COMPUTERISED CCD WHEEL ALIGNER

OPERATING MANUAL
(Ver.1.2)

Dear Customer,

Congratulations, for selecting Computerised Wheel aligner as your Wheel alignment computer.
Our Wheel aligners are user friendly system which can be used effectively to correct all the
alignment angles of four wheelers.

We take special care to ensure that every Wheel aligner leaving our Factory is in the best
operating condition. This OPERATING MANUAL has been prepared to help you in getting the
best performance out of the equipment. Still, if you have any doubt, please do not hesitate to
contact us.

Read the Operating manual carefully before starting to use the equipment

Every attempt is made in this manual to guide the User on the effective use of the
Equipment. Any suggestion may please be sent to us for improvement.

INDEX
Page No.
1.

WARRANTY STATUTORY CLAUSE

2.

SAFETY
2.1.
INTENDED USE
2.2.
SAFETY INSTRUCTIONS FOR COMMISSIONING
2.3.
SAFETY INSTRUCTIONS FOR OPERATION
2.4.
SAFETY INSTRUCTIONS FOR SERVICING
2.5.
SAFETY FEATURES
2.5.1.
POWER FAILURE DATA RECOVERY
2.5.2.
CONTROL FUSES
2.6.
SAFETY LABEL INFORMATION

2
2
2
3
3
4
4
4
4

3.

FEATURES & SPECIFICATIONS

4.

INSTALLATION
4.1.
INSTALLATION REQUIREMENTS
4.2.
LOCATION
4.3.
SPACE REQUIREMENTS
4.3.1.
ALIGNMENT PIT DIMENSIONS
4.3.2.
ALIGNMENT LIFT DIMENSIONS
4.4.
POWER REQUIREMENT

7
7
7
7
7
10
11

5.

WHEEL ALIGNMENT PARAMETERS

5.1.
CAMBER
5.2.
TOE
5.3.
CASTER
5.4.
KINGPIN INCLINATION (Steering axis inclination)
5.5.
THRUST ANGLE
5.6.
FRONT WHEEL SETBACK
5.7.
REAR WHEEL SETBACK
5.8.
WHEEL RUNOUT
5.9.
INCLUDED ANGLE
5.10.
TRACK WIDTH DIFFERENCE
5.11.
LOCK ANGLE
5.12.
TOE OUT ON TURNS

12
12
14
15
16
17
18
19
20
21
22
23
24

6.

DESCRIPTION OF MAIN PARTS

6.1.
MAIN CABINET
6.2.
DESKTOP COMPUTER (refer scope of supply)
6.3.
INTERFACE BOX
6.4.
DISPLAY UNIT (refer scope of supply)
6.5.
RF TRANSCEIVER UNIT
6.6.
SENSOR ARMS
6.7.
ARM RESTING BRACKETS
6.8.
KEYBOARD (refer scope of supply)
6.9.
MOUSE (refer scope of supply)
6.10.
STANDARD ACCESSORIES
6.10.1.
WHEEL BRACKET
6.10.2.
LCV ROTARY PLATE - 2 ton (Applicable only for LCV models)
6.10.3.
LCV BRAKE PEDAL LOCK
6.10.4.
STEERING LOCK
6.10.5.
DATA MANAGER SOFTWARE
6.11.
OPTIONAL ACCESSORIES
6.11.1.
MECHANICAL ROTARY PLATE WITH ANGLE INDICATOR
6.11.2.
WHEEL BRACKET EXTENSION ADAPTER
6.11.3.
FOUR SHAFT CALIBRATION KIT
6.11.4.
SINGLE SHAFT CALIBRATION KIT
6.11.5.
RIM LOCKING PIN (HCV)
6.11.6.
RIM LOCKING PIN (suitable for Run flat tyre rims)
6.11.7.
RIM LOCKING PIN (suitable for Steel rims with fancy disc)
6.11.8.
REAR WHEEL SLIDER
6.11.9.
LONGER REAR WHEEL SLIDER
6.11.10. SENSOR ARM CABLE KIT
6.11.11. PRINTER (refer scope of supply)
6.11.12. MULTIMEDIA SPEAKER (refer scope of supply)
6.11.13. INTERNATIONAL VEHICLE DATA (refer scope of supply)

25
26
26
26
27
28
28
30
30
30
31
31
32
32
32
33
33
33
33
34
34
34
34
34
35
35
35
35
36
36

7.

OPERATION
7.1.
DEFECTS / MALFUNCTIONS
7.2.
PRELIMINARY ALIGNMENT PREPARATION
7.2.1.
ALIGNMENT USING ALIGNMENT PIT
7.2.2.
ALIGNMENT USING ALIGNMENT LIFT
7.3.
MAIN MENU
7.4.
ALIGNMENT
7.4.1.
VEHICLE SELECTION
7.4.2.
VEHICLE INSPECTION
7.4.3.
WHEEL RUNOUT
7.4.3.1
PUSH-PULL RUNOUT METHOD (applicable only for PPR models)
7.4.3.2
FOUR POINT RUNOUT METHOD
7.4.4.
CASTER & KINGPIN SWING
7.4.4.1
ARMS HORIZONTAL
7.4.4.2
TOE OUT ON TURNS & LOCK ANGLE MEASUREMENT
7.4.4.3
TURN LEFT
7.4.4.4
TURN RIGHT
7.4.4.5
STRAIGHT AHEAD
7.4.5.
ALIGNMENT PARAMETERS & RESULTS
7.4.5.1
REAR WHEEL PARAMETERS
7.4.5.2
FRONT WHEEL PARAMETERS
7.4.5.3
RESULTS
7.4.5.4
ADJUSTMENT TYPES
7.5.
QUICK WHEEL ALIGNMENT
7.6.
DATA MANAGER
7.6.1.
DATE BASED ALIGNMENT REPORT
7.6.2.
REGISTRATION NUMBER BASED ALIGNMENT REPORT
7.6.3.
YEAR BASED ALIGNMENT REPORT
7.6.4.
TECHNICIAN BASED ALIGNMENT REPORT
7.6.5.
CUSTOMER DATABASE
7.6.6.
REMINDER TO CUSTOMER
7.7.
SETTINGS
7.7.1.
VEHICLE SPECIFICATIONS
7.7.1.1
EUROPEAN / BRAZILIAN / UNITED STATES VEHICLE DATA
7.7.1.2
INDIAN VEHICLE DATA
7.7.1.3
USER DEFINED VEHICLE DATA
7.7.2.
MEASUREMENT UNITS
7.7.3.
RESTORE CALIBRATION DATA
7.7.3.1
BACKUP CALIB DATA FROM PC TO SENSOR ARM
7.7.3.2
RESTORE CALIB DATA FROM SENSOR ARM TO PC
7.7.3.3
RESTORE FACTORY CALIBRATION DATA TO PC
7.7.3.4
BACKUP CALIB DATA FROM PC TO OTHER LOCATION/DEVICE
7.7.3.5
RESTORE CALIB DATA FROM OTHER LOCATION/DEVICE TO PC
7.7.4.
WORKSHOP INFORMATION
7.7.5.
PASSWORDS
7.7.5.1
SETTINGS PASSWORD
7.7.5.2
VEHICLE DATA PASSWORD
7.7.5.3
ELECTRONIC TURN TABLE (ERP) PASSWORD
7.7.5.4
RAPID / PUSH-PULL RUNOUT (PPR) PASSWORD
7.7.5.5
MECHANICAL TURN TABLE (with Angle indicator) PASSWORD
7.7.6.
CALIBRATION HISTORY
7.7.7.
USER LOGIN
7.7.8.
ARM COMMUNICATION CHECK
7.7.9.
RESET JOB NUMBER
7.7.10.
TESTING OPTIONS
7.7.10.1
KEYPAD TESTING
7.7.10.2
BUZZER TESTING
7.8.
LANGUAGE SETTINGS

37
37
37
38
38
39
41
42
44
46
47
49
50
50
51
52
52
52
54
55
57
60
61
67
68
68
70
71
72
72
73
74
75
75
75
76
78
78
79
79
79
80
80
80
80
81
81
83
83
83
84
84
84
85
85
85
86
86

8.

MAINTENANCE

87

9.

TROUBLE SHOOTING
9.1.
HARDWARE TROUBLE SHOOTING
9.2.
SOFTWARE TROUBLE SHOOTING
9.3.
SELF DIAGNOSIS
9.4.
MIS-ALIGNMENT TROUBLE SHOOTING

88
88
92
93
94

1.

WARRANTY STATUTORY CLAUSE

The equipment is provided with Warranty for one year from the date of installation or thirteen
months from the date of despatch whichever is earlier, against any manufacturing defect. The
Warranty is subjected to the following conditions:
1.
Ensure that proper power supply with protective Earthing is provided to the equipment.
Any high voltage may damage the components, leading to system failure or electrical
hazards.
Power supply : Single Phase, 230V AC 10%, 50 Hz + N + PE
(N - Neutral, PE - Protective Earth)
Warranty ceases if this condition is not satisfied
2.

Power supply to the equipment should be connected only through an UPS of minimum
1KVA capacity with AVR (Automatic Voltage Regulator) circuit. The system must be shut
down before the UPS power trip OFF. Failing to comply may lead to software corruption.
Warranty ceases if this condition is not satisfied

3.

Do not attempt to open or service the equipment under any circumstances. Risk of
electric shock may happen. Only Authorised / qualified service personnel should trouble
shoot the equipment.
Warranty ceases if the equipment is opened/tampered or serviced by un-authorised
personnel

4.

Warranty ceases if this equipment is used for any purpose other than intended use.

5.

The equipment must be installed Indoor away from Sunlight, rain / moist areas
Warranty ceases if the equipment is exposed to Sunlight, Rain / Water

6.

Do not attempt to load any other Application software (Audio, Video etc.) under any
circumstances, other than the alignment program loaded in the Factory.
Warranty ceases if the system is loaded with any other Application software

7.

If transportation, lifting, unpacking, installation, assembly, start up, testing, repair and
maintenance have been performed by un-authorised personnel, the manufacturer shall
not be responsible for injury to personnel or damage to objects.

8.

DO NOT remove or modify any parts of the equipment as this could compromise the
equipment's intended use. For any modifications / repairs consult the Manufacturer.

9.

The Vehicle specification data must be entered by End user only. MANUFACTURER IS
NOT RESPONSIBLE FOR ANY INCORRECT OR INCOMPLETE VEHICLE
SPECIFICATIONS ENTERED INTO THE SYSTEM. No claim is entertained for any
damage or loss.

10.

Follow the Alignment lift manufacturers safety recommendations when lifting a vehicle.

MANUFACTURER IS NOT LIABLE FOR ANY DAMAGES CAUSED due to noncompliance

11.

Make the warranty registration by duly signing the counterfoil of the Warranty card sent
along with the equipment.

The Rechargeable batteries are provided with Warranty for six months from the date of
installation or seven months from the date of despatch only whichever is earlier, against any
manufacturing defect. It is the responsibility of End-user in handing over scrap batteries to
Authorised collection centres for safe disposal in order to comply with the Battery (M&H) rules of
National regulatory authority
MANUFACTURER does not warrant third party products / software added to our Wheel aligner
through our Factory integration system. The below listed Third party products / peripherals /
software are covered under the warranties provided by the respective OEM. Third party
manufacturer's warranty may vary from product to product. Consult the respective product
documentation for warranty information:
1.
Desktop computer with Monitor
2.
Printer
3.
Keyboard
4.
Mouse
5.
Multimedia speakers
6.
Operating system software
Ref.: CCDWA - OM

2.

SAFETY
Thoroughly read all Safety labