wheel aligner wr 328a - cormach 328a service manual.pdf · the configuration outlined here refers...

WHEEL ALIGNER

WR 328A

SERVICE MANUAL UK

Rev. 0 03/2019

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Technical service manual WR328A 3

SOMMARIOINTRODUCTION .............................................................................4TECHNICAL DATA ..........................................................................4WHEEL ALIGNER COMPOSITION ...............................................4INSTALLATION ...............................................................................4CENTRAL UNIT ...............................................................................8WHEEL ALIGNER SOFTWARE .....................................................8CENTRAL UNIT RADIO SET .......................................................18MEASURING SENSORS ...............................................................18SIM CARDS AND SMART CARDS ..............................................22INSTALLING THE DATABANK UPGRADE ...............................22CALIBRATION ...............................................................................23UTILITY PROGRAMS ...................................................................27SERVICE PROGRAM .....................................................................28RADIO .............................................................................................31INSTALLING THE SOFTWARE UPGRADE ...............................35PROBLEM-SOLVING ...................................................................37GENERAL ELECTRICAL WIRING DIAGRAM (FIG.52) ...........39

4 Technical service manual WR328A

INTRODUCTIONThe purpose of this manual is to provide instructions for the installation and mainte-nance of the wheel aligner.This manual is for use in addition to the User and Service Manual supplied with the equipment, and does not cover the same topics.

TECHNICAL DATARefer to the operator's manual for full details of the technical data of this wheel aligner.Special attention must be paid to the working ambient conditions in relation to the wheel aligner configuration. Versions fitted with LCD monitor and/or INKJET printers are suitable only for a temperature range between 5 - 35°C instead of the usual 0 - 40°C of the other versions (further restrictions may also apply; for these components always check the manual supplied with the component itself).Note that 5 - 35°C is the maximum temperature range these components can resist and that their operation outside the 10 - 30°C range may not be optimal.

WHEEL ALIGNER COMPOSITIONThe wheel aligner consists of a central unit and four measuring sensors to apply to the wheels of the vehicle.The central unit consists of a cabinet containing the monitor, the keypad, the printer, the personal computer and the radio interface.The personal computer contains the electronics necessary for the wheel aligner to operate.The four measuring sensors are fitted with micro-controller circuit boards for full control of the angle measuring sensors (infrared CCD goniometers) and the electronic inclinometers for measuring the camber and levelling the sensor.

INSTALLATIONInstall the wheel aligner following the instructions in the User and Service Manual. The electrical connections between the various devices are shown in the wiring diagram (Fig.52).

CENTRAL UNIT

Installing the central unit and making the electrical connections

•The PC used is a computer tested to run the working programme of the wheel aligner, which does not contain any special electronic circuit boards. Power supply connectors used to supply the communication peripheral devices (radio circuit boards or the measuring sensors themselves) are provided on the outside of the PC case together with the measuring sensor charging housing.


SMART CARDS The aligner cannot be operated unless a hardware protection key has been inserted. The main protection board configured for the basic version is supplied with the ma-chine. Additional functions can be added to the wheel aligner by installing the up-grade kits (see the User and Service Manual).

INSTALLING THE HARD LOCK DEVICE:Insert the tip of a pen into the hole at the side to open the SIM holder (Fig. 7).Remove the wheel aligner SIM card (Fig. 6) from its punched support (keep the support with the serial number for future queries) and insert in the SIM holder (Fig. 7), with the gold contacts facing upward. Push the SIM holder in.For the update procedure, refer to the User and Service Manual.

RADIO HEADSThe radio heads kit consists of 4 sensors, provided with 6 rechargeable NiMH batteries to power the heads, and the radio set for the central unit.The way a battery is charged for the first time affects its performance for the rest of its life. For the best performance, consult the first charge instructions provided in the "Battery Pack" sec-tion. In case of a radio communications malfunc-tion, the ordinary head cables can be used to connect the heads to the central unit. Set cable communication mode in the assistant setup.

ELECTRICAL CONNECTOR PANEL

Install the electrical connector panel at the bottom of the cabinet (Fig. 1). Connect electrical connector panel to one of the HDD power cables leading out of the back of the PC and to the Hard Lock device with a USB cable (G, F, Fig. 2).

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HARD LOCK

Fasten the Hard Lock device (B, Fig.4) on the back of the cabinet using the fastening screws provided. Connect the 2 USB cables to the Hard Lock device. Connect the first one to an unused USB port on the PC. Connect the second one to the USB port on the electrical connector panel (E, F, Fig. 2).Two LEDs (a green and a yellow one) are located on the Hard Lock and are visible from the outside:

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B

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Condition LED status

Aligner power-on Lamp Test of both LEDs

Main SIM CARD present GREEN LED is lit up with a fixed light

Remote control signal reception

GREEN LED changes status upon receipt of input pulse from remote control

Radio communication with heads

YELLOW LED flashes in synch with communication

HARDLOCK OPERATION:

Hardlock and the main sim card work linked.A linked hardlock ONLY works with its own sim card.A linked sim card only works with its own hardlock.If a previously linked sim card is inserted in a virgin hardlock (new, never linked), the sim card and the hardlock will link and work together. The sim card will lose the informa-tion from the previous link and will no longer work with the hardlock with which it was previously linked.If there are problems with the sim card, the aligner will continue to function. The opera-tor will be informed of the malfunction by a message on the screen.To obtain a replacement sim card, send the following information to technical assis-tance:

1) The alphanumeric code indicated in the error message on the screen, or2) A copy of the "WA007.oca" file, contained in the folder "C:\Program Files\Align-

ment", or3) The alphanumeric code stamped on the plastic support of the sim card.

