
32. labeled as V1 and V2 V1 is the 5 volt line and V2 is the 12 volt line Each output voltage has it s own separate ground When measuring the output voltage of the power supply the technician must attach the leads of the VOM to the appropriate ground to receive back the correct voltage Failure to connect the VOM to the correct pins will result in a incorrect voltage reading and may cause the technician to prematurely replace a good power supply DC Output CN2 AU Input CNT AC Input CN1 V1 5VDC Red 1 AC L White G1 5VGND 2 AC Blu perii Ls V2 12VDC White G2 12VGND Green To back of cabinet Effective 04 2005 Page 1 3 CHAPTER 1 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 From PC USB oV GND From Power Supply HUB BOARD The HUB board is housed inside an aluminum extrusion behind the camera beam The HUB board s purpose is to pass information to and from each of the camera s directly to one of the USB Ports on the back of the PC The HUB board has 4 USB connectors for either a two camera system or a three came
33. operator for a brand disk The unit is shipped with this brand disk and must be inserted into the floppy drive to re brand both the hard drive and the designated camera If the brand floppy cannot be located the technician must call the technical support department so a verification can be done and a key code generated for the branding of the unit A technician should at that time reorder a brand key disk to replace the lost disk that came with the unit initially SPECIFICATIONS The unit is also shipped with a specification key disk that activates vehicle specifications for alignment use Once the specification key disk has been installed and specifications initiated the key disk is no longer needed On boot up the designated camera will do a roll call with the computers hard drive if the information agrees the vehicle specification will be available for alignments Future specification updates will be sent with each specifications CD and will need to be installed before specifications from the new CD are available The operator can then discard the older specification key disk as it will not work with the newer specification software If for any reason a technician cannot locate the specification key disk or finds the one sent with the specification update is not usable the technician can call the technical support department Once the specifi cation update has been verified the technical support department can generate a Key Code for specifica
34. same static potential as the equipment Grasp the PCB from opposite sides using your fingertips Do not grasp the components on the board WARNING USE STANDARD ANT STATIC PROCEDURES WHILE PERFORMING THESE INSTRUCTIONS Effective 04 2005 Page 1 1 CHAPTER 1 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 Avoid handling components needlessly Do not set PCBs on insulating surfaces such as paper glass rubber or plastic Static is generated by friction The following actions promote static generation Wearing silk or nylon clothing Walking on carpets Walking with rubber soled shoes Static generation is increased when certain environmental conditions exist Conditions of low humidity com bined with wearing silks or nylons walking on carpets or walking with rubber soled shoes may create large electrostatic charges on your person capable of blowing a hole in the substrate of an IC SERVICE GUIDELINES BEFORE REPLACING circuit boards verify that the main power supply operates within specifications VERIFY that board connectors are fully seated NEVER remove boards or disconnect a connector with the power on MAKE SURE that you completely understand what the alig
35. the problem Also try using the device when no other USB peripherals are connected More than likely you have a driver problem but it could be a power or bandwidth issue Controller hub compatibility USB computers manufactured before 2002 are limited to USB 1 1 devices USB 2 0 is much faster and is usually backward compatible with the older 1 1 but it s possible that a USB 2 0 device could refuse to work on a USB 1 1 controller or external hub so check to see if there s a compatibility issue Assuming a firmware update is available you may need access to a USB 2 0 equipped computer to apply it Configurations for add on USB controllers Check the Windows Device Manager to see if the USB controller is recognized or is experiencing a conflict In Windows XP click Start Control Panel select the Systems applet click the Hardware tab and then click the Device Manager button The Device Manager will likely refer to the USB controller as a USB Root Hub USB Controller or USB Bridge The usual suspects of IRQ addresses and memory address conflicts are the first things to check PCI devices shouldn t have many problems being Plug and Play but EISA cards may require more adjustment If the hardware appears to work reinstall the drivers Integrated USB controller settings If you suspect the trouble is with your USB controller settings check the Device Manager for a conflict De pending upon how well integrated the controller is with Windows
36. time normal wear and tear is natural One item that will show this wear is the pod car residue that will fall onto the micro switch stops at the bottom of the columns The illustration on the right shows the residue of a 13 year life cycle on a unit at the factory The integritity of the aligner was not jepordized and the unit still functioned flawlessly Remove the plastic dust with a soft cloth or paint brush never use compressed air POWER SUPPLY ADJUSTMENT The power supply used to drive the Ultra Arago is identical to that of the conventional Ultra However it may be necessary to adjust to 5VDC output on the power supply to achieve maximum performance to run the camera that is furthest away from the supply 1 The power supply is mounted inside the cabinet access to the power supply is on the back of each cabinet 2 Unload the power supply by disconnecting the har ness from the back of the cabinet leading to the cameras 3 Place the DVM on the Red Wire and Black Wire LEBO I 4 Using a small screwdriver turn the potentiometer until a voltage output of 5 25 5 30 15 obtained 5 Place aligner back in service and retest MOTOR CONTROLLER PCB JUMPER The motors are ID d on the Ultra Arago This allows the software to identify and individually control both motors for any difference in travel soeed See the illustration for the correct jumper location
37. with one that provides more watts Bandwidth can also be an issue if several active devices are transferring large amounts of data Potential peripheral bandwidth hogs include printers scanners hard drives and CD DVD or CDR W drives Eliminating bandwidth problems might mean replacing a demanding USB device with an integrated replacement or dividing the USB devices between different USB root hubs See below for more on bandwidth issues Scenario Several devices never work but others are fine Possible causes Controller hub compatibility configurations for USB controllers power management controller drivers device drivers bandwidth 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 This procedure is automatic Remove external hubs from the equation to see if they are the problem Try the problematic devices individually on the computer if they work it s either a device driver or power issue If they never work it s a controller Effective Page 3 50 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE compatibility issue a device driver problem or a lack of bandwidth Solving compatibility issues and driver errors requires updating drivers or obtaining appropriate patches Scen
38. you may be able to adjust the IRQ or memory address settings from the Device Manager Effective 04 2005 Page 3 49 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE Try rebooting the PC and entering the BIOS configuration USB settings are usually listed in the Peripherals section You ll need to check for an entry marked USB Controller that is off or inactive If this entry is already active check the IRQ and memory addresses Use the Device Manager to ensure that no other device is using those settings You may need to reboot a few times to find a valid IRQ memory address combination that won t conflict with other devices If the hardware settings are fine reinstall the drivers USB Keyboards When editing the BIOS enable DOS USB Keyboard Support Enabling this option will allow you to use a USB keyboard when booting a system with a boot disk Controller drivers Many motherboard suppliers release driver combinations that include a number of hardware drivers Confirm that you have the latest driver installed Some operating systems also provide drivers so make sure you have the latest available software patch as well Scenario No device ever works Possible causes Operating system compatibility controller hub compatibility configurations for USB control lers controller drivers 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
39. 1 1 2 55 32 PH IUS retCode if 115 102 1m 102 2 56 32 PM 5 imgtount 1173 1168 1168 1158 1147 5811 2 54 32 5 plnt munt 545 541 349 587 543 7495 2 56 32 PM IUS strobe 5 2 56 33 PM IUS amp gain 8 33 5 intensity 142 B 8 3 Z 56w 195 subtBack B B B B B 2 55 33 Wd 105 threshold amp 3 ca amp 3 a a 1 2 58 22 15 Fi idslizsed 33 2 56 33 PM IU grace 64 1 3 2 56 33 5 B 0431 B B mngpg VUE 3 2 54 34 PH 5 acq B B B B 2 55 33 PM IUS distherN 180 0008 179 8804 28608 0088 700 8000 208 0088 2 56 32 PM IUS thetMeas 35 8008 231 7968 35 0000 35 8008 35 8008 2 55 33 5 35 0008 752 2825 95 0008 35 0000 35 0008 3 2 55 34 FM IUS alphHeas 35 H0HBB 142 7447 35 008080 35 H8BB 35 2 55 37 PH 5 uheel 4 strobe SBB gain 18 mode 3 bhksub B 4 4 4 H 2 56 37 PM IUS retCode 102 115 i 11 115 1 2 56 37 PM IUS imgCcount 1173 1164 1164 1159 1148 5816 2 56 37 PM IUS plnCount 515 541 349 537 5a 2585 2 96 37 PM 5 strobe B B B B B 2 55 37 PH IUS gain 14 H 2 56 37 PM IUS intensity 142 6g 143 2 55 37 PM IUS subtBack 7 2 56 37 PM IUS thresholds 63 5H 63 5H 5H 3 2 54 37 5 Fidslsed
40. 110 VAC above safety ground Assume that points inside the aligner console are at 110VAC observe all safety precautions If you make measurements with grounded test equipment use an isolation transformer An oscilloscope is an example of such test equipment 2 healigner is susceptible to power line spikes and noise You must connect the equipment to safety ground Does your machine do strange things or exhibit intermittent problems Check for a proper ground at the machine and the power outlet If you re using an extension cord check that too It must be constructed of at least 16 gauge wire and under 50 feet long 3 Schematic voltages refer to the return side of the line not safety ground When measuring AC voltages use the white wire on the line power terminal block as ground Don t use the third center safety ground terminal Another place to access ground is at the shield The black wire in the shielded transducer cables also connects to the ground return HANDLING STATIC SENSITIVE PCB S Electrostatic discharge can destroy high impedance ICs if uncontrolled Use the follow ing techniques to avoid damaging ICs Leave new circuit boards in their antistatic bags until ready for use When replacing boards proms etc be sure to turn off power to the machine first Use an anti static wrist strap Connect it to chassis ground on the equipment or to an available raw ground Touch the chassis of the equipment to put yourself at the
41. 2 AC THEORY OF OPERATIONS attend dimid be ant 1 3 ACDISTRIBUTIONS SR C E 1 3 DG THEORY OPOP RATIONESSS te caisse aise need ect tes 1 3 POWER SUPREME A en ste 1 3 COOP TK PE 1 4 CAMERA ODASSEMBISY tigate lair u mua 155 CHAPTER 2 THEORY OF OPERATION G N RALE 2 1 CAMERAS 2 1 A a 2 3 e TON 2 4 Ly SIO NTE OR m 2 4 E 2 4 FORESAOPTENING aaa 2 6 2 7 POSITIONING SEQUENCE 2 z u a ee eee nc 2 9 SIDE TO SDE D TERMINATION ES po 2 10 RELATIVE CAMERA POSITIONING RCP 2 11 EURE RSS UE NTC 2 11 MODELING THE VEHICLE IN 3 DIMENSIONAL 6 2 14 MEASURING STEERING ANGLES 2 23 Lu uuu u Reste 2 14 Effective 04 2005 TABLE OF CONTENTS CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE TROUBLESHOOTING THE SYSTEM ucu xu Anota 3 1 CUIDELI
42. 4 Optical heads toe sensors ll Menu Mode 2 From the Preference menu select the lt USER INTERACTIONS icon 3 Fromthe User Interaction menu select the SECURITY tab z ity MAP F Enable MAP MKS r Enable OEM Wizard Always Use Standard Wizard 7 Always Use OEM Wizard Prompt When OEM Wizard Tire Diameter Thresholds 0 Automatic Screen Sfvance 2 54 Front Enable Scree Advance 2 5 to Rear Difference 3 1 Tyrout seconds 227 2 Rear Difference r Display Out Of Specification Indicator On Prysfout Automatic Caster Swing F Enable Automatic Caster 7 2 Initiation Angle security cs W BUICK 1991 PARK AVENUE ORE Effective Page 3 16 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 4 From the Security Menu select the KEY DISK n 1 radio button Insert the VOICEALIGN KEY DISK into the floppy drive and select lt APPLY gt Once the Key Disk has been loaded the disk is branded rendering it useless for installations on Key 0000 other units Store the disk in the cabinet for future Select One installations for this unit only 5 For VoiceAlign to be activated the aligner must be restarted If in the Non Desktop mode click the X box in the upper right corner of any screen or the Shut Down Windows icon on the Main Me
