SERVICE MANUAL

WHEEL ALIGNMENT

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CONTENTS

1. PARTS LIST 3 2 Data Communication method 9 3 Power device 10 3-1 How to recharge Batteries 3-2 How to check Battery charging status 3-3 How to check charging device 4 Problem diagnosis program 12 4-1 Clamp Diagnosis 4-2 Aligning Calibration Jig 4-3 Sensor Value change 4-4 Sensor Diagnosis 5 Head Disassembly 15 5-1 Diassemble head face cover 5-2 Disassemble sensor from base 5-3 Jumper Pin selection 5-4 Connection of cable to Main PC Board 6 Zero calibration by using Calibration Jig 17 6-1 Saving Calibration Data 6-2 Line module Insertion and communication cable connection 6-3 Levelling Calibration Jig

6-4 Initiating Zero Calibration 6-5 Saving Calibrated Data on to Main PCB of Head 7 Service Q & A 22 7-1 Power Problem 7-2 Communication Problem 7-3 Measured data Accuracy Problem 7-4 Case Study

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1. PARTS LIST 1-1 PARTS LIST (Total)

PARTS NO. Parts name Quantity Remark

PHA1001 HEAD BASE 4

PHA1002 HEAD COVER 4

PHA1003 SETBACK BASE 4

PHA1004 SETBACK COVER 4

PHA1005 BRACKET A 4

PHA1007 BRACKET B 4

PHA1008 BATTERY CASE 4

PHA1009 BATTERY COVER 4

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PARTS NO. Parts name Quantity Remark

PHA1010 WEIGHT COVER 4

PHA1011 MAIN BOARD 4

PHA1012 SENSOR ASS’Y 8

PHA1013 USB Module Socket 1

PHA1014 KEY PANNEL 4

PHA1015 RF SOCKET PCB 1

PHA1016 NAME PLATE 4

PHA1017 BATTERY PCB 4

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PARTS NO. Parts name Quantity Remark

PHA1018 WIRELESS MODULE 2

PHA1019 WIRE MODULE 1

PHA1020 LEVEL 4

PHA1021 SHAFT 4

PHA1022 FLAT CABLE 1 6P

PHA1023 FLAT CABLE 1 10P

PHA1024 FLAT CABLE 1 12P

PHA1025 FLAT CABLE 1 20P

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PARTS NO. Parts name Quantity Remark

PHA1026 POWER CASE 1

PHA1027 POWER PCB 1

PHA1028 CHARGE CABLE 4 1.5 M

PHA1029 CROSS CABLE 1 4 M

PHA1031 SETBACK BAR 4

PHA1032 CLAMP 4

PHA1033 Turn table (front) 2

PHA1034 Turn table (rear) 2

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PARTS NO. Parts name Quantity Remark

PHA1035 Steering wheel holder 1

PHA1036 Brake pedal deprresor 1

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1

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1-2 PARTS LIST (Main Parts)

PARTS NO. Parts name Quantity Remark

PHA1011 MAIN BOARD

PHA1012 SENSOR ASS’Y

PHA1027 POWER PCB

PHA1014 KEY PANNEL

PHA1018 WIRELESS MODULE

PHA1015 RF SOCKET PCB

PHA1028 CHARGE CABLE

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2. Data Communication System

2-1. Wireless communication

2 FR(Front Right) 4 RR(Rear Right)

Lap-top computer

RF Module

1 FL(Front Left) 3 RL(Rear Left) Bluetooth wireless communication

Infra red wireless communication

Laptop Computer and Front Left head is communicated by Bluetooth RF module, Between head is communicated by Infra red light

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3. Power supply

3-1 How to Charge Battery 3-1-1 Turn the power switch on 3-1-2 Connect round end to the Charger 3-1-3 Connect Square end of charge cable to the head facia 3-1-4 When red light is lit on the facia of head, Battery is charging

3-2 Confirming Battery charging status

① ②

3-2-1 Using Multimeter testing device, measure ① and ② voltage. 3-2-2 If voltage is over 6.8V, the battery is fully charged (It has a overcharging protection on the charging unit)

▣ Use rechargeable batteries only otherwise malfunction could occur

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3-3. Testing the charging unit device

1) Plug round end of charging cable to the charger unit

2) Using multimeter tester, Check if voltage is within 7.4V ~7.8V

.