The replacement sim card will only function in the hardlock with which it was previously linked, as it is a clone of the original sim card.NB: THE DAMAGED SIM CARD MUST BE RETURNED TO TECHNICAL ASSISTANCE, WHICH WILL REPLACE IT. If the hardlock is faulty, a new (virgin) hardlock must be requested from Technical As-sistance. In this way, the customer's sim card will link with this hardlock and the aligner can continue to work.


CENTRAL UNITSK INTEL DG41RQ BIOS CONFIGURATION

The configuration outlined here refers to BIOS version RQG4110H.86A.0011.2009.0626.1639Listed below are the items using settings other than the default configuration (Load Optimal Default).

Menu Submenu Item Parameter

Advanced

Peripheral configuration

Parallel port Disable

Audio Disable

On Board LAN Disable

Video configuration

IGD DVMT Memory 128 MB

Primary video adaptor Int Graphics IGD

Chipset configuration

HPET Disable

PowerACPI Suspend State S1 State

Processor power management Disable

Boot

Boot device priorityCd-Rom Drive

Hard Disk Drive

Boot to removable device Disable

Boot to Network Disable

Usb Boot Disable

Boot USB device first Disable

WHEEL ALIGNER SOFTWARE

The wheel aligner is supplied with the operating system and software already installed.The CD-ROM supplied carries a copy of the wheel aligner software.The DVD-ROM supplied carries a Ghost image of the operating system only, customised for the motherboard.

The computer is pre-configured to perform the login automatically, so that the user is

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not required to identify himself whenever he powers up the wheel aligner computer. The following parameters have been set:

User name: AdministratorPassword: administrator [ in lower-case letters ].

During installation or upgrade of the wheel aligner software, the computer is restarted once or more. When the computer is restarted, you will be prompted to enter the password: type administrator

The standard user has also been entered to maintain compatibility with a number of vehicle manufacturers:User name: UserPassword: user

NOTE: the wheel aligner must be set for access by means of the Administrator user name.

When the machine is switched on, the release of the software installed will appear on the screen. Compare this release with that stated on the installation CD-ROM supplied with the aligner.If the CD-ROM release is more recent than the release installed, upgrade the aligner software.

NB: To restore the original operating system configuration, use the GHOST-DVD supplied.WARNING: before using the GHOST-DVD, check that the screen printing on the DVD carries the same model as the motherboard to be reset.WARNING: using the GHOST-DVD causes loss of all the data relating to the jobs done and the set-ups of the peripherals installed (e.g. the printer).

Instructions for changing the language settings

1) Open "Control Panel"

Technical service manual WR328A


2) Open "Date, Time, Language and Regional Options"

3) Select "Regional and Language Options"

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4) Select the language required from the pull-down menu and click on "Customise"

5) Select the "Time" menu

6) Select the "HH:mm:ss" format and confirm by clicking on "OK"

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7) Select "Languages"

8) Select the language required from the pull-down menu (see below for order in which languages appear)

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Then select the "Advanced" menu and select the language required from the pull-

down menu.

Confirm the selections by clicking on OK.

KoreanJapaneseTraditional ChineseSimplified ChineseArabicGreek


9) Click "YES" in the next window:

10) Click on "OK", restart the PC and continue with the usual testing operations

Settings for a correct graphic print

When a printer is installed, the graphic print emitted by the alignment programme may not be correctly laid out.This problem depends on the type of print resolution (print quality) set:

To resolve the problem, intervene on the file "Printer.ini", found in the path:c:\program files\alignmentTo correctly set the print resolution information in the file "Printer.ini", proceed as follows:

a. From the aligner logo page, press the keys "Shift" + "F4" (in this moment, if the file "Printer.ini" does not exist, it is created; if it exists, the lines specified below are added to it).

One row displays the name of the printer, preceded by the string "Printer." (between square brackets, e.g. [Printer.HP Deskjet 920c]), and then a line with a numerical description.

The numerical description depends on the setting of the print quality of the printer:Example:Fast DraftDraftFast NormalNormalEtc.

The format of the numerical description depends on the type of printer installed and could be (for example):

_300=300or_3=-3or_-3=-3

b. Exit the aligner programme.c. Open the file "Printer.ini", found in the path "C:\program files\Alignment"


In the file "Printer.ini", there could also be the names of other printer models, with their respective settings.

d. Identify the line corresponding to one of the printer in use (described above) (generally the last line, at the end of the file).e. Set the line with a numerical description, on the basis of the following cases:Case with value expressed as resolution (E.g. _300=300) It is not necessary to modify the setting Case with value expressed as indicative of the resolution (E.g. _3=-3 or

_-3=-3)

In this case, there are two possibilities:1. If available, the printing resolution value can be read on the printer’s printing

quality set-up screen; in other words, check whether the "dpi" number of the correct setting is shown on this screen. Example: if we have installed an HP Deskjet 5652 printer, and we have set the print quality as "Fast Normal" on the screen, we can read 600dpi next to the choice made. Consequently, if the following inscription is shown in the file "Printer.ini":

[Printer.HP Deskjet 5600 Series]_-3=-3we must modify and save the numerical description as follows:[Printer.HP Deskjet 5600 Series]-3=600 We have removed the underlining symbol (the first character) and kept the rest

unaltered; we have replaced the characters after "=" with the resolution value read.

2. If the print resolution value is not available on the page where the print quality is set, you must proceed with attempts, using the following logical reasoning.

Example: if we have installed an HP Deskjet 3745 printer, and we have set the print quality as "Fast Normal", if the following inscription is shown in the file "Printer.ini":

[Printer.HP Deskjet 3740 Series]_-3=-3we must modify and save the numerical description as follows:[Printer.HP Deskjet 3740 Series]-3=300Print a graphic test page. If the graphic image is:Correctthe setting made for the test is correct and we can leave that setting[Printer.HP Deskjet 3740 Series]-3=300Smaller, half-sizethe setting made for the test is not correct and we must modify and save the setting

as follows[Printer.HP Deskjet 3740 Series]-3=600Larger, double-sizethe setting made for the test is not correct and we must modify and save the setting

as follows


[Printer.HP Deskjet 3740 Series]-3=150

In any case, we have removed the underlining symbol (the first character), leaving the rest unaltered, and we have replaced the number after "=" with the chosen resolution value.

Note: to make the setting in the "printer.ini" file, repeat the entire procedure described above (starting from point a) and following the procedure again up to this point) for every possible printer printing quality set-up (modifying the printing quality in the printer properties each time); one line will be added to the file for every possible setting attempted. For example, the following is the complete final section for the HP Deskjet 5652 printer.

[Printer.HP Deskjet 5600 Series]-1=300-2=600-3=600-4=600

Warning:with the settings at the limit ("Maximum dpi"), the printer becomes very slow and the cartridges are consumed quickly. In addition, some printers give resolution identification codes that are identical. It is highly important not to give repeated indications in the file "printer.ini"

Example:for the HP Deskjet 5652 printer, we have the following condition:[Printer.HP Deskjet 5600 Series]_-1=-1 (Fast Draft) 300 dpi_-2=-2 (Draft) 600 dpi_-3=-3 (Fast Normal) 600 dpi_-4=-4 (Normal) 600 dpi_-4=-4 (Maximum dpi) 1200 dpi

In this case there are two lines with an index of "_-4="It is important not to repeat two lines with the same index so, in view of what has just been said, we recommend that you insert, in the file "Printer.ini", the indices of the print quality which can presumably be used to print the aligner reports.

Note: if the printout consists of several sheets, with successive sheets containing only part of the text and not a cut-off part of the graphics, first of all check that the paper size being used is the same as the paper size set in the printer.


Setting the customer LOGO for paper printouts

To customise the paper printout (by adding the customer’s logo), this function must be enabled in the wheel aligner configuration, and the following files must be modified:

imgprbarra3.bmpimgprbarra4.bmp

These files are installed in the path: c:\program files\alignment\graphics\image.The logo size must be 1100x354 pixel.

ALIGNMENT SOFTWARE

The wheel aligner is supplied with the software already installed. The CD supplied car-ries a copy of the software.The program is installed in the C:\Program Files\Alignment\… folder.When the equipment is switched on, the software release installed will be displayed on the screen (centre left).Compare this release with that stated on the installation CD-ROM supplied with the aligner.If the CD-ROM release is more recent than the release installed, upgrade the aligner software.

Upgrading the wheel aligner softwareThe files which contain the translations of the program texts into foreign languages will be found in the folder: C:\PROGRAM FILES\ALIGNMENT\TEXT\Each language has its own files in a specific sub-directory:STRING.INI: contains all the texts of the icons and the program windows.REGOLAZ.INI: the texts of the animations.STRSETUP.INI: the texts of the user set-up.STRSETUPA.INI: the texts of the after-sales service set-up.The files which contain the foreign-language translations of the “On-line help” pages are in the folder: C:\PROGRAM FILES\ALIGNMENT\HELP\.

•Quittheoperatingsystembyclickingthe icon and entering the password “end” (in lower-case letters).

•InserttheCD-ROMinthedriveandwaitfortheupgradeinstallationprogramtorunautomatically.

•Selectthelanguagerequiredandproceedwiththeinstallationprocedure.

WARNING

Once the software has been installed, the PC restarts automatically.


WARNINGIf Windows has to be reinstalled or if the PC does not carry the wheel aligner soft-ware, do not connect the CARD USB reader. Only connect it after having installed the aligner software and restarted the PC; only then will the connection drivers be present.

CENTRAL UNIT RADIO SETThe radio device consists of the transceiver module (Hard Lock, Fig. 3). Connection to the central unit is achieved by two USB cables; the first cable is connect-ed to an unused USB port on the back of the PC, the other one to the electrical connector panel card (Fig. 2).The wiring is also illustrated on the wiring diagram.

MEASURING SENSORSThe measuring sensors consist of angular CCD sensors, inclinometer and electronic level.

The electrical connections between the various devices are shown in the wiring diagram (Fig.52).

When connecting the measuring sensors to the central unit by means of cables, use the side connectors (A, Fig. 11); either connector may be used.

CPU Board (Fig.12)The measuring sensor CPU board is a micro-controller circuit board which acquires and processes the angles read by means of the goniometer and inclinometers and transmits them to the central unit.The measuring sensors are assigned to the vehicle's wheels by means of switches 1 and 2 of CPU board DIP_SWITCH SW3

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11A B


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CONNECTOR DESCRIPTION

JCCDT1 Transversal CCD camera (left - right)

JCCDL1 Longitudinal CCD video camera (front - back)

JINCL1 Two-axis inclinometer (channel Y=camber, channel X=level)

JSMF1Semaphores positioned in the transversal cap (indicating the adjustment of the angles in relation to the databank value)

JT1 Measuring sensor keypad

JT2 Measuring sensor keypad

JRAD24 Radio board

SW3 Configuration of measuring sensor position (see table)

JALSX1 - JALDX1 Cable for measuring sensor connectors (power supply and data)

JBATAUX1 Battery

JBOOT1BOOT switch: if NORMAL (switch up), standard work mode and firmware download. If BOOT (switch down), emergency firmware download

JALEX1 Battery charging rods

Configuration of measuring sensor position by means of SW3:

SW3 1 2 3 4

Front left OFF OFF OFF OFF

Front right ON OFF OFF OFF

Rear left ON ON OFF OFF

Rear right OFF ON OFF OFF

Emergency firmware boot X X X ON


It is possible to update the measuring sensor programme (FIRMWARE) by means of a service programme, without the need to open the measuring sensor itself. For measur-ing sensor programming, see "Utility Programs".