43. Aligner Setup is performing the requested operations Installing C Program Files Snap on Technologies Inc Aligner Reports Brakelnspect rpt InstallShield Aligner Setup InstallShield Wizard Complete The InstallShield Wizard has successfully installed Aligner Before you can use the program you must restart your computer No will restart my computer later Remove any disks from their drives and then click Finish to complete setup 2 tu C Effective 04 2005 13 During the re booting process a screen will appear asking the user to insert the Key Disk for branding Insert the brand specific Key Disk into the floppy drive and click on OK Once the Key Disk has been loaded the disk is branded rendering it useless for installations on other units Store the disk in the cabinet for future installations for this unit only The Aligner software auto loads at start up If the aligner software has never been loaded or the machine branded then the screen shown will prompt the installer to insert the Activation Brand Key Disk This disk performs two functions activating the Pro32 software and applies the desired channel brand to the aligner Insert the key disk into the floppy drive and select OK The proper files are read from the floppy and stored on the aligner system Once the syst
44. E NEW VALUES ARE USED RCP Fixture Assembly 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 e Large and Small Target e 3 8 nut driver flatblade screwdriver 3 Attach the small target to the single leg bracket 4 Attach the large target to the double leg bracket 5 Clean the targets using glass cleaner and a soft lint free towel DO NOT USE A SHOP TOWEL Effective 04 2005 Page 3 23 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE RELATIVE CAMERA POSITIONING RCP The purpose of the camera calibration procedure is to measure the cameras positions relative to each other This allows the aligner to make accurate measurements between the left and right sides of the vehicle For this reason the alignment program will not run until a valid RCP has been performed The unit is shipped from the factory with valid RCP factors and it is not necessary to perform RCP unless a Camera is exchanged Tools needed Fixed Length Steel Fixture with two targets 1 2 Raise the empty lift to working height no vehicle Close the garage door to block any stray daylight Prepare the Calibration Fixture Clean the two targets on the fixture according to the user manual Use a glass cleaning fluid and a soft cloth Make sure that the glass is free from grease and dirt Power on the Alignment System
45. EFERENCE BACKUP All alignment machines are unique in their own way Each aligner has different calibration factors and preferences CCP alignment software also offers users many different options in the way of looks and feel Each user spends many hours customizing the alignment software for his her look and feel Each alignment shop may have a different logo that may show up on a printout of each printed alignment result Calibration and Prefer ence backup offers the user or technician a way of backing up all customized options and alignment calibration to a 1 44mb floppy diskette Should an alignment machine require a hard drive replacement the user or technician can simply restore all data from a saved floppy diskette back on to the newly installed hard drive From the Main Menu click on the Maintenance Tab click on the Calibration icon and then click on the Calibration Utilities icon on the toolbar as illustrated above Backup It is recommended after every calibration that the user backup the new data in case of a PC or Hard Drive failure This enables the user to quickly restore the alignment system s calibration and preference data after the operating system has been restored It is recommended that each time the system is backed up that the same disk be used and dated on the floppy disk label A 1 44mb formatted floppy diskette is required to perform this opera tion If the floppy diskette being used contains any informa tion
46. From the Preference Tab select the System Configuration icon 2 Click on the Wheel Clamp icon in the lower left corner 3 Select the correct wheel clamp by clicking on the icon that represents the wheel clamp being used Page 5 12 Imaging System Type Three Cameras Ride height target Motorized Pods Pod Motors Available Enable Motor Target Search 87 0 Distance between limit switches inches Calibrate Pod Motors Up Down CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg ExtiCrew Cab Effective 04 2005 CHAPTER 5 ULTRA ARAGO 3 CAMERA POD ROTATION NOTE THIS PROCEDURE MUST BE FOLLOWED ANY TIME A CAM TARGET OR POD ADJUSTMENT LEVER IS REPLACED 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 The Arago does not require RCP because the third camera main tains constant calibration 1 From the calibration menu single click on the Camera Pod Rotation icon 2 Adjust the camera lever s to the illustrated position shown on the screen and click on OK Move the pod levers to the displayed position and Press OK Left Small Right Small Lei Small Righi Median Lei Medium Righi Medi
47. ING IN THE EXTREME WEATHER MODE CHANGES DEFAULTS Effective 04 2005 Page 3 45 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE TROUBLESHOOTING THE SYSTEM The Ultra Aligner can be easily broken down into these major components e PC usb amp drivers e Power Supply e Hub PCB 3 on Arago Cameras on Arago e Cables e USB Motors Moveable Beam amp Arago Each of these components need to be working to acquire images for the PC processor to display the images on the screen for the operator Should any of these components fail the result could be no images or errattic images NOTE WHEN USING A TEST CAMERA AS A TROUBLE SHOOTING TOOL ALWAYS UNPLUG BOTH CAMERAS THIS WILL ENABLE YOU TO TEST THE SYSTEM WITHOUT HAVING TO TRANS FER SECURITY CODES TO THE NEW CAMERA USB devices normally requires an array of hardware settings that can create conflicts Debugging becomes a different process since USB takes Plug and Play to a new level by allowing multiple devices to share a single path into the PC such as pointing devices printers remote readers and now Ultra Cameras Troubleshooting USB requires a bit more effort than other connection methods because the entire bus could be malfunctioning Examine the troubleshooting scenarios below until you find one that applies to your situation These scenarios provide general descriptions of possible errors along with steps you can use to resolve the problem You ll also find tips for troub
48. N AND MAINTENANCE RACK CHECK The image aligner is designed to perform a perfect alignment every time The levelness of the rack side to side or front to rear is irrelevant to performing this perfect alignment however a rack that is non coplanar parallel will induce erroneous readings because the suspension of the vehicle is under stress m Non Coplanar rack is evident when one runway is tipped down more than the opposite runway his test checks how coplanar parallel the rack is Even though we are very resistant to rack problems non coplanar racks can introduce some error to our system e lag between rails is less then 0 02 inches 0 5 mm the rack is considered to be coplanar e Ifthe lag is greater then 0 02 inches and less then 0 3 inches we display the value but leave it up to the individual shop to decide what to do Although this will not cause a great deal of problems is will affect the alignment readings a small amount e Ifthe lag is over 0 3 7 5mm inches we tell the user to adjust the rack to the manufacturers specifications as this will affect alignment accuracy This test requires the use of the RCP fixture The technician must have this fixture to check the rack rails for a coplanar parallel condition 1 Place the RCP fixture across the rack with the small target on the RF turntable and the large target on the LF
49. NDEARTH 177 ri AC DC POWER DISTRIBUTION DWG PAGE 1 1 5 15 Page left blank intentionally 309 Exchange Avenue Conway AR 72032 546 Rev 04 2005 2005 Printed in U S A
50. NES EH S 3 1 POA E IM MM e M E LEM EL 3 2 ECT 3 3 PO ROOK OP nM 3 3 CAMERA REMOVAL amp REPLACEMENT eee ette eter N N 3 4 HUB PCB REMOVAL amp REPLACEMENT at 3 5 ALIGNMENT SOFTWARE 00 0000006 3 6 SPECIFICATION INSTALLATION is uuu ku Ire a uut aat oe Cue atico cies 3 10 PLATINUM SOFTWARE mereri rennes 3 14 VOICEALIGN SOFTWARE 3 16 MAINTENANCE MENU ae eats a Su tus 3 18 CALIBRA HON eR MT MCN 3 19 E ce MR E I Su usus iS Say E a ee 3 20 AGE UD PROCES MIS a I eee ee DM NU UNI MEI Sasi tie 3 20 RELATIVE CAMERA POSITIONING BGP 5 u uni eo ated eec Cue 3 24 ACTIVATE AND CALIBRATE THE RIDE HEIGHT MEASURING DEVICE NN 3 27 GAMERA IDENTIFICA TION 5 n Ec RD ED 3 29 CALIBRATION AND PREFERENCE 2 0 2 60 6 3 30 D AGNOS TG cU 3 31 CAMERA VIENS es 3 32 DATA EXAMINATION 3 33 CODES LIKELY TO APPEAR ON DATA EXAMINATION SC
51. RA BEAM EU UE 7 sa 1 W 3 s cae ERN OR FS fi Lu 0 9 ose 079 078 077 976 075 074 073 A ar mu 1 Effective Page 3 4 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE HUB PCB REMOVAL amp REPLACEMENT ile 2 HUB PCB is located directly behind the camera cross beam 3 Disconnect the power cables from the Hub PCB both sides 4 Disconnect the USB cables from the Hub PCB both sides 5 Access to the HUB PCB can be made from either side of the beam Remove the two screws securing the cover plate 6 Gently slide the HUB PCB out 7 Reverse the procedure for installation Cover Plate screw B J O bdo ES TN T x Cover Plate screw Effective Page 3 5 Follow the proper power down sequence 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE ALIGNMENT SOFTWARE INSTALLATION There are different versions of software and these instructions may not reflect the exact process of what is being installed but is similar Following the default procedures is recommended 1
52. REEN 3 34 CAMERA TEST ce bea cate eae ee Scie ena 3 35 ease TETTE 3 36 STORED DATA VIEWING TOOLS ER Po u UR MER IU ru qe ure iss 3 3 STORED IMAGE ANALYSIS ossis 3 3 STORED DIAGNOSTIC FILE ANALYSIS 3 3 OR GREATER 3 38 EXPORT DIAGNOSTIC FILES 3 3 OR GREATER 3 40 WINDOWS UTILITIBS uu MEE Ee 3 41 COVERING THE BASICS t L awh eee 3 42 o SR PHEEFERENGES ates liec ec eee sn 3 43 STEPS FOR CHANGINS PRAMETERS tnt tu ye o e xx dee tu veo rax eiue 3 43 neni Dept bh I DEL ES 3 44 PARAMETERS luz Sousa susah a M MEC REL opel 3 45 TROUBLESHOOTING THE SYSTEMS u uuu ts artis eau a E 3 46 PD BASIC Ou u xa 3 48 GAMERA TROUBEESHOG TIN Gi ur 3 49 OTHER USB DEVICE TROUBLESHOOTING PROCEDURES
53. RY 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 Since the software knows what a target looks like when it sees an object that may be a target it applies what is called a fit algorithm how closely does that object match what it knows to be a target In this way objects that are not targets Such as reflective lamps on the vehicle are ignored As each target is found and fitted or acquired it turns blue on the screen and appears attached to the wheel When a target is acquired the software hones in on that region of the camera view ignoring activity in the background This allows the system to be more responsive to changes in target position 3D VISION THEORY From the previous discussions of the components of the 3D Aligner we have a basic understanding of how the hardware system functions But how does the software take these camera images of target dots and interpret them as wheel alignment angles PERSPECTIVE One of the things the 3D Aligner must determine is how far away each target is from the cameras at any given moment As everyone knows objects appear to get smaller as the move farther away even though their actual size remains the same If you
54. Service Manual EEWA13 A EEWAS44A EEWAS45A EEWAS46A EEWASS0A EEWA 7124 EEWA714AL WHEEL ALIGNER All information contained or disclosed in this document is considered confidential and proprietary by Snap on Tools Company All manufacturing use reproduction 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 written consent of Snap on Tools Company SNAP ONO is a registered trademark of Snap on Incorporated TABLE OF CONTENTS Table of Contents INTRODUCTION GENERAL uuu k uz ee E te a au ALIGNMENT FUNG HONG uu u a aa has PREFERENCE FUNCTIONS I MAINTENANCE MENU uu u uu cretus IH AE IV SOPIWARE FEATURES SE de nement en Rite nine V IMPORTANT SAEFETY INSTRUGTIONS uuu u ia innate nano VI CHAPTER 1 AC DC POWER DISTRIBUTION ELECTRICAL SAFETY PRECAUTIONS Sn unten anand ane ion 1 1 HANDEINCSTATIC SENSITIVE POB S umayman phan umawan uma St sata toma unas 1 1 SERVICE GUIDEDINESTZ a ne cet 1 2 LOCKOUT AND OR TAGOUT SYSTEM PROCEDURE a a arsa 1
55. and applying mathematics it is possible to determine the screwdriver s angle of orientation with respect to the normal view Effective Page 2 6 04 2005 CHAPTER 2 THEORY OF OPERATION Pen known length fixed Focal Length fixed by lens l 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 The size of the pen is a known value P created by the designers of the pen The observed size of the pen is measured by our software at the focal point and becomes a known value B The goal of this exercise is to determine the angle of orientation R away from the normal position THE CIRCLE Hopefully by now we have some understanding of how the 3D Aligner can determine how far away the targets are and their angle of orientation Of course when placed on a vehicle the dots are likely to be at varying distances from the cameras and at varying angles or orientation at any given moment An observer to the above may ask how can the aligner tell the difference between the effects of perspective and foreshortening All it knows is the targets images are smaller than their actual size What about orientation changes in 3 dimensions The answer is a powerful geometric shape the circle As you will find out the circle was chosen as the geometric shape for the targets because of its mathem
56. ard rotate the tire back until a stop sign appears as in step 8 and hold the wheel steady as another reading will be taken CHEVROLET 1997 BERETTA 8 After the readings are taken the arrows indicate to rotate the tire and wheel assembly forward 90 Rotate the wheel until a stop sign appears and hold the wheel steady as a reading will be taken CHEVROLET 1997 BERETTA 9 After the completion of a successful target ID the screen indicates to lower the wheel This is not necessary if the opposite side target is needing to be ID click on the lt OK gt button and select the next target Lower the wheels after all four targets have been ID d CHEVROLET 1997 BERETTA 4T Mera Made Effective Page 3 22 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE Tz 10 The program returns to the Target Selection screen to allow additional targets to be ID d Repeat this process for all targets A green check mark appears next to the targets that have been ID d 11 Checking current TID dates can quickly be determined by clicking on the date icon in the tool bar The software brings a date screen forward displaying a matrix for each target and the last date that TID was done on each target Installed TID 7 27 01 7 27 01 7 27 01 7 27 01 NOTE TARGET ID IS ALWAYS PERFORMED WITH THE FRONT OR REAR TARGET MOUNTED TO THE FRONT WHEELS THE ALIGNMENT PROGRAM MUST BE RE BOOTED BEFORE TH
57. are without actually having a vehicle available It is a useful tool for training new or experienced users about machine features See Operators Manual for details Windows Utilities Allows access to the Windows Desktop and also allows the operator to perform routine installation of printers software etc See Windows Utilities for details Database Utilities The feature is used for backing up and restoring alignment based data files customer data etc See Operators Manual for details Speaker Training Optional Hardware Software package that allows and end user to control the aligner through voice commands See Operators Manual for details Effective i 04 2005 Page iii INTRODUCTION TOOLBAR The toolbar is a series of buttons at the top of each alignment screen The toolbar is interactive and changes with each screen depending on the location within the software Each button and an explanation of it s can be found in the operators manual however some will be pointed out in this manual Moving the pointing device over each button will give the operator a quick overview of the button lfa button is active it will be displayed in full color however if the button is not active it will not be highlighed Alignment Help Opens the operators guide within Adobe Acrobat Meter Screen Jumps to the Alignment reading screen Home This button be found on all toolbars this enables the oper
58. ario Several devices occasionally stop working at the same time while others are fine Possible causes Power management device drivers bandwidth As you would with any other sporadic hardware conflict try to isolate the particular event that s common to all failures The system may be experiencing a sporadic controller failure if your devices are split across root hubs Try moving the devices to another root hub to see if the problem is in a particular root hub or in the devices themselves Remove external hubs from the equation to see if they are the problem Try the problematic devices individually on the computer if they work it s a device driver power issue or bandwidth pinch Power management Most computers have some form of sleep mode connected with the screensaver A controller is not harmed when an energy setting kicks and eliminates its power However the OS may fail to power up the controller again You can eliminate this error by opening Power Options Lie Hal disabling System Standby as shown in Figure In Power Schemes Advanced Hbemate UPS Windows XP go to Start Control Panel Power Options 4 Liens Wath De ren P You ll find the System Standby option on the Power Schemes ee ha nue ey wanasqa tab which opens by default Powel schemet Cane Lael er Settings For Desk poseer scheme Tum off morior Tum off hand disks Heer
59. atical relationships For this discussion assume the aligner targets consist of a single large dot Normal View of Circle Moving Away The circle has some unique characteristics that make it useful for the 3D Aligner When you look at a circle from the normal position straight on or a 90 degree angle the diameter across is equal no matter where it is measured As the circle moves away from you the diameters appear to get smaller due to the effects of perspective as discussed earlier Effective 04 2005 Page 2 7 CHAPTER 2 THEORY OF OPERATION Now look what happens as the circle is rotated about the X axis in two dimensions it appears to be an ellipti cal shape Rotated X The more we rotate the circle about the x axis the smaller the y axis diameter appears In fact a mathematical relationship exists that says if you can measure the length of the y axis line and the length of the x axis the 5 true diameter you can determine the angle of rotation To put this all together no matter how you rotate the circle in any dimension X Y Z the true diameter axis is always visible This is called the ellipse s long axis The 3D Aligner measures every diameter on the target dot and uses the long axis it finds as the true diameter to determine how far away the target is through perspective Then it looks at the diameters in the other dimensions that are 90 degrees to the true diameter to find the short axis and determin
60. ator to jump back to the Main Menu 5 A Print Enables the operator to immedi ately access the print menu Logo Screen Takes the operator to the Logo Screen Shop Management Runs the Shop Management Program if purchased Optional Information Systems Runs the Mitchell Program if purchased Optional Page iv OG 5 Alignment Preferences Maintenance Rack A 4 Optical heads 8 toe sensors Menu Mode Regional Settings Allows the operator to quickly changes between Languages and Specification databases Wizard Allows the operator to choose from several standard alignment wizards or customize his her own Log In Out Allows the operator the capability to set up an unlimited amount of custom users for the aligner MKS Merecedes Benz MKS system Only available with Mercedes Software About Displays the current software and alignment vehicle database revisions Effective 04 2005 INTRODUCTION SOFTWARE FEATURES All Models Live Vehicle Dimensions e Equalize Toe Warning Unique e Adjust Front Before Rear Warning Unique e Enhanced Printouts e Voice driven alignment Customer database backup and restore V3D CCD Sensor Switching Enhanced Manual Ride Height Measurement Screens e Backup and Restore of Calibration and Setup Data e Changeable Readings in Demo Mode e Enhanced Ford Bushing Program Unique e NorthStar Shim Program Update e Update
61. by the operator if a failure in the alignment mode occurs Camera Test Test both the strobe and the gain of the camera and it s ability to recognize images with gain and strobe changes Rack Check This test checks how coplanar parallel the rack is Even though we are very resistant to rack problems non coplanar racks can introduce some error to our system Stored Image Analysis This allows you to view and zoom into stored images stored using Ctrl Alt P 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 Export Diagostic Files The diagnostic file export icon allows the technician to easily find and export all potential diagnostic information to a floppy disk or to any other location Page 3 31 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE CAMERA VIEW Targets must be mounted ona vehicle or placed on the rack e This screen displays a count of the received images over each sides display If one camera is sending a lot less images than another 15 this may be an indication of a camera problem e Displays a camera error icon if no images been received from a camera Camera error icons will appear if no valid images are acquired Click or Cancel to exit CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg Ext Crew Cab Menu Mode Effective Page 3 32 04 2005
62. 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 Since we know P and r we can calculate D we now know the distance the pen is from the camera Applying this to the 3D Aligner the image analysis software takes each image and precisely measures the size of each dot on the photograph this is the perceived size A We already discussed the known values of focal length F and size of the dots P Thus using the above math the 3D Aligner can measure the distance from the cameras to any dot on the targets and can do so with a high degree of accuracy it can measure a target 20 feet away to less than 1 mm accuracy Effective 04 2005 Page 2 5 CHAPTER 2 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 Look what happens to the observed size of the screwdriver when it is rotated away from 90 degrees to your eye it appears smaller The observed size of the screwdriver becomes shorter The more it is rotated the smaller it appears to be This effect is called foreshortening As before if you know the actual size of the screwdriver is 6 inches by measur ing the observed size
63. ce the small target on the right rail and the large target on the left rail Center the feet front to rear Click on lt OK gt when done 13 Place the cal bar on the left rail with the small target in the center of the front table and the large towards the rear outside of the rail Click on lt OK gt when done 14 Extend the plunger under the rear foot Click on lt OK gt when done Congratulations You have successfully completed calibration Effective Page 3 26 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE MEASURING DEVICE Imaging System Type Two Cameras 3 Ride height target From the Main Menu select the Preference tab click on the System Configuration icon and click on Ride Height Target to activate the Ride Height Target feature CALIBRATE 1 From the Main Menu select the Maintenance tab click on the Calibration icon and click on Ride Height Target Calibration icon to begin the calibration process 2 Locate the Ride Height Calibration fixture and place the fixture on one of the lift runways so the straight edge is toward the camera 3 Select the side of the rack you are to calibrate from 4 Place the tip of the target pointer into the hole in the base of the calibration fixture Right 0 00 0 00 0 00 Move the Ride height target to the displayed position and Press OK NOTE THE POINTER TIP MUST REMAIN IN THE HOLE DURING ALL STEPS OF CALIBRATION 5 iltthe ta
64. 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 You can identify integrated USB controllers by the location of the ports if they are adjacent to the PS 2 ports the USB service is likely provided by an integrated controller If the USB ports are located anywhere else on the back of the computer you re probably dealing with a USB add on card Front mounted USB ports can be either type You may have to open the PC case and visually inspect the USB ports to see whether they connect directly to the motherboard or to an add on card Scenario All devices occasionally stop working at the same time Possible causes Power management configurations for USB controllers controller drivers bandwidth If the system experiences sporadic controller failure the primary suspect on the PC OS side is power manage ment although it could be either an intermittent conflict or a problem with the USB controller Try to isolate a particular event common to all the failures just as you would with any other sporadic hardware conflict This could lead you back to a power issue if you have bus powered scanners or hard drives that might be drawing more power than the PC can provide If the system requires more power try replacing the PC s power supply
65. cows 22 Excessive loads on the bus also cause power problems The USB controller can power USB devices Small devices like mice and keyboards aren t a significant drain but larger devices such as scanners hard drives Web cams and speakers can draw considerable power You might be able to eliminate the problem by spreading the power hungry devices across multiple root hubs Otherwise acquire a good self powered external USB hub 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 This means that skipping the reboot will break the whole process If you think the new drivers aren t receiving priority completely uninstall the device in question You have to leave the device connected to uninstall it properly At other times you may be able to remove a device s drivers using Control Panel s Add Remove Programs applet just as you would with other software Sometimes it s necessary to upgrade a device s firmware which is basically a driver that runs on the peripheral The more advanced the device the more likely it is that the firmware can be upgraded Mice being sim
66. d PDF Operator Manuals e Updated Worldwide Translations e Proper Shutdown Button Operation CCD Models Only e Enhanced Sensor Diagnostics Imaging Models Only Rolling Radius Auto Advance 2 wheel Alignment 2 amp 4 Target Unique Caster Trail Scrub Radius SAI amp Included Angle Measurement Screen Unique e Automated Ride Height Measurement Unique e Illumination LED Management Note Excludes Entry Level models Platinum software only Requires accessory purchase Effective 04 2005 Page v IMPORTANT SAFETY INSTRUCTIONS When using this equipment basic safety precautions should always be followed including the following 1 2 10 11 Read all instructions Do not operate equipment with a damaged power cord or if the equipment has been damaged until it has been examined by a qualified authorized service technician If an extension cord is used a cord with a current rating equal to or more than that of the machine should be used Cords rated for less current than the equipment may overheat Care should be taken to arrange the cord so that it will not be tripped over or pulled Always unplug equipment from electrical outlet when not in use Never use the cord to pull the plug from the outlet Grasp plug and pull to disconnect To reduce the risk of fire do not operate equipment in the vicinity of open containers of flammable liquids gasoline Keep hair loose fitting clothing
67. d click OK or you can double click on the desired wheel CHEVROLET 1997 BERETTA 3 Once the wheel is selected the screen will instruct the operator to place the target clamp assembly on the front wheel and lock the steering wheel using the clamp This step insures the wheels will not move laterally during the Target ID procedure The next step on this screen is to elevate the front wheels to allow them to rotate as needed Click OK when ready to proceed Place target on front wheel Install steering wheel holder NOTE USE RIGID SUPPORTS JACKS ON LOCKS ANY DOWN MOVEMENT OF THE WHEELS CAN AND WILL CAUSE INCORRECT MEASUREMENTS WHICH WILL IN TURN CAUSE INACCURATE ALIGNMENT READ INGS 4 Once the system acquires the target an arrow indicates the direction to rotate the target wheel The initial rotation is 25 forward 5 Ifthe tire and wheel is rotated past the 25 point the arrows will change from blue to red letting the operator know to rotate back Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 6 Once the wheel has reached the desired location a stop sign will appear in the center of the wheel Hold the wheel steady as the aligner will take a reading CHEVROLET 1997 BERETTA 4 Mera Made 7 After the readings have been taken the screen instructs with arrows indicating to rotate the wheel and target back 90 This 90 degrees is from the first 25 forw
68. de Rack A 4 Optical heads 5 toe sensors Page 3 11 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 7 Choose the Windows Utilities icon from the Maintenance Menu 8 Double click on the lt Install gt icon from the Windows Utilities Desktop Access Printers wnload Specs Snap On i orton Utilities 9 Insert the specification CD in the DVD drive and Installation Window choose the Install from CD radio button and click on lt gt Page 3 12 Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 10 Choose the language for installation This does Choose Setup Language not choose a particular specification database m This language selection only changes the dialogue for the installation of the software 11 Follow all on screen instructions using the default directory for installation When prompted re boot the aligner SPECIFICATION INSTALLATION COMPLETED Effective 04 2005 Page 3 13 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE PLATINUM SOFTWARE INSTALLATION 1 Choose the PREFERENCES tab from the main menu of the alignment software Preferences Rack 4 Optical heads toe sensors ll Menu Mode 2 Fromthe Preference menu select the USER INTERACTION icon Menu Mode 3 Fromthe User Interaction menu select the SECURITY tab secur ity MAP Enable MKS r Enable
69. deter mined inspections Six Inspection screen are available under Inspections as well as a Diagnos tics icon These are Pre Alignment Inspection Tire Inspection Brake Inspection Under Car Inspection Under Hood Inspection and Courtesy Inspection Measurement Offers quick access to several angular measurement screens such as Caster SAI Steering Angles and Vehicle Dimensions Adjustment Offers access to a variety of features that assist the technician with adjustment of alignment angles Some of these features include Live Caster A Arm Adjust Rear Shim Programs and Cradle Adjust Customer Data Offers the operator easy control for finding adding or editing any customer data that has been previously saved from past alignments Information can then be retrieved and sorted through a myriad of different options PREFERENCE FUNCTIONS Page ii User Interaction Gives the operator control of Features Displays User Login and Security Maintenance bia zl it ts JE 00 8540 mE E kc ati Ju jd MEN Preferences Units of Measure Allows the operator to control the way the unit displays alignment measure ments CSR Preferences This is a secure location for technical personnel only Allows a field technician to overide any security that may have been entered by the operator Connectivy Protocall options for various alignment opt
70. dure for installation and follow the pod sync procedures to properly time the cameras Effective 04 2005 Page 5 7 CHAPTER 5 ULTRA ARAGO 3 STROBE BOARD REPLACEMENT NOTE THE STROBE PCB IN THE ONLY PART OF THE CAMERA ASSEMBLY THAT CAN BE RE PLACED AS A SINGLE PIECE THE CAMERA PCB S ARE PART OF AN ASSEMBLY AND SHOULD NEVER BE REPLACED ALONE 1 Power down the unit by toggling the switch to the Power Supply to the OFF position 2 Un plug the power cable from the power source 3 Remove the screws from the bottom of the Pod Covers and gently remove the pod covers 4 Remove the 4 screws securing the strobe pcb to the assembly 5 Disconnect the data ribbon cable and the strobe cables 6 Reverse procedure making sure that the rubber protection gasket yellow arrow is placed between the strobe pcb and the camera frame NOTE CHECK THE PIN LENGTH ON THE BACK OF THE STROBE PCB AND TRIM ANY EXCESS LENGTH 7 Use the data examination mode to ensure that both the strobe and gain are at an acceptable level BOTTOM TOP SWITCH REPLACEMENT 1 Power down the unit by toggling the switch to the Power Supply to the OFF position 2 Un plug the power cable from the power source 3 Remove the screws from the bottom of the Pod Covers and gently remove the pod covers 4 From the front of the camera assembly disconnect the cable from the faulty switch and remove the 2 screws securing the switch 5
71. e ON LED indicator was added to the strobe board to alert the technician or alignment technician that the strobe LED s are firing This LED is located behind the intuitive cover and is not visible to the operator however it can be seen by looking closely Roll Directional Strobe ON Indicators Indicator Target Not Acquired Indicators Indicators Target Not Acquired Indicators Effective 04 2005 Page 1 5 CHAPTER 1 AC DC POWER DISTRIBUTION When the targets have been mounted to the wheel and tire of the vehicle the Target Indicator LED s will illumi nate green once the targets have been acquired Target Acquired Indicators Target Acquired Indicators Effective Page 1 6 04 2005 All information contained this document is considered confidential and proprietary by Snap on Tools manufacturing use reproduction and sales rights are reserved by Snap on Tools and the information contained herein shall not be used in whole or in part without the express written consent of Snap on Tools or 4 Stroke Connection LEFT CAMERA wm
72. e axis by turning the wheels First we turn one direction 10 to 13 degrees The software monitors the movement of the target dots which scribe an arc The program finds the center of each of the 33 arcs averages and knows where the steering axis is located As with the spindle determination we check our findings by turning the wheels the other direction If the two steering axis calculations agree we pass this along to other parts of the software that convert axis locations to caster and SAI angles referenced to the vehicle plane Effective Page 2 14 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE TROUBLESHOOTING THE SYSTEM This Chapter was written for the purpose of troubleshooting the ULTRAsystem Earlier systems had different components that are not the ULTRA system Using this manual to troubleshoot earlier systems will result in return errors from some of the DIAGNOSTIC TEST S Before using this troubleshooting guide there are some steps that the user must follow Failure to follow these guidelines will result in longer repair times and repeated callbacks In using this guide always start with basics regardless of the complaint Some of the screen captures in this Chapter were taken using a two camera system Servicing an Ultra Arago will only add an additional camera view The troubleshooting is handled the same GUIDELINES e Before beginning any diagnosis verify the customer s complaint and aligner s condition in great
73. echnology that provides many benefits to the shop owner and alignment technicians It is the fastest most accurate and easiest to use aligner ever made One of the benefits of new technologies is the use of state of the art compo nents and computer programming that makes the task of servicing this product easier than previous genera tions of alignment equipment One of the most obvious differences is the lack of an electronic measuring head the source of many of the failures and inaccuracies on conventional products The eyes of the vision based 3D Aligner are the two cameras mounted on either end of a camera beam The proprietary design lens 15 for this usage and is permanently mounted to the camera and triple sealed for protection The camera also has a band pass filter limiting the spectrum of light that can enter the lens With any camera there is an optical field of view that is a characteristic of the lens design Anyone who has used a camera knows that what you see is what you get no more no less The cameras on the 3D Aligner are no different This unit incorporates many security features that totally eliminates unauthorized use of the software Once the software has been successfully loaded the unit disables the Key Disk leaving them useless on other units The unit transfers the information from the Key Disk to the CAMERA PCB s that in turn transfers it to the hard drive This information is stored in both locatio
74. el alignment equipment uses the spindle as a starting point usually by either placing the measuring device directly opposite the spindle or by performing a runout compensation referencing gravity or the rack The 3D Aligner finds the spindles in a unique way that improves accuracy and speed Axis of Rotation single point on the wheel tire is represented by the star If we rotate the wheel tire and track the position of the star at various points we would find the star movement forms a circle If we determine the center of the circle we have defined the axis of rotation of the wheel tire automotive terms the axis of rotation of the wheel is called the spindle The 3D Aligner locates the vehicle spindles directly using a procedure called positioning In positioning we rotate the wheel tire target by pushing the vehicle back As the vehicle moves the cameras track the location and orientation of the target dots If the wheel went through a complete 360 degree rotation each dot would scribe a circle as illustrated in the picture below If we took our scribed circle and determined where the center of that circle was located we would find the spindle The dot moves back as well as rotating about the axis this allows the software to locate the spindle position in 3 dimensions with respect to the camera Of course there is more than one point on our targets that the cameras can track there are 33 reflective dots As we move the car back each d
75. ely to happen in every day usage Effective 04 2005 Page 2 13 CHAPTER 2 THEORY OF OPERATION MODELING THE VEHICLE IN 3 DIMENSIONAL SPACE After Positioning is completed and the program is able to relate one side of the vehicle to the other the software knows 4 distinct points that create a plane in space that are part of the vehicle It takes these points and creates a 3 dimensional model of the vehicle plane From this model all alignment angles caster SAI camber and toe are referenced to the vehicle plane This is in contrast to conventional measuring head aligners that use gravity or the rack surface as a reference For this reason the 3D Aligner does not rely on a level lift In reality the aligner does not require gravity to measure but our vehicle s physical state will change radically in a weight less environment 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 Conventional 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 Once again the 3D Aligner is unique and superior The 3D program locates the steering axis directly in 3 dimensional space in the same way it found the vehicle s spindles We locate the axis by putting our targets in motion about th
76. em is activated a serial number unique to the aligner being installed is then written to an encrypted file on the floppy thus preventing it from being used in any machine other than the unit just installed Once the unit boots up the unit will offer the selec tion type Imaging or CCD Select the target for imaging and click on OK By default the logo screen is the first screen to appear after the alignment software loads To access the alignment software click on the lt OK gt button in the lower right hand corner of the screen SOFTWARE INSTALLATION COMPLETED Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE Security xl Insert the Keydisk for Branding Enter the key codes 0000 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE SPECIFICATION INSTALLATION 1 Choose the PREFERENCES tab from the main menu of the alignment software Rack 4 4 Optical heads toe sensors Menu Mode 2 Fromthe Preference menu select the USER INTERACTION icon Prot LSA MODS TN Demo Bide Menu Mode 3 From the User Interaction menu select the F nd Use imita SECURITY tab 83 gt sel Features Disp Wizard Secu rity
77. er We must perform Relative Camera Positioning THE FIXTURE The fixture used to perform RCP is also used for camera aiming It consists essentially of a bar about 5 5 feet in length with a target attached on each end a front and rear Stands are used to place it on the alignment rack which should be at alignment height so the targets are visible to the cameras Due to manufacturing tolerances and transportation of the fixture we cannot be sure its dimensions are the same as the design We must measure it each time we perform RCP Of course we always have a highly accurate measurement tool at our disposal the 3D Aligner To measure the length of the fixture we place the assembly on the right runway of the rack in the view of the right camera RCP The right camera measures the distance to the front target and the rear target and subtracts the two with the difference being the fixture length This is stored in memory for usage later in the RCP procedure Effective 04 2005 Page 2 11 CHAPTER 2 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 RCP Y The right camera measures the distance to the right target the left camera measures the distance to the left target and the memory has the fixture length We have 3 of the 4 sides of a trape
78. es that the camera has acquired Number of Images Number of raw images that the camera has acquired Tage LLL Left 4012 Right 3646 Retrieve additional data by clicking on the target identification icon R F Intensity The amount of light sent back from the target Minimum 100 Goal 160 Maximum 220 Strobe Brightness of the LED s Right Front r3 Gain The amount gain depends on the brightness of the image The brighter the image the lower the gain value RF LR RR Threshold 50 Acquire Count 0 RMS 1 24 Target Blobs Blobs Number of Planes 1379 Strobe Distance 118 6 will be Normally the gain on the rear targets will be at a a JM AME a greater value than the front to adjust for the distance the c cameras are away from the targets _ Threshold All pixels received by the cameras have a brightness level of 0 to 255 Threshold tells the cam eras to ignore any pixel with a brightness level below a certain number Threshold levels are software controlled and are primarily for engineering use Acquire Count How many images it takes to acquire a target Effective 04 2005 Page 3 33 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE The user can quickly jump to each targets information by clicking on the target identification icon This screen will display warning indications if any of the following criteria have been exceeded or if a target is not visible
79. es the angle of orientation away from normal with foreshortening Using these methods it determines where the target dot is in three dimensional space with respect to the camera both distance and orientation It is the circle s unique characteristics that allow the aligner to distinguish between the effects of perspective and orientation Examine below to see and example of a target rotated in different directions For this discussion we assumed the target has only one dot In reality each target has 33 dots and there are 4 targets and the 3D Aligner s powerful computer system analyzes each circle simultaneously for incredible accuracy and resolution We have now seen how the aligner uses the camera images to determine the targets location and orientation in 3 dimensional space It now has the capability to measure but how does it use these principles to measure wheel alignment angles Effective Page 2 8 04 2005 CHAPTER 2 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 is a bit misleading We don t adjust the wheels we adjust the suspension and steering components resulting in changes at the wheel It is the vehicle spindle that receives the alignment and the wheels are just along for the ride All whe
80. he power supply to the cameras The aligner loads a Generic USB HUB at startup and must be present in order to operate the cameras and pass information The Ultra Arago uses 3 Generic Hubs and each must be present Also the camera device drivers must be loaded and will also show up in the device manager The conventional will show 2 cameras and the Arago will show either 3 or 4 depending on whether the unit is equipped with a remote camera The Ultra Cameras will not show up in the device manager if the Generic USB Hub is not present The Ultra Arago will also show 2 USB motors used to drive the camera pods up and down the towers aio x File Action View Help B amp Disk drives Display adapters 45 DYD CD ROM drives 4 Floppy disk controllers J Floppy disk drives Human Interface Devices IDE controllers 5 gt Keyboards Mice and other pointing devices Monitors B Network adapters 27 Ports COM amp LPT me Processors Sound video and game controllers System devices Universal Serial Bus controllers Gc Generic USB Hub Generic USB Hub 6 Generic USB Hub Ge Intel R 82801FB FBM USB Universal Host Controller 2658 Intel R 82801FB FBM USB Universal Host Controller 2659 6 Intel R 82801 USB Universal Host Controller 2654 6 Intel R 82801 USB Universal Host Controller 2658 E Ee Ee Ee Ee F1 OH M
81. i NOTE CLICK ON OK OR CANCEL TO EXIT ALL TESTS 101 118 123 223 151 158 152 139 Effective Page 3 34 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE CAMERA TEST For the aligner to accurately collect data and display images it has to continuously acquire images and send this information back to the Main CPU 1 Make sure that the unit is powered up 2 Raise the alignment rack to alignment height and place the rear targets just behind the front turnplates 3 From within the Diagnostic options single click on the Camera test icon 4 Animage of the targets should appear on the monitor 5 Beginning with the left camera slide both the GAIN and the STROBE slider bars all the way to the right lt ETES The image of the target for the left side should respond to the change by BLOOMING Maximum Gain 48 Maximum Strobe 315 6 Using a white piece of paper cover the complete BUICK 1991 PARK AVENUE camera lens The entire image for that side should turn GREEN The image should not have any black spots which would indicate dirt on the lens If black spots show up try lightly blowing off the camera lens with a can of compressed air If the spots remain replace the camera assembly and retest Repeat the process on the LH side If any part of this test fails camera replacement is recommended Effective 04 2005 Page 3 35 CHAPTER 3 CHECKOUT CALIBRATIO
82. idered confidential and proprietary by Snap on Tools All
83. illustrations below show the PC hookup currently available with the alignment system Specifications are subject to change without notice The current PC is a DELL configured Celeron Parallel PS2 Printer LAN Mouse Connection Serial CRT PS2 USB Sound Connection Keyboard Connection Connection Effective 04 2005 Page 3 3 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE CAMERA REMOVAL amp REPLACEMENT 1 Follow the proper power down sequence Remove the 5 phillip screws from the back of the camera Slide the camera cover forward and place off to the side Disconnect the USB and Molex connector from the camera Loosen the 2 1 2 nuts securing the camera to the beam Gently slide the camera off the end of the beam Reverse the procedure for installation D See Camera Indentification later in this chapter for the proper procedure to train the alignment system after a camera has been installed 4 Uo Le eS 92255 VE SR KE gt ee 5 CS N je e e 7 666 CS Se 2099 4 ames rui T DS 7 ome a Lie DS pe 07 08 e Ue PNM Delo D AS QD o cs er 952 ORB s Ex w er t i WE D27 EM t a iiid 3 irs NOTE AFTERINSTALLING A np SI EU NEW CAMERA MAKE SURE THE Doers SO n EDGE OF THE CAMERA CHASSIS 44 342 32 4 x IS ALIGNED WITH THE EDGE OF Y W 15 THE CAME
84. in diag is a diagnostic file generated when you use the Ctrl Alt P diagnostic logging mode Stored Images saves all images saved using the Ctrl Alt P diagnostic logging mode into a zip file Expat Dinapa Pasa x named mages zip Hmain txt When an item has been selected to export the default directory is the location where the file is currently Hmain d lac located To save it on a floppy for example simply select Floppy A from the Save the pull down menu and click Save By default the files are named accordingly e Hmain txt Hmain diag Stored Imag es mages zip Multiple images of raw camera Views mumumuna NOTE IF MULTIPLE DIAGNOSTIC FILES ARE TO BE SAVED EACH FILE MUST PORTED AND SAVED AS A DIFFERENT NAME EXAMPLE 1st set of saved files Hmain txt Images zip 2nd set of saved files 1Hmain diag 1Hmain txt 1Images zip 3rd set of saved files 2Hmain diag 2Hmain txt 2Images zip Click on OK or Cancel to exit this test Effective Page 3 40 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE WINDOWS UTILITIES The Windows operating system is transparent to the operator Without having access to Windows the user would not be able to perform some of the needed functions to maintain the aligner The Windows utility r menu offers all of the needed access to Windows Desktop Access Dis
85. in the equipment will not operate CAUTION RETURN OPERATING CONTROL S TO NEUTRAL OR OFF POSITION AFTER THE TEST DE ENERGIZED STATE The equipment is now locked out or tagged out Effective 04 2005 CHAPTER 1 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 WARNING DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT AC DISTRIBUTION Alignment Console primary voltage is 110VAC 6 2 via the hot side black wire of the AC power cord On the Alignment console the power comes to a power strip then is distributed to the Monitor Printer and if so equipped the battery charger for voice control module For the camera power supply box the power comes via the hot side black wire of the AC power cord to an EMI filter to a on off switch then to the power supplies D C THEORY OF OPERATION POWER SUPPLY The power supply is a COSEL LEB100F 0512 The output voltage of the power supply is 5V and 12V 5 Peak 10 A The power supply is used to supply the camera with 5 volts to run the wheel indicator LED s and the 12 volts is used to run the strobe LED s The output connector on the power supply is
86. ions System Configuration Select either two or three camera system Select Wizard Allows the operator to select any default alignment wizard or access to customize wizards to meet their specific alignment option needs Store Name Allows the operator to input specific store information to be used on printouts Regional Settings Allows the opera tor to choose screen language and an alternate language if installed Also allows access to different spec data bases Effective 04 2005 INTRODUCTION MAINTENANCE MENU General Maintenance for the Ultra system is performed using this Maintenance Menu Always check the current revision of software before calling technical support for assistance as Maintenance Menus and icons are subject to change Calibration Software used to perform several calibration procedures including TID Camera Aim Hub Pin ID RCP and RCP Check Diagnostic Several diag nostic procedures used to troubleshoot different parts of the system including Camera View Camera Check IVS Processing Test and Target Check CHEVROLET TRUCKS 1883 ASTRO AND Menu Mode Preventative Maintenance Software feature that guides the equipment operator through recommended periodic aligner maintenance See Operators Manual for details Demo Mode A program used primarily by sales representatives and training personnel This is a program that demonstrates the capabilities of the aligner softw
87. it to a stop Should the motors get out of sync of each other the operator would simply use the aligner diagnostic screen in the alignment mode or the Camera View in the maintenance menu and manually force both cameras to either the top or bottom of the columns after which they would travel together The right pod assembly consist of a Right Camera and a Target and motor drive assembly This assembly is referred to as CAM TARGET Each are unique in design and replaced as assemblies NOTE AT NO TIME SHOULD A CAMERA COMPONENT BE REPLACED THE CAMERAS MUST BE REPLACED AS AN ASSEMBLY HOWEVER STROBE PCB S AND MOTOR DRIVE CAN BE REPLACED INDEPENTLY Each camera is mounted a Pod Car assembly the Pod Cars are identical in design however the mount ing orientation of the camera assemblies are different The Power Supply used in the Ultra Arago 3 is indentical to the conventional Ultra V3D However it may be necessary to adjust the 5VDC output to drive the camera furthest from the supply The Power Supply is also used to supply the drive motors with 12VDC Effective 04 2005 Page 5 1 CHAPTER 5 ULTRA ARAGO 3 COMPONENT IDENTIFICATION Top Limit Stops As vy Left Camera Assmbly Cam Cam Right Camera
88. l surface of an average car In fact the cameras are initially aimed at the factory so that the targets when mounted onto an average vehicle would be located in the center of that tunnel This insures that any vehicle placed on the rack in front of the 3D Aligner from the widest to the narrowest will have the targets mounted within the cameras field of view Effective 04 2005 Page 2 1 CHAPTER 2 THEORY OF OPERATION Side Field of View Figure 2 1 Top Field of View Figure 2 2 The Strobe Board contains 80 infared LED s in an array to provide a source of bright light to reflect off the targets when camera images are taken These LED s are rated for 100 000 hours continuous operation and up to 5096 of the LED s can fail without affecting the cameras ability to see the targets These infared LED s are synchronized with the cameras so an image is captured every time the lights flash roughly 2 times per second Effective Page 2 2 04 2005 CHAPTER 2 THEORY OF OPERATION TARGETS 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 looking at the reflected light it is brightest at the center of the light source As we move away from the source the brightne
89. leshooting common causes of USB failures Become familiar with using the Device Man ager as a troubleshooting tool Use the following sequence to open the Device Manager Hold down both the Windows Key and the Pause Break Key on the keyboard The following window should pop up The user can also click on the lt START gt button and right click on My Computer and select Properties After opening the System Properties click on the Hardware tab to open the hardware menu 2 xl System Restore Automatic Updates Remote General Computer Hame Hardware Advanced System Microsoft Windows Home Edition Version 2002 Service Pack 1 Registered to Harrison 5527 7 DEM DOT 1303 001 02 Manufactured and supported by DELL Dell Computer Corporation Dell OPTIPLES Geseri ntel H CPU 2 20GHz 2 19 GHz 128 MB of RAM Support Information Cancel Apply Effective Page 3 46 04 2005 After opening the Hardware Menu click on the Device Manager button to open the device manager CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE System Properties zjx System Restore Automatic Updates Remote General Computer Name Hardware Advanced Add Hardware Wizard The Add Hardware Wizard helps you install hardware Add Hardware Wizard Device Manager The Device Manager lists all the hard
90. look at a screwdriver 2 feet away from you it looks much larger than it does at 20 feet away This effect is called perspective Artists create the illusion of depth and distance in two dimensional drawings using this technique Crew Si Ize Distance from Eye In the example above assume that the screwdriver is 6 inches long If you had a way to measure the exact size of the screwdriver your eye sees at some distance away through the application of high school level mathematics you can determine how far the screwdriver is from your eye On the following page there is a more detailed explanation of the mathematical principles Effective Page 2 4 04 2005 CHAPTER 2 THEORY OF OPERATION Pen known length fixed Focal Length fixed by lens r Eu aa hs 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 The size of the pen is a known value P created by the designers of the pen The perceived size of the pen is measured by our software at the focal point and becomes a known value A The goal of this exercise is to determine the distance D from the camera to the pen First we must find the angle r by applying formulas from basic trigonometry tanr A 2 and Z P 2 D F Since we know A F P and Z can be
91. lows and end user to control the aligner through voice commands See Operators Manual for details Effective Page 3 18 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE CALIBRATION The Calibration software is used to perform periodic maintenance to the aligner This software is mainly used by the repair technician The Target Identification and Hub Pin Clamp Identification features are used by the customer to perform general maintenance should a target need replacing or an accidental drop TID Utilities used for performing Target Identification for 3 different types of clamps available to the end user including Standard Clamps Universal Clamps and CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg Ext Crew Cab Menu Mode Hub Pin Clamps Camera Aim Utility to aim the camera after installation Maxi mizes the range for the camera to see targets for most alignments Procedure TBD Relative Camera Position RCP Process used to identify the camera s distance from one another Two Camera System Only Ride Height Target Calibration Utility used to calibrate the Ride Height Target if available See the section to activate and calibrate ride height target for more information Camera Identification Utility for teaching the alignment system the correct camera and it s location Effective 04 2005 Page 3 19 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE TID The V3D
92. ment of spindle locations The software then compares the results of the roll back with those of the roll forward if they agree the program is satisfied and moves if they do not agree an error message appears called Wheel Wobble and we are forced to repeat positioning until they agree This is one of many examples of where the 3D Aligner performs quality checks to insure the highest degree of accuracy possible SIDE TO SIDE DETERMINATION The SD Aligner gathers target images utilizing two cameras mounted on the ends of a beam This beam is positioned higher than the vehicle s wheels to allow the cameras to see the rear targets the front targets are smaller allowing easier viewing of the rear Each camera can see a front and rear target on its side of the vehicle and thus determine their locations and orientations and find the two spindles on that side However each camera cannot see the targets on the other side of the vehicle When determining alignment angles such as thrust angle and setback it is necessary to connect the vehicle sides to know the relationship of the left side to the right side To do this the 3D Aligner must know the positions of each camera with respect to one another To get an idea of the type of analysis the 3D Aligner program must do In the picture there is a vehicle with all targets attached The program can determine the distance from each camera to the front and rear targets on its side of the
93. n sequence prisur tam usqha during caster sweeps to display the measure 13 3 Front First Threshold ment Note The more it is the more repeat able the measurements Linear Stability Tolerance Default 10 Distance Measurement Measures the height of the target and must be constant to acquire a target Angular Stability Tolerance Default 05 Angle of the target Measures the width of the target and must be constant to acquire a target Positioning Angle Default 40 How many degrees the target must rollback before acquiring a reading Positioning Angle Tolerance Default 10 Minimum Maximum for Positioning Angle Centering Tolerance Default 25 The maximum a target can be turned before the unit will ask the operator to steer the wheels straight ahead Steering angle during centering Positioning Wobble Tolerance Default 10 Maximum angle that a target can move during positioning before wheel wobble occurs Caster Roll Tolerance Default 30 Maximum angle that a target can roll during caster sweep before wheel roll occurs omoothing Factor Default 7 Smooths out display meters Note Keeps meters from jumping Dropout 10ms units Default 350 Amount of time it takes to drop a target when a target is blocked Front First Threshold Default 1 32 sets the value at which the Adjust Front First Indicator Icon appears on any of the rear reading screens See operator manual for details NOTE RUNN
94. n to appear is the language selec Setup Type tion screen The aligner has many different languages for easy user interface Select the languages for this installation and then click lt NEXT gt Finnish Flemish French French Canadian German Italian Portuguese Latin American Spanish Spanish Latin amp merican Swedish L L L lt Back Cancel Effective 04 2005 Page 3 7 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 10 The aligner confirms the languages that have been chosen Click on lt NEXT gt to proceed with the installation If a language is not chosen the operator can click on lt gt to step back a screen the select additional languages NOTE AFTERINSTALLATION A USER CAN ADD ADDITIONAL LANGUAGES AT ANY TIME BY REINSTALLING THE SOFTWARE THIS PROCESS WILL NOT OVERWRITE ANY PREFERENCES ALREADY SETUP BY OTHER USERS IF THE DEFAULT DESIGNATION WAS CHOSEN IN STEP 9 11 The next screen shows a percentage of completeion Screen 12 After a successful installation the Install Shield Wizard will display a installation complete The unit will need to be re booted before you can use the program click on FINISH to re boot the aligner Page 3 8 Aligner Setup Information Please read the following text Please click Next to start installation lAstallShrela InstallShield Wizard Setup Status
95. ner does works you can t fix it Refer to the Aligner Operator s Manual application notes and flow diagrams BE CAREFUL when handling circuit boards Wear an anti static wrist strap WHEN TRANSPORTING circuit boards use anti static bags NOTE RELATIVE HUMIDITY HAS A DIRECT EFFECT ON STATIC CHARGE BUILDUP AS HUMIDITY DECREASES STATIC BUILDUP USUALLY INCREASES LOCKOUT AND OR TAGOUT SYSTEM PROCEDURE Page 1 2 Notify all affected employees that a lockout or tagout system is going to be utilized and the reason thereof The authorized employee shall know the type and magnitude of energy that the machine or equipment utilized and shall understand the hazards thereof If the machine or equipment is operating shut it down by the normal stopping procedure depress the stop button open toggle switch etc Operate the switch valve or other energy isolating device s so that the equipment is isolated from its energy source s Stored energy such as that in springs elevated machine members rotating flywheels hydraulic systems and air gas steam or water pressure etc must be dissipated or restrained by meth ods such as repositioning blocking bleeding down etc Lockout and or tagout the energy isolating devices with individual lock s or tag s After ensuring that no personnel are exposed and as a check on having disconnected the energy sources operate the push button or other normal operating controls to make certa
96. ns If for any reason the unit requires that the software be reloaded it uses the information from the CAMERA that was taken from the Key Disk on the initial loading process ALIGNMENT FUNCTIONS The main menu of the aligner is the control center for the unit It offers the operator easy control of the basic alignment features Moving the mouse pointer over the icon gives the operator a short description of the icon function See the operators manual for a more detailed list and description of the many features and functions of the aligner Run Wizard Steps the operator through a com plete alignment The alignment machine offers many factory default wizards that can be edited by the operator to either add or delete certain steps Vehicle Selection Allows the operator to select a particular vehicle for an alignment This selection can be made at any point in the alignment by clicking on the Home icon and selecting the Vehicle Selection icon Back amp d Ophea heads ll toe sensors EPA Alignment Vehicle Specification Allows the operator to view the specifications for the vehicle chosen from the vehicle selection icon The operator has the ability to edit the specifications and save the edit specification to a custom specification database Effective 04 2005 Page INTRODUCTION 2 Inspection Offers a variety of inspection menu allowing the operator to perform pre
97. nu screen If the aligner is setup to run in the Desktop or Windows access mode simply Rack A 4 Optical heads tos sensors Menu Mode restart the aligner program VOICEALIGN INSTALLATION COMPLETED Effective 04 2005 Page 3 17 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE MAINTENANCE MENU General Maintenance for the Ultra system is done using this Maintenance Menu Calibration Used to perform calibration procedures on the aligner DIAGNOSTICS Utilities used to troubleshoot and diagnose the alignment system CHEVROLET TRUCKS 1993 ASTRO 2WD Menu Mode Preventative Maintenance Software feature that guides the equipment operator through recommended periodic aligner maintenance See Operators Manual for details Demo Mode Aprogram used primarily by sales representatives and training personnel This is a program that demonstrates the capabilities of the aligner software without actually having a vehicle available It is a useful tool for training new or experienced users about machine features See Operators Manual for details Windows Utilities Allows access to the Windows Desktop and also allows the operator to perform routine installation of printers software etc Database Utilities The feature is used for backing up and restoring alignment based data files customer data etc See Operators Manual for details Speaker Training Optional Hardware Software package that al
98. oles circled in yellow are used for the left camera assembly and the index holes circled in red are used for the right camera assembly Failure to assemble the camera correctly will cause a loss of targets the camera view See lllustraion 5 Gently pull the camera assembly from the pod car and un plug both USB and Power cables from the camera PCB 6 Reverse procedure for installation making sure that the rubber shock bumper is in place Follow the Camera Identification and Camera Aim procedure before returning the unit to service MOTOR DRIVE REPLACEMENT NOTE THE MOTOR DRIVE ASSEMBLY MUST REPLACED AS A COMPLETE UNIT THE UNIT IS ASSEMBLED AT THE FACTORY USING LOCTITE FAILURE TO REPLACE AS AN ASSEMBLY CAN AND WILL CAUSE THE UNIT TO EVENTU ALLY FAIL 1 Power down the unit by toggling the switch to the Power Supply to the OFF position 2 Un plug the power cable from the power source 3 Remove the screws from the bottom of the Pod Covers and gently remove the pod covers 4 From the back of the camera assembly un plug the cable from the motor control PCB leading to the motor a nd m 5 Clip the zip tie blue arrow securing the cable It is important that the cable be tied back failure to do so may allow the cable to interefere with gear and rack during normal operation al 1 6 Remove the 3 screws securing the motor drive assembly shown with red arrows 7 Reverse proce
99. one correctly Do not at anytime assume that the installation of any unit is correct Failure to follow the correct installation proce dure can and will produce errors in the system Become familiar with the correct installation procedures and deminsions Knowing this information can save many hours of customer down time and diagnostic time The installation instructions can be found in the back of this manual Electrical components of the Ultra Arago 3 have been described in detail in chapter 1 The Ultra Arago 3 have identical camera components used on the conventional Ultra V3D however these components have been assembled at the factory as calibrated assemblies References to the cameras are made in this chapter and the installation instructions that need to be identified The left pod assembly consist of a Left Camera and Calibration Camera and motor drive assembly This assembly is referred to as CAM CAM The assembly also contains a Motor PCB that is connected through a Connector PCB The Motor PCB is controlled thru a chip on the Mini Hub at the base of each column Each motor is controlled independently from each other The Mini Hub contains the logic basically telling the motor which direction to run either up or down and when to stop The Motor Controller is jumpered on the PCB as left and right J5 Should the motor come in contact with an object that could stop it an over current is generated on the Motor PCB bringing
100. or location Y cursor location Pixel 391 181 187 Pixel value intensity Effective 04 2005 Page 3 37 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE STORED DIAGNOSTIC FILE ANALYSIS 3 3 OR GREATER This allows the operator to examine a stored hmain diag file stored using Ctrl Alt P without having to search the hard drive It can also allow the operator to examine the Hmain txt file Playback of the file in a data examination mode allows simulated real time analysis of problems Clicking on the Stored Diagnostic File Analysis icon accesses the Hmain diag and Hmain txt file These stored diagnostic files gives the operator the same information as turning on the Mpacifier in the command file in previous versions of software Should a unit have intermittent failures the technician should instruct the customer to activate the diagnostic software by clicking on Ctrl Alt P at the time of the failure This enables the diagnostic software to capture all of the data for future playback The diagnostic file will automatically terminate at the beginning of the next alignment If Ctrl Alt P is pressed again a new diagnostic file will over write previous information H di fil Di viis saline Prag Demo Mode red Diagnostic File Analysi Mm x main diag T information 2 2 FILS 2 56 32 PM 5 uheel 1 ANPI strobe 5440 gain 10 mode 4 bksub 1 4 1
101. ot is tracked for distance and orientation with the software using this data to IT Movement of a Point During Positioning create 33 circles of different sizes Each circle is then analyzed for the center point with the results averaged to determine the vehicle s spindle Since there is a target on each wheel the software finds each of the 4 spindles simultaneously In the last paragraphs the positioning sequence described the targets dots scribing a circle through a 360 degree rotation of the wheel In reality this is not practical a full wheel rotation would require a roll back of 5 to 7 feet depending on the circumference of the tire Most alignment racks cannot handle this The engineers were able to shorten the wheel rotation angle to 35 degrees 5 This works out to 6 to 10 inches of roll back which is easy to accomplish with most vehicles Effective 04 2005 Page 2 9 CHAPTER 2 THEORY OF OPERATION When the vehicle is rolled back 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 back off the rack turntables it is necessary to roll it forward to perform any corrections The aligner uses the software when rolling the vehicle forward as a check of the results of the roll back As the operator moves the vehicle forward we repeat the positioning sequence When the vehicle returns to the turntables we have a new measure
102. play Settings Devices install while maintaining the Windows environment integrity 5 MetSpecs Snap On Notepad Volume Control Desktop Access Allows access to the Windows desktop in emergency situations Disables access to seca the Windows Desktop Should the unit arrive without access to the desktop a password is available to the service technician to allow access To obtain security access the technician must call the Support Help Desk to obtain access rights For security purposes this access code is not given in any docu mentation This is to prevent unauthorized entry to the Windows environment CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg Ext Crew Cab Tt Network Allows the operator access to Windows networking utilities Devices Allows the operator access to Windows system properties Install Used to Install Alignment Software upgrades and Specification updates Download Specs Future expansion that will allow the customer to download specification updates from the internet Snap on Hyperlink to Snap on and subsidiary companies of Snap on Use F5 to back page Notepad Allows access to Windows Notepad Volume Allows access to control the volume output of the speakers Effective 04 2005 Page 3 41 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE COVERING THE BASICS These procedures must be followed before placing a call to tech support Failure to have these answers when
103. ple devices don t require firmware upgrades Scanners hard disks printers optical disks and other sophisticated peripherals likely have upgradeable firmware Check the manufacturer s site to ensure you ve loaded the most recent update Effective 04 2005 Page 3 51 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE Bandwidth USB root hubs can each support up to 128 devices but they can run out of bandwidth depending on consump tion rates USB 1 1 is limited to 12 Mbps not counting the bus management overhead USB 2 0 has 480 Mbps with about 420 Mbps available so it can support more devices Combine an Ethernet adapter a printer and an external CD ROM or hard drive on a single USB controller though and the PC can quickly exhaust its Capacity The only solution for bandwidth problems is to either stop using all the devices simultaneously or to distribute the load Make sure you put devices that will always see use like Ethernet adapters and USB speakers on different root hubs You may need to get additional USB controllers which are inexpensive Effective Page 3 52 04 2005 CHAPTER 4 SECURITY GENERAL The aligner incorporates many security features that totally eliminates unlawful duplication of the software The loading of each piece of software requires that a key disk be installed to load the software Once the software has been successfully loaded the unit disables the Key Disk leaving them useless for use with other
104. pliant Pro32 software has a robust set of features adds the familiarity and power of Windows and has 27 different languages and 13 different specification databases In addition Windows offers powerful networking capabilities that will gain in importance as the automotive service industry discovers the benefits of information sharing between the front point of sale counter and the back shop CAMERAS The eyes of the vision based 3D Aligner are the two cameras mounted on either end of a camera beam The cameras are high resolution CCD video type operating in gray scale similar to those used in security and surveillance applications The proprietary design lens is for this usage and is permanently mounted to the camera and triple sealed for protection The camera also has a band pass filter limiting the spectrum of light that can enter the lens With any camera there is an optical field of view that is a characteristic of the lens design Anyone who has used a camera knows that what you see is what you get no more no less The cameras on the 3D Aligner are no different The field of view Figure 2 1 2 2 is located along each side of the alignment rack and is a cone shaped tunnel that expands size as it moves further away from the cameras The tunnel is approximately 21 2 feet in diameter near the front turntables The centerlines of the tunnels are close to vehicle spindle height and about 18 inches outside of the outer whee
105. ra system The Db9 connector at the bottom of the HUB Board is a direct link to the PC the other 3 connections are equivalent for the camera s any camera will plug into any of the three camera connections There is also Db15 connector on the HUB Board for future motor control EAP 238J31A REV CameraUSB r n LN Kola gt 9 E Camera USB Camera Pwr zJ 2 Camera Pwr To PC USB e Camera USB Incoming Camera Pwr Camera Pwr Motor Control Effective 04 2005 Page 1 4 CHAPTER 1 AC DC POWER DISTRIBUTION 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 indicators and directional LED s and 12VDC to power the strobe Camera Board Camera USB Strobe Board Camera Power The strobe is held on the camera pod assembly with 4 screws and lockwashers 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 Each of these LED s require 5VDC to light these LED s with the exception of the Strobe ON indicator it uses 12VDC The strobe LED s are infared and appear to be off during the alignment process however this Strob
106. rd Bias Angle amount of wobble during TID 0 10 3 Wobble Tolerance 2 0 4 Maximum Claw Change 5 4 TID Stability Count IO Maximum Claw Change Default 2 0 Maxi mum amount of claw change before software flags errors during TID ResetTolrances TID Stability Count Default 5 Minimum amount of consecutive snapshots of the target before the unit identifies it as a valid target IO Menu Mode IO Reset Tolerances Resets the unit back to manufacture defaults Effective Page 3 44 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE PARAM ETERS a s 3 xj 6 Click on the Parameters Preferences tab to access ee view Command Preferences The CSR Parameters js Command Parameters Edited radio button must be selected to view and Positioning Stability Count Reset Tolerances edit these parameters Click on lt OK gt to save 4 Caster Stability Count changes and exit 0 77 Linear Stability Tolerance Q IO IO IO IO IO IO IO IO IO IO IO 0 05 Angular Stability Tolerance Positioning Stability Count Default 5 How 40 Positioning Angle many planes the unit must acquire in sequence 10 Jhon Ange before measurements are displayed ma 0 12 Positioning Wobble Tolerance Caster Stability Count Default 5 How many een 0 7 Smoothing Factor planes the unit must acquire i
107. rget to the first position The reflective surface of the target should be facing the camera The target should HONDA 1882 ACCORD ex Wagon be steady during each step 6 When the circled 1 is Checked tilt the target to position 2 HONDA 1982 ACCORD ex Wagon Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE 7 Proceed with calibration until all three steps have been completed Right 000 0 00 0 00 Move the Ride height target to the displayed position and Press OK HONDA 1882 ACCORD ex Wagon 8 Should calibration of the ride height target fail a warning vs dialogue box will pop up and the user must begin the AN Calibration Failed please recalibrate process from the beginning s O NOTE IF THE TIP BECOMES DAMAGED AS SHOWN BELOW DRESS THE TIP WITH A FILE AND RE CALIBRATE Effective Page 3 28 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE CAMERA IDENTIFICATION After a camera has been installed it will be necessary to train the alignment system which side the new camera has been installed This procedure is password protected Call EquiServ s Technical Support Department for the proper password NOTE FAILURE TO FOLLOW THIS PROCEDURE AFTER NEW CAMERA INSTALLATION WILL RESULT IN IN ACCURATE ALIGNMENT RESULTS 1 From the calibration menu click on the Camera Indentification icon 2 Enterthe proper password to gain access 3 Select the proper
108. rom just before the pacifier was enabled The aligner stays in this record mode until a new alignment is begun or the hmain diag file is viewed using the utility below v9 F The following dialog shows you that the mode has been enabled After pressing OK please wait a few seconds while the images are being saved before N Diag nostics Enabled continuing STORED IMAGE ANALYSIS e This allows you to view and zoom into stored images stored using Ctrl Alt P NOTE EACH TIME CTRL ALT P IS PRESSED IT WILL OVERWRITE THE PREVIOUS STORED IMAGES IF TARGETS ARE NOT AVAILABLE IN THE CAMERA VIEW THERE WILL BE NO IMAGES TO LOOK AT USING THIS FUNCTION e Allows you to view individual pixel intensity levels e Display interlaced images to allow for verification of eee E correct interlacing An interlacing error will be DA j I evident by blobs that are non contiguous over each line An interlacing error will indicate a faulty camera this has nothing to do with CRT interlacing Left click the Moving the cursor over the image displays both the X and MT Y location of the cursor it also displays the pixel value mouse on the intensity of the cursor location The brighter the cursor location the higher the intensity value Left clicking the image using the mouse zooms in on that location Pixel 298 239 208 Click on or Cancel to exit this test X curs
109. ss of the light diminishes rapidly Street signs have retroreflection material on certain parts of their surface This material reflects light from a vehicle s headlights back to the motorist s eyes The portion of the sign that traffic control wants the driver to pay attention to is reflective while the rest of the sign fades into darkness Drivers in other cars cannot see the reflected light from the headlights of other cars because the angle of view is too large In the case of the 3D Aligner light is generated by the LED s hits the target and returns along the same path to the camera when placed in the center of the LED array The retroreflection material is placed on an aluminum backing plate to insure the reflective pattern remains flat This assembly is then mounted into a hard ABS plastic housing for shock and damage protection Finally a special piece of tempered glass is placed on top of the retroreflection material for final protection from damage The top glass is special for two reasons First it is an optical grade glass that is free of imperfections and impurities This is necessary so the reflected image the cameras see is not altered by glass imperfections Second the backside of the glass contains a pattern of dots etched from a jet black emulsion material This dot pattern created by the glass allows the cameras to see a very unique item that the 3D Aligner recognizes The various dimensions of this pa
110. the system will automatically prompt the user to format the diskette using the operating systems format command Restore Should a hard drive failure occur simply install the last known alignment calibration and preference data disk and restore the aligner back to the user s prefered preference NOTE IF THE OPERATOR IS NOT SURE IF THE SAVED DATA ON THE FLOPPY DISKETTE IS NOT CURRENT IT IS RECOMMENDED THAT A CALIBRATION BE PERFORMED FAILURE TO HAVE ACCURATE CALIBRATION DATA CAN AND WILL CAUSE EXCESSIVE TIRE WEAR Page 3 30 CHEVROLET TRUCKS 2002 K2500 PICKUP HD RegExt Crew Cab Effective 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE DIAGNOSTICS The Diagnostics menu offers the technicians tools to trobleshoot and diagnose problems with the aligner only These diagonstic routines will not diagnose all problems that could arrise The technician should also become familiar with the proper hookup and voltage that is supplied to this unit The hookup and voltage check points can be found in other parts of this manual Loading FPGAs TD Effective 04 2005 Camera View This screen shows the view as seen by the camera This is a good tool to use to verify live images CHEVROLET TRUCKS 2002 K2500 PICKUP K25 HD Reg Ext Crew Cab 2 Menu Mode Data Examination Mode The data examination mode displays a myriad of information The information is updated on going and can be used
111. tions A technician should at that time reorder a specification key disk to replace the lost disk that came with the software Effective 04 2005 Page 4 1 CHAPTER 4 SECURITY SOFTWARE FEATURES Each unit is sold with a software package Each package activates particular software features of the align ment system On the initial load of the aligner the operator technician 15 instructed to install the software features key disk After installing the key disk the aligner writes this information to both the desingated camera and the computers hard drive On all other boot ups the designated camera will do a roll call with the computers hard drive If the information agrees the software features will be available for alignments If for any reason a technician cannot locate the software features key disk or finds the one sent with the aligner is not usable the technician can call the technical support department Once the software features have been verified the technical support department can generate a key code for software features A technician should at that time reorder a software features key disk to replace the lost disk that came with the aligner DESIGNATED CAMERA The desingated camera is the control center for all security key features for the aligner Information is written to the designated camera and this information is used each time the aligner boots The designated camera performs a roll call of Branding Specification and Sof
112. ttern of dots is a known quantity that is stored within the program and is used as a constant forming the basis of our vision based measuring system There are 33 dots on each target laid out in a very distinct manner A great deal of time and effort was placed on designing this pattern of dots In some ways the dots appear to be randomly placed but in other ways appear to have some symmetry Some of the dots are larger than other dots and there is even one dot that is a donut It must be noted that these circles we see are geometrically the roundest circles we will ever encounter this is necessary for the interpretation of angles as we will learn later Note also that the dots on the rear targets are larger than the front targets to allow vision at a further distance Since the engineers designed the target dot pattern with great precision they know the exact dimensions of each dot and the distance from any one dot to another It is possible then to create a computer model of this pattern that the 3D Aligner software could use as it looked at camera images This would be usable in the program only if we were certain that the target attached to the vehicle matched the computer model Since it is impractical to have an engineer hand make each target to the required precision a detailed manufacturing process was created to make sure each target was an exact duplicate of the original design Effective 04 2005 Page 2 3 CHAPTER 2 THEO
113. turntable and press OK 2 Move the RCP fixture towards the rear of the rack just FORWARD of the rear slip plates 1413 The rack rails are parallel No adjustment ack cnock is bosse t R See the resulls on the indicated check your rack specification to make any 3 Read the results neccessary adjustments Click on or Cancel to exit this test The rack rails arg parallel CHEVROLET TRUCKS 2002 2500 PICKUP K25 HD Reg Ext Crew Cab PARALLEL RESULTS The front right or the rear left is up 0 4 Rack Check Complete See the results on the left If indicated check yaur rack specification La neccessary adjusimanis Adjust the rack to the manufacturers specifications Le Ehe Loire CHEVROLET TRUCKS 2002 2500 PICKUP K25 HD Reg Ext Crew ADJUSTMENT NEEDED Effective Page 3 36 04 2005 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE STORED DATA VIEWING TOOLS These tools are used to view or analyze previously store diagnostics data The main way of storing this data is using the pacifier enable keystroke combination Ctrl Alt P When a user is having some problems with the Aligner he she can enable this mode which saves images from all wheels and starts saving pacifier data in a Hmain diag file which also contains the contents of the Hmain txtfile f
114. tware Features Once this information is known the alignment software will utilize this information to perform each alignment and maintenance function If an aligner hard drive were to be formatted and reloaded with Windows and Alignment software the information that is stored on the designated camera will load all previous features Effective Page 4 2 04 2005 CHAPTER 5 ULTRA ARAGO 3 GENERAL This chapter was written for the purpose of removing and replacing components used on the Ultra Arago 3 alignment system The service technician should use the previous chapters of this manual to troubleshoot the Ultra Arago 3 The unique design of an Arago 3 system does not require calibration at installation or at anytime thereafter The unit comes equipped with a third camera that constantly monitors calibration and makes any adjustments necessary through the use of the software The camera assemblies are factory calibrated and can be placed into service after installation and setup Camera assemblies do not have to be replaced as a pair The Arago 3 is made up of two aluminum extrusions mounted in front of the alignment rack on the outboard edge so that the CCD camera systems can see down the length of the vehicle on both sides Each aluminum extrusion have camera pods mounted on them that move in a vertical direction as the lift is raised or lowerd The Ultra Arago 3 will operate at optimum performance providing the installation was d
115. ug a spare camera into the Hub location of the camera that is not working If the spare camera Is working the problem is either the camera or the cable If the camera does not come on the problem is in the hub Scenario 2 Both cameras stop working Plug a Spare power usb cable and camera into the back of the console and check to see if the Device manager recognizes an Ultra camera If so we can assume that the PC and 5V GND USB root hub and Universal host controller and power supply are i working correctly If the Ultra Camera does not show up in the device manager remove the power connection and check for the proper voltage 2 I at the back of the console 5v T OG ent Looking at the connector on the back of the cabinet check for both the 5 a E 5V and 12V remembering that each voltages utilizes separate ground see connector pinout Should any of the two voltages be absent or not within range replace the camera power supply and retest OTHER USB DEVICE TROUBLESHOOTING PROCEDURES Scenario One device occasionally stops working Possible causes Device drivers power management bandwidth It s important to isolate the particular event that s common to all failures Move the device to another root hub to see if the problem is in a particular root hub or in the device itself Remove external hubs from the equation to confirm they are
116. um Left Large Right Mediar Left Large Right Lange Note Pod Rotation Position should be performed any time a pod is changed or the towers arem CHEVROLET 2000 3 After clicking on as indicated step 2 the camera rotation levers change positions Move the camera levers to the position shown and click lt gt Move the pod levers to the displayed position and Press OK Left Small Right Stal Left Small Right Medium Lett Medium Right Medium Left Large Right Medium Left Large Right Large Note Pod Rotation Position should be performed any time a pod is changed er the mowed Towers are 4 Continue the process until all camera positons have been checked After the final rotation lever has been checked click on the Cancel button to exit Figure 5 19 Move the pod levers to the displayed position and Press OR NOTE IF A MISTAKE IS MADE DURING THE TEACHING PROCESS THE OPERATOR CAN SIMPLY CLICK ON THE RESET BUTTON CLEAR THE LEARN VP ING PROCESS AND START AT THE BEGINNING tedium Note Pod Rotation Position should be perlormed any time a pod is changed or the re moved towers Reset CHEVROLET 2000 CAMARO Effective 04 2005 Page 5 13 CHAPTER 5 ULTRA ARAGO 3 Effective Page 5 14 04 2005 All information contained or disclosed in this document is cons
117. units this ensures the disk are used only on the aligner it was originally installed on The unit transfers the information from the Key Disk to the a designated camera The designated camera in turn transfers it to the hard drive This information is stored in both locations If for any reason the unit requires that the software be reloaded it uses the information from the designated camera that was taken from the Key Disk on the initial loading process SECURITY KEY DISK 1 Brand Specific Activation 2 Specification 3 Software Features 4 VoiceAlign Optional 5 Replacement Key Disk Comes with Camera BRAND SPECIFIC As stated in the software installation the unit requires that it be branded before it is usable The new CCP software loads many different brands of software however the branding disk initiates the foreground software All commands between the different software brands are identical but the look is the only difference Once the unit has been branded the unit will display that particular software foreground This information is stored on both the computers hard drive and the designated camera On each boot up the software will perform a roll call with the designated camera If the branding that is written on the hard drive and the designated camera match the unit will continue with the loading process If during roll call both the hard drive and the designated camera are different the unit will prompt the
118. vehicle as indicated by the check marks using perspective What it cannot do directly is determine the distance from the camera to the front and rear targets on the other side question marks The way to find the cross distance is to know the distance between the 2 cameras called RCP on the figure If RCP is known itis straightforward mathematics to determine the cross distance in question since two sides of a right triangle are known Pythagorean Theorum b c But how does the program know the dimension RCP We must tell it RCP Effective Page 2 10 04 2005 CHAPTER 2 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 manufacture 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 manufacturing tolerances in the beam and camera assemblies are too variable to be counted on When the aligner is installed the technician mounts the cameras onto the beam Later the technician performs a camera aim in which he she alters the position of the cameras Once all camera movements are completed it is time for us to help the program find out where the cameras are with respect to each oth
119. ware devices installed on your computer Use the Device Manager to change the properties of any device Signing Device Manager Hardware Profiles Hardware profiles provide a way for vou to set up and store different hardware configurations Hardware Profiles Cancel Apply Locate the Univeral Serial Bus Controller at the bottom and click on the to view all of the active devices Effective 04 2005 C1 Device Manager File Action View Help gt 10 x RJHALIGNER E Computer B Disk drives H Display adapters BJ DVD CD ROM drives HS Floppy disk controllers Floppy disk drives Human InterFace Devices Fy IDE ATAJATAPI controllers 1 52 Keyboards ET Mice and other pointing devices rm 2 Monitors mg Network adapters fly Ports COM amp LPT mm Processors pi Sound video and game controllers Page 3 47 CHAPTER 3 CHECKOUT CALIBRATION AND MAINTENANCE USB BASICS USB controllers are known as root hubs They re integrated on the motherboard in most computers Current motherboards typically have between two and six root hubs each with at least two headers for connecting ports Older computers may only have one hub on the motherboard or a PC may have an add on PCI or EISA control ler 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 t
120. zoid and through application of mathematics we can determine the fourth RCP We also recheck our calculations several times by placing the fixture back on the runways at different points before proceeding Effective Page 2 12 04 2005 CHAPTER 2 THEORY OF OPERATION The RCP procedure establishes the missing dimension that allows side to side determination each camera s position with respect to each other The accuracy of this calculation is highly dependent on the fixture being dimensionally stable as we move it from point to point on the rack The final step is to recheck the fixture to make sure it is the same length We call this rechecking the fixture length We do this by placing the fixture on the left runway so that both targets are in the visual field of the left camera 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 E If the final check reveals the fixture has changed dimensions during the process we given notice and must repeat the RCP procedure from the beginning Because the Camera Beam is rigid the cameras are mounted to the beam And the structure is away from the action the system does not require periodic mainte nance calibration The only way the accuracy of the RCP can be affected is if one camera moves with respect to the other not lik

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