+ -

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4. Diagnostics program This program is to aid finding of the cause or parts when problem occurs

Main Screen Select “F4” Diagnostic program

4-1 Calmp Diagnosis

This allows identify the clamp which is out of accuracy. Follow the steps as instructed by the screen

4-2 Alignment of Calibration Jig

This is to realign the calibration jig. Frequent calibration, transport vibration may cause misalignment of jig

and can be realigned by this program

< Normal position>

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< 180 degree position>

1) Periodically realign the jig. preferably every 6 to 12 month 2) Main Screen--- F4 Diagnostic program --

Calibration Block realignment 3) As per screen instruction, mount Front right and rear right head

and then press Enter Then M button 4) Next is to turn the same head 180 degrees(Upside down as per picture)

then press Enter and M button 5) Adjust block so that the value comes within range of 0±2 on the screen 4-3 Sensor value Change

It measures the value of sensor for certain period and check if any sensor has a irratic sensor value change during normal communication

4-4 Sensor diagnosis

Caustion: This program must be executed with the heads mounted on vehicle and it is level.

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4-4-1 Head communication Status

① H(1~4) Comm shows communication status between head

. ② Off means head is not communicating On means it is normal

4-4-2 Head Measuring status It shows “Toe” “Set” “Cam” “Cas” value of eash head being measured. If abnormal, some value will not display.

4-4-3 Diagnosing the problem by the communication status between head

① If H1 is OFF then all head will show off ☞ Restart Computer ( Check if program port and computer port is matching) ☞ Problem of USB port or RF module ☞ Power Charging device malfunction

☞ Front Left head RF module is faulty

② H1(Front left) is ON but H2 (Front Right) is OFF ( This will also show H4(Rear Right) is off)

☞ Check Front left head set back cable and connector ☞ Check Front Left Setback sensor Assembly ☞ Check Front right Setback sensor Assembly ☞ Check Front right head set back cable and connector ☞ Check Front right Main PCB

③ H3 (Rear left)COMM is OFF ☞ Check Front left head set back cable and connector

☞ Check Front left Setback sensor Assembly ☞ Check Rear Right Setback sensor Assembly ☞ Check Rear Right head set back cable and connector ☞ Check Rear left head Main PCB

④ H4 (Rear left)COMM is OFF

☞ Check Front Right head set back cable and connector ☞ Check Front Right Setback sensor Assembly ☞ Check Rear left head set back cable and connector ☞ Check Rear left Setback sensor Assembly ☞ Check Rear Right head Main PCB

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5. Head disassembly steps

5-1 Head Facia disassembly

① ④

5-1-1 Undo 4 screws of ① and lift the cover 5-2 Sensor Assembly pull out ① ②

5-2-1 Disconnect the cable and undo 2 screw ① and pull out sensor 5-2-2 Undo screw ② and pull out Main PCB

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5-3 Adjustment of Jumper pin ② ③

①

5-3-1 Selection of Jumper pin according to the position of head

FRONT LEFT No Jumper. FRONT RIGHT ① Jumper should be inserted on ③ REAR LEFT ① Jumper should be inserted on ② REAR RIGHT ① Jumper should be inserted on ②and③

5-4 Connection of cable to the Main PCB

① ② ③

④ ⑤

① : Not use ② : Power ③ : Key board ④ : Setback Sensor ⑤ : RF Module

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6. Zero Calibration of heads on the Jig

6-1 Saving Calibrated data on to PCB of heads

1. Saving of Calibrated data Calibrated data is saved on computer and sensor head

and used independently 2. When Calibration ended and saved, the data is only stored on the computer 3, The actual measurement displayed on the screen is coming from the data

stored on the heads therefore it is essential to save to Compensation data onto PCB of the heads to get correct measurement

4. When installing the new machine, it is a good practice to save a data from heads to computer in case of PCB boar memory loss.

◈ Individual data on each head stored separately so it is not necessary to

replace all data when 1 of head is replaced F3 System configration - “admin” - Self calibration Input data

Read from Head Click

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6-2 Line Module insertion and Communication Cable connection

① Unplug RF Module from Power charging Device and insert Line Module.

② Connect round end of 2 cable to the Power Charging Device and connect square end to the head cover

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6-3. Levelling Calibration Jig

① Place the jig on firm ground ② Using spirit level, adjust height of left and right leg ③ For more precise leveling, adjust it as below

a. Mount Front Left head on the left Jig Block b. Get the value of Camber H1 Cam from Diagnostic program

c. Now Mount Front left head on right block of Jig d. Get the Value of H1 Cam

e. Adjust level of the jig until the difference of H1 Cam value comes within “ 5”

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6-4. Initiating Zero calibration The steps instructed here must be followed for correct Calibration

1) F3 System Configuration Self CalibrationZero Calibration

Mount H2 head on the right and H4 Head On the left side of Jig

ENTER M Follow Screen Instruction

2) Now Mount H3 On the right and H1 on the left block of Jig

ENTER M Follow Screen Instruction

3) Mount H2 on the Right and H2 on the left

ENTER M Follow Screen Instruction

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4) Mount H3 on the left and H4 on the right

ENTER M Follow Screen Instruction

F5 END

5). Saving Data on the head

Press Save to Head and it prmpts to put a password. Input “ admin” as a password ◈ Do not Press Read from Head , This will delete all saved Calibration data

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7. Service Q & A 7-1. Power Problem

< Symptom >

* Battery is not charging * Red Led light is not coming on the head * Battery Discharges too quick < Cause >

* Charging Device is faulty * Battery could be faulty * Internal cable connection or cable could be faulty * Cable connector could be faulty * Key panel on the head could be faulty * Main PCB could be faulty on the head

7-2. Communication Problem < Symptom >

* RF Module is not communicating * While measuring, Monitor is unplugged message appears * Only Front right and rear Right is not communicating * A certain head alone is not communicating * Cannot proceed Run out

< Cause >

* Power charging Device faulty * USB Communication Port selection is not correct * Internal Connector and Cable faulty * Excessive misalignment of vehicle (Out of sensor range) * Connector faulty * Head selection Jumper pin is in wrong position

* Main PCB faulty * Sensor Assembly is faulty

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7-3. Measurement accuracy Problem

< Symptom > * Steering is off from the center when going straight forward

* Uneven wear pattern is noticed after adjustment * Car is pulling to one side < Cause >

* Zero Calibration is out * Lower body of Car has problem

* Light Deflection cause abnormal measurement * Main PCB calibration Data is deleted

7-4. Case Study

1) RF Module faulty ① In diagnostic mode, all 4 heads is not Communicating ② If cable is connected from Power Charging device to Front Left head and

H1 is “ON” , Then the RF Module is faulty 2) Main PCB is Faulty

① When no communication is established and Toe, Setback, value is not displayed

② Calibration Data is deleted and bring up wrong vehicle measurement ③ The + - value of the Sensor seems to be opposite

④ Battery is not Charging , Power cannot be turned on the head 3) Sensor Assembly is faulty

① In Diagnosis Mode, Head is not communicating but shows partial value of Either toe and Setback

② At certain angle, it is not communicating due to wrong Offset Value of Calibration Data

4) Connector contact is faulty

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◈ How to use new car data update program

① Download New data from PINETEC homepage and copy it in a computer. (At this time, you have to copy both wheel.dbf file and wheel.mdx file to use it.) www.pinetec.co.kr Technique Wheel alignment data

wheel alignment specification Down load wheel.dbf file and wheel.mdx file and CarDBConv.exe file

② Execute CarDBConv .exe file. ③ Press Select File button and select only wheel.dbf file where New data exist. ④ If you press Update button, it automatically runs, and it does not overwrite the old data but compare it with the old data to add and register missing part automatically.