BATTERY CHARGEREach sensor head is powered by a NiMH battery that is recharged by connecting the sensor head recharge cable to the electrical connector panel (H, fig. 2). The yellow LED on the sensor head connector lights to indicate when charging is in progress.The manufacturer cannot be held responsible for any damage caused by the use of non-original batteries or battery chargers.

BATTERY RECHARGING PROCEDUREBattery charging is managed directly from the head board. The charging cables carry 12 V DCvoltage directly from the PC power unit.The batteries may be charged by connecting the sensors to the central unit with the emergency cables.The possible signals displayed by the sensor head during charging are described as follows.•YellowLEDon:charginginprogress;•RedLEDon:chargingerror;•bothLEDsoffandsensorheadworking:batterycharged;•bothLEDsoffandsensorheadnotworking:batteryfaultyorabsent

RUN-DOWN PROCESSFor maximum durability and optimum operation, the NiMH type batteries used in the wheel balancer sensor heads must be periodically run-down.The run-down process consists in draining all four batteries completely with a constantabsorption current, and then recharging them.We recommend running down the batteries every 15 - 30 days, depending on the number of recharge cycles performed (the more frequently the batteries are charged, the more frequently the run-down procedure is necessary). To run down the batteries, leave the sensor heads on (from the sensor head test screen) until the batteries are fully drained.

Note:Rechargeable NiMh AA penlight batteries are used. When fully charged, new batteries with will ensure 8 hours of continuous operation.

Note:Each head is powered by six 1.2V-2600 mA/h NiMh AA penlight batteries.WARNING: USE ONLY RECHARGEABLE 1.2V-2600 mA/h NiMh AA BATTERIES.

MEASURING SENSOR RADIO UNIT The radio measuring sensor kit consists of:A. 4 measuring sensors complete with batteries and emergency cables


B 1 radio set for the central unit (HARDLOCK).The way a battery is charged for the first time affects its performance for the rest of its useful life.For the best performance, consult the first charge instructions provided in the "Battery charger" section. In case of radio communication malfunction, the regular measuring sensor cables can be used to connect the measuring sensors to the central unit.

CENTRAL UNIT RADIO SET (HARDLOCK)This is supplied with the radio measuring sensor kit. Fix the set to the central unit "A", on the back of the equipment, as shown in Fig. 4. In the event of transmission problems, change the fixing position of the radio set on the central unit (see figs. 15 - 16 - 17), or the transmission channel, see the "Radio channel modification" chapter.

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SIM CARDS AND SMART CARDSThe aligner cannot be operated unless a hardware protection key (SIM) has been inserted.The main protection circuit board configured for the basic version is supplied with the machine.

Additional functions can be added to the wheel aligner by installing the upgrade kits (see the User and Service Manual).

INSTALLING THE DATABANK UPGRADEThe databank upgrade simultaneously also upgrades the wheel aligner software.- To perform the upgrade, the "Databank upgrade kit" must be obtainedThe kit contains a CD-ROM with the installation software, a "SIM CARD" and the in-struction leaflet.1) Exit the aligner application to access the operating system2) Remove the main SIM CARD from the Hard Lock3) Insert the update SIM CARD into the HARD_LOCK4) Insert the CD-ROM into the drive and wait for the software installation programme to

auto-run5) When you restart the software, you will be prompted to insert the main SIM CARD and then the update SIM CARD6) You will be prompted to insert the main SIM CARD7) The update procedure will continue as usual8) Remove the CD-ROM from the drive


SWAPPING MEASURING SENSOR POSITIONS

The measuring sensors are assigned to the vehicle's wheels by means of switches 1 and 2 of CPU board DIP_SWITCH SW3 see "CPU Board" section.This procedure is useful when the front left-hand measuring sensor has to be swapped with the rear right-hand one, or vice-versa, or the front right-hand measuring sensor with the rear left-hand one, or vice-versa.This may be necessary when the front and rear measuring sensors have to be swapped during servicing to check that they are operating correctly.

SW3 1 2 3 4

Front left OFF OFF OFF OFF

Front right ON OFF OFF OFF

Rear left ON ON OFF OFF

Rear right OFF ON OFF OFF

WARNINGThe rear measuring sensors differ from the front ones due to the number of emer-gency cable connectors. Keep this difference in mind if a set of measuring sensors must be used, connected via a cable.

CALIBRATIONMeasuring sensor calibration

•Completefullscalecalibrationshouldalwaysbecarriedoutuponinstallation.•Alltheproceduresindicatedinthissectionshouldbecarriedoutconnectingtheheadstothecentralunitwithacable.

•Fullscalecalibrationshouldbecarriedoutatleastonceayearorwheneverneces-sary (large variations in temperature at different times of year, etc.).

•Calibrationmustalwaysbecarriedoutwiththemeasuringsensorsconnectedbycable.

The calibrator, available as an optional accessory, is able to calibrate all four measuring sensors simultaneously.Users may perform zero calibration or full scale calibration (with the appropriate acces-sories) or run a calibration check.Before a calibration or calibration check, a number of preliminary operations are re-quired:•fitthecalibratorfeetandlevelthecalibrator•fitthemeasuringsensorsonthecalibratorfollowingtheinstructionsprovidedbythe

decals on the measuring sensors and shown on the monitor.


•connectandswitchonallfourmeasuringsensors•levelthecalibratorusingthescrewsinthefeet•levelthemeasuringsensorsusingthespiritlevelsuppliedwiththecalibrator

Recall the calibration procedure from the main menu by selecting the icon and selecting the options “Service Programs” ➔ “Head Calibration”.

The screen shown on figure 6 will be displayed (prompting the operator to level the measuring sensors on the calibrator, using the spirit level supplied):

Select the icon to access the menu on fig. 6a:

Zero calibrationThis program step calibrates only the measuring sensor transducer zero values.This procedure must be performed whenever there are doubts about the aligner’s measurements, or if several cars are found to have crooked steering wheels after ad-justment.Make sure that the calibrator and measuring sensors are perfectly levelled before starting the procedure.The sensor values displayed on the screen are on a green or red background depend-ing on whether or not they are inside the tolerance range. The icon only becomes active, allowing the user to continue with the procedure, if the values are stable and within the tolerance range.The end of the operation and the saving of the new calibration values are shown on figure 7.

Full scale calibrationThis procedure calculates the coefficients which the central unit will apply to the read-ings of the individual transducers. This transforms the signals picked up into angles which allow for the physical param-eters of the system.This procedure must be carried out when the wheel aligner is installed and whenever the inside of the measuring sensor head is accessed or a sensor is replaced.

Access the procedure by clicking the icon and selecting the “Full scale calibra-tion” option. The procedure consists of various different steps characterised by the different system configurations.The values of the measuring sensors involved in the active calibration stage are dis-played alongside each sensor head. The colour of the fields depends on whether the associated value is being stabilised, within the tolerance range or outside the tolerance range.The full scale values of the longitudinal and transverse goniometers are calibrated at the start of the procedure. This procedure is automatic and requires no intervention from the user, unless the


values read by the goniometers are outside the permitted ranges (figs. 8 - 9 - 10).When goniometer calibration is complete, the inclinometer full scale calibration stage starts.

X axis inclinometer full scale calibration - 1st Stage Place the thick shim as shown in the diagram. As soon as the shim has been fitted, the procedure continues automatically (Fig. 11).X-axis inclinometer full scale calibration - 2nd Stage Place two thick shims as shown. As soon as the shims have been fitted, the procedure continues automatically (Fig. 12).

Y-axis inclinometer full scale calibration - 1st Stage Place the medium and thin shims as shown. As soon as the shims have been fitted, the procedure continues automatically (Fig. 13).Y-axis inclinometer full scale calibration - 2nd Stage Place the medium and thin shims as shown. As soon as the shims have been fitted, the procedure continues automatically (Fig. 14).

The user is then prompted to set the calibrator horizontal. The remaining compensations will then be carried out and all the data indicated will be shown in green, indicating that the full scale calibration was successful (Fig. 15 ).If some values are different from those at the start of calibration (the levelling of the calibrator or one or more sensors has changed), they will be highlighted in orange; in this case, exit the calibration procedure, correct the levelling of all devices and repeat the calibration.On completion of the procedure the video will show the screen shown in fig. 16.Confirm by pressing the F3 key.

Calibration CheckThe values displayed show the variation since the latest 0 calibration performed.

By means of the icon and the “UP” and “DOWN” options, the full scale calibra-tion check can be performed step by step (using the appropriate accessories)

Mechanical Calibration CheckThe numbers displayed are the data read by each individual transducer, on a green or red background depending on whether or not they are inside the tolerance range.The data displayed refer to the transducers’ mechanical values, data unaffected by compensation and calibration.If one or more transducers are on a red background, try switching the measuring sensor off and back on.If the new values shown are still on a red background, calibration cannot be performed. The relative icons are deactivated but the transducer affected must be replaced or mechanically repaired.

Measuring sensor TESTScreen that displays the condition of the wheel aligner sensors. The following data are displayed for each measuring sensor (fig. 17):


a) transverse goniometer;b) longitudinal goniometer;c) X-axis inclinometer (spirit level);d) Y-axis inclinometer (camber measurement);e) transverse goniometer gain;f) longitudinal goniometer gain.g) installed firmware release

The goniometer and inclinometer data are calibrated, compensated values expressed in grades.Users can also recall a “Service” window (similar to the one described in the “Service Programme” section) by pressing the “F12” key for a few seconds from any working screen where communication with the measuring sensors is present. This service screen displays all the data relating to the measuring sensors.


UTILITY PROGRAMSThe alignment program gives access to a series of utility tools for servicing and setting up the aligner, as well as a number of service programs.

Click on the main page.

The following menu will be displayed: On the third window the following three options are available:•TechnicalAssistance:allowsaccesstotheconfigurationutility❱ Head hardware.❱ DEMO procedure enabling.❱ ALT+TAB enabling.❱ Communication hardware port.

•SmartCarddatacard:allowsaccesstothealignerupgradeutilitybymeansoftheSmart Card.

•Radiomodulesconfiguration:allowsaccesstotheradiocircuitboardprogrammingutility.

Measuring sensor Set-up Code (CIM – Configurazione Identificativo Muta)

The wheel aligner is able to operate with various measuring sensor set-ups. To type the CIM correctly, the head should have the Control panel (connected to the head card by means of the flat cable). If the flat cable is damaged, the CIM cannot be typed.

To do this, the aligner must “know” which type of measuring sensor is being used. To specify the type of measuring sensors being used, type the CIM (Configurazione Identificativo Muta - Sensor Set-up Code).The CIM is set in the factory during production of the measuring sensors.It may need to be entered again in the following circumstances:

1. Replacement of a CPU board in one or more measuring sensors.2. Upgrade of the measuring sensor CPU board firmware.

The aligner prompts the user to perform the CIM setting procedure automatically when necessary, at the beginning of an alignment procedure, by displaying the screen shown on figure 18.

To set the CIM, proceed as follows:

a) In the “MEASURING SENSOR SET CONFIGURATION” field, select the “4 SENSORS 8 CCD” set-up (as shown on figure 18)

Note: Once the CIM has been typed, the operation cannot be repeated. Take great care not to make mistakes when selecting the set-up.


The option selected must be the same as the actual measuring sensor set-up.b) Click on the “Type CIM” key. The red circles underneath the words “CIM writing result” will turn green (as shown

on figure 19).If the CIM is not entered correctly (the circles are still red), proceed as follows:Press the “Esc” key on the keyboard to move back one screen.1. Press the “F3” key to restart the alignment procedure.The screen shown on figure 18 will be displayed again.2. In the “MEASURING SENSOR SET CONFIGURATION” field, select the “4 SEN-SORS 8 CCD” set-up (as shown on figure 18)Note: Once the CIM has been typed, the operation cannot be repeated. Take great care not to make mistakes when selecting the set-up. The option selected must be the same as the actual measuring sensor set-up.3. Click on the “Write CIM” key.All of the red circles underneath the words “CIM writing result” will turn green (as shown on figure 19).

c) Press the “Esc” key on the keyboard to move back one screen.

The CIM setting procedure is now complete and the setting prompt screen will not be displayed again except in the specific circumstances listed above. The wheel aligner can now be used normally.

If the CIM is not entered correctly (the circles are still red), check the following:•Checkthatthemeasuringsensorsareallturnedon.•Connectthemeasuringsensorsviacableandswitchthemon,toensurethatoneor

more measuring sensors cannot be switched off accidentally.•Repeattheprocedurefromthebeginning,checkingthepreviouspointscareful-

ly.

If everything is operational but the program does not complete entering the CIM for all the measuring sensors, contact the after-sales service.

SERVICE PROGRAMUtility programs for wheel aligner service and/or set-up.

To launch the programme currently separated from the aligner software, exit the aligner

programme and go to the operating system using the icon entering the password "end" (in lower-case letters).Double click on the icon "Alig_Service_USB.exe".

The Service program will open.When the program is accessed, there are 5 buttons in the left-hand column:

•SERVICE•SOFTWARE(inItalian).Firmware(inEnglish)


•RADIO•SET-UP•ABOUT

Pressing the "SERVICE" button accesses the diagnostics procedure, which lists all the values of the angles measured for each measuring sensor.Pressing the "SOFTWARE/FIRMWARE" button accesses the procedure for programming/upgrading the measuring sensor firmware.Press the "RADIO" button to start the radio unit and Hard Lock programming utility.Press the "SETUP" button to set the language (using the arrow keys).Click the "ABOUT" button to display information about the program (software release number, date and time).

36Service (Fig.36)

Switch on / connect the four measuring sensors via the cables.Pressing the "START" button starts the measuring sensor test procedure, which shows the following values for each head:

Shows the value read by the electronic turntable encoder.

Shows the value read by the transverse goniometer.

Shows the value read by the electronic levelling device.

Shows the value read by the electronic inclinometer (camber).

Shows the value read by the longitudinal goniometer.

Shows the value read by the wheel encoder.


The controls section provides 6 buttons with the following functions:

Auto Sets standard emission for the infrared LEDs of the goniometers

EncP=0 Resets the turntable encoder

Off Switches off the measuring sensors

VerSw Shows the firmware release currently installed on the measuring sensors

MEASURING SENSOR FIRMWARE UPGRADE PROCEDURE(firmware programming)

Proceed as follows:1. Connect the four measuring sensors via the cables.2. Select "SOFTWARE" in the Service programme.3. Check the current firmware and bootloader versions available on the measuring

sensors by clicking on .4. Current versions are shown in the top fields.5. If the firmware version of the measuring sensors is different (lower) from that

displayed in the yellow line (Available software upgrade version), press QUICK FIRMWARE DOWNLOAD (Sensor cover close).

6. The update will start.7. Wait until the procedure is completed.8. When the procedure has been completed, press ENTER and exit the Service pro-

gramme.If you encounter any problems with firmware programming, perform "cold" program-ming (e.g.: it is impossible to update the firmware).

Fig.37


NB: The programming procedure outlined above lets you update the head firmware only. To update bootloader version, you will need to perform the "cold" programming procedure described at the next paragraph.

"COLD" PROGRAMMING OF MEASURING SENSORS(firmware and bootloader programming)

•DisconnectthePCpowersupplycablefromtheelectricalconnectorpanel.•Removethemeasuringsensorcoversbyundoingthefixingscrewsontheback.•Removethemeasuringsensorbatteries.•Setselector4ofswitchSW3toON;itisfoundoneverymeasuringsensorcard.•Connectthecablestotheopenmeasuringsensorsandtotheelectricalconnector

panel. •ConnectthePCpowersupplycabletotheelectricalconnectorpanel.•PressthekeyEMERGENCYFW.DOWNLOAD(Sensorcoveropen).•Performtheproceduredescribedabovefromstep6.•When the procedure has been completed successfully, switch off the measuring sen-

sors, disconnect the batteries and the connection cable for the central unit, and set the selectors 4 of switches SW3 back to OFF again.

•Closethemeasuringsensors.•Theprocedureiscompletedandthenewfirmware/bootloaderhasbeencorrectly

installed on the measuring sensors.

RADIOCENTRAL UNIT RADIO BOARD

The central unit establishes radio communication with the four measuring sensors via the radio board included in the Hard Lock at 2.4 GHz frequency.The Hard Lock is mounted on the back of the central unit cabinet.

RADIO UNIT INSTALLATION INSTRUCTIONSTo assure the most efficient radio communications between measuring sensors and the central unit, proceed as follows.

Hard Lock:Installation The radio unit must be placed in a position where it will be easier for the measuring sensors to pick up its signals (with fewest metal objects in-between) and well away from any metal objects that might block electromagnetic waves. Two mounting posi-tions are provided on the back of the cabinet.

Controlling the 2.4 GHz radio unitPress the "Radio" key (Figure 38).

The upper function controls the communication channel of the PC radio (Hardlock) and


the measuring sensor radios (heads).The lower function is used to programme the PC radio module firmware (Hardlock).

HARD LOCKRadio channel read and write operationsRead1. Press "OK" or the radio board button (figure 38).

Fig.38

2. Select "Channel" in section "PC Radio".3. Press the "Check" button in section "Radio PC". The configured "Channel" is read.

Fig.39


HARD LOCKRadio channel read and write operationsWrite (Configuration)After the channel is read as outlined in paragraph "Read" above, it is possible to write data (Configuration) to the radio module.1. Select the required "Channel" among available channels in section "Radio PC".2. Press the "Set" button in section "Radio PC".Data is written to the selected "Channel".3. Wait for the message confirming that data was written successfully.4. Press the "OK" button.5. Perform a reading operation of the configuration of the radio module to ensure that

the procedure was completed successfully.

HARD LOCKRadio channel read and write operationsStandard programming (Standard configuration)This procedure is used when the native configuration (factory programming) of the radio module needs to be restored.After the channel is read as outlined in paragraph "Read" above, it is possible to write data (Configuration) to the radio module.1. Press the "STANDARD PROGRAMMING" button located in section "Radio PC".2. Wait for the message confirming that data was written successfully.3. Press the "OK" button.4. Perform a reading operation of the configuration of the radio module to ensure that

the procedure was completed successfully."Channel" must be set to 40.

Radio measuring sensors (Heads)Radio channel read and write operationsRead1. Connect all measuring sensors (heads) to the central unit.2. Press "OK" or the radio board button (figure 22).3. Go to section "Radio Sensor".4. Select "Channel".5. Press the "Check" button in section "Radio Sensor".The configured "Channel" is read.

Radio measuring sensors (Heads)Radio channel read and write operationsWrite (Configuration)After the channel is read as outlined in paragraph "Read" above, it is possible to write data (Configuration) to the radio modules.1. Select the required "Channel" among available channels in section "Radio Sensor"

(set the same channel as for the PC radio module (Central Unit).2. Press the "Set" button in section "Radio Sensor".Data is written to the selected "Channel".3. Wait for the message confirming that data was written successfully.


4. Press the "OK" button.5. Perform a reading operation of the configuration of the radio modules to ensure that

the procedure was completed successfully.

Radio measuring sensors (Heads)Radio channel read and write operationsStandard programming (Standard configuration)This procedure is used when the native configuration (factory programming) of the radio modules needs to be restored.After the channel is read as outlined in paragraph "Read" above, it is possible to write data (Configuration) to the radio module.1. Press the "STANDARD PROGRAMMING" button located in section "Radio Sensor".2. Wait for the message confirming that data was written successfully.3. Press the "OK" button.4. Perform a reading operation of the configuration of the radio modules to ensure that

the procedure was completed successfully."Channel" must be set to 40.

Operation with other radio alignersIf other aligners of the same type are installed in the same place, Hark Lock and head channels need to be set to a channel other than number 40 as in standard programming. For instance, a first aligner may retain the channel 40 setting, a second one may be set to channel 30, and so on.WARNING: You will need to switch off the central unit and heads of any other aligners of the same type before programming the radio channels.

Hard Lock firmware programming1. Press "OK" or the Hard Lock device button (Figure 38).

Fig.40


2. Check the current firmware and bootloader versions available on the Hard.

3. Lock device by clicking on .4. Current versions are shown in the top fields.5. If the Hard Lock firmware or bootloader version is different (lower) from that displayed in the yellow lines (Available software upgrade version), press "QUICK FIRMWARE DOWNLOAD PC-RADIO (Box cover close)".6. The update will start.7. Wait until the procedure is completed.8. When the procedure has been completed, press ENTER and exit the Service programme.

CAUTIONNone of the procedures described below require the reinstallation of the Operating System.

INSTALLING THE SOFTWARE UPGRADEThe software upgrade procedure upgrades the wheel aligner software and the structures of the files in the client and previous jobs databanks.

- To perform the upgrade, the wheel aligner software installation CD-ROM in the "Software upgrade kit" must be obtained. The CD-ROM supplied in the "Databank upgrade kit" (Note 2) or a CD-ROM supplied with the aligners may also be used.

- Check that the software release on the CD-ROM is more recent than the one on the aligner.

- From the wheel aligner software, exit to the operating system.

- Insert the CD-ROM in the drive and wait for the software installation program to start up automatically.

- Select the preferred language and follow the instructions.

- When the PC is rebooted, the aligner software will automatically launch. The databank upgrade procedure may take a few minutes; the system imports all preceding jobs and the client databank, with a series of messages on the screen indicating progress (Note 1).

- When file synchronisation is complete, the message window disappears and the program is ready for use.

- Remove the CD-ROM from the drive.

WARNINGPasswords and set-up settings


The installation procedure does not modify the passwords or the set-up settings made previously.The new set-up options or additional passwords, not included in the previous release, will be set at the default values.

NOTES

Note 1Messages which appear on the video during the databank update procedure:

- Databank file upgrade, step …1.9 = copy all existing databanks (main databank, customer databank, preceding jobs databank,…) into …\\backupDB

- Databank file upgrade, step …2.9 = upgrading main databank (with the new databank if the smart card is enabled, otherwise upgrades structure only)

- Databank file upgrade, step …3.9 = upgrading demo mode databank

- Databank file upgrade, step …4.9 = upgrading customer databank

- Databank file upgrade, step …5.9 = upgrading system files

- Databank file upgrade, step …6.9 = upgrading jobs databank

- Databank file upgrade, step …7.9 = upgrading calibrations databank

- Databank file upgrade, step …8.9 = upgrading various files

- Databank file upgrade, step …9.9 = upgrading various files

- Copying databank files …1.2 = upgrading animation files

- Copying databank files …2.2 = upgrading chassis height files

In the event of first installation there will be the following three steps:

- Copying databank files …1.3 = copying databank files

- Copying databank files …2.3 = copying animation files

- Copying databank files …3.3 = copying chassis height files

Note 2The "SIM-CARD" update can only be used once. Its purpose is to update the password for access to the new databank stored on the aligner SIM-CARD (the one supplied with the equipment).If the aligner SIM-CARD is already enabled for use of the new databank release, the upgrade SIM-CARD is not annulled and can be used for a further upgrade.The SIM-CARD is still usable if its serial number is "0", see "Enabling additional wheel aligner functions" section of the operator’s manual.The CD-ROM can still be used for software upgrades; it is the same CD-ROM as supplied in the "Software upgrade kit".

PROBLEM-SOLVING


The installation programme does not run, "wheel alignment software running" errorExit the installation procedure and run and then shut down the wheel aligner software again.

If the problem persists, delete the following file in manual mode:C:\PROGRAM FILES\ALIGNMENT\EXIST.INI

Interruption of installation during updating of the filesIf the installation crashes during the file update, the initial situation has to be restored before any further operations can be carried out. Any second installation attempt performed without first restoring the original files causes the loss of the job records stored.


- To restore the original files, copy all the files contained in the folder: C:\PROGRAM FILES\ALIGNMENT\BACKUPDB\*.*Into:C:\PROGRAM FILES\ALIGNMENT\BANK- Place the new files, which are files with structure updated to the latest release without which

the aligner software might not work, in the installation folder.Copy all the files from the folder:C:\PROGRAM FILES\ALIGNMENT\NEWBANK\Yxxxx\*.*

Into:C:\PROGRAM FILES\ALIGNMENT\DOWNLOAD\BANK\CAUTIONFolder:C:\PROGRAM FILES\ALIGNMENT\NEWBANK\contains several subdirectories called Yxxxx, where xxxx corresponds to a year (e.g. 2000 or 2001).To activate this procedure, the files contained in the folder of the current year must be copied.- Restart the aligner programme. The installation procedure will recover the data from the old

files and transfer them to the new files.

First installation or using an existing installation with a SIM-CARD updated to a different databank.When installing the aligner software on a PC for the first time (this may occur when the operating system has been reinstalled or a replacement PC has been purchased) you may find that the smart card is enabled to read a databank of a different release from the one contained on the installation CD-ROM.The same may occur when a customer’s aligner’s PC is replaced with one belonging to the after-sales service.

WARNINGIt is important to use the customer’s SIM CARD on the new PC, since it enables access to all the additional functions purchased with the aligner.

To allow the aligner to operate, proceed as follows.


- From the logo screen, access the page which summarises the SIM CARD features.

- Read the year of the databank which the SIM CARD is enabled to access, "Year" field.


- Place the databank of the year for which the SIM-CARD is enabled in the appropriate folder.

Copy file DBStd.mdb from folder:C:\PROGRAM FILES\ALIGNMENT\NEWBANK\Yxxxx\Into:C:\PROGRAM FILES\ALIGNMENT\BANK\CAUTION Folder: C:\PROGRAM FILES\ALIGNMENT\NEWBANK\contains several subdirectories called Yxxxx, where xxxx corresponds to a year (e.g. 2000 or 2001).Copy the file from the folder the year of which is the same as the year read in the "Year" field of the smart card.

- To update the structure of the databank of a previous year to the latest release, copy all the files from the folder C:

C:\PROGRAM FILES\ALIGNMENT\NEWBANK\Yxxxx\*.*Into:C:\PROGRAM FILES\ALIGNMENT\DOWNLOAD\BANK\

CAUTION Folder:

C:\PROGRAM FILES\ALIGNMENT\NEWBANK\contains several subdirectories called Yxxxx, where xxxx corresponds to a year (e.g. 2000 or 2001). Copy the files contained in the folder of the most recent year.

- Restart the aligner programme. The installation procedure will recover the data from the old files and transfer them to the new files.

Copying original filesThe HD contains an original copy of all the databank and management files used by the aligner.

This means that if a file is damaged, it can be restored using the relative copy.

To understand which file is affected, use the system error message, which provides the name of a file at the end.

For the file containing the record of the jobs done (WORK.MDB) this means losing the data.

If the damaged file is the main databank (DBSTD.MDB) refer to the "First installation or using an existing installation with a SIM-CARD updated to a different databank" section.

The kit CD-ROM software release is older than the release installed.

Upgrade the databank using the most recent installation CD-ROM and the SIM-CARD supplied with the databank upgrade kit.


GENERAL ELECTRICAL WIRING DIAGRAM (FIG.52)

AP1 Personal computerAP3 KeypadAP4 PrinterAP5 MonitorAP9 Radio RX / TX cardAP10 Main card (CPU)AP14 Control panelAP16 MouseAP20 Hard LockAP21 Electrical connector panelB1 SpeakerBP1 Angular transducerBP2 InclinometerFU.. Fuse 10 A TGB1 BatteryHL1 LED beaconQS1 Main switchXB1 Measuring sensor connectorXB2 ConnectorXB3 USB connectorXB4 IR remote control connectorXB5 HDD connectorXS2 Multiple socket


52

CORMACH S.r.l. via A. Pignedoli, 2 42015 CORREGGIO (RE) ITALY Tel. +39 0522 631274 - Fax +39 0522 631284 e-mail: [email protected] www.cormachsrl.com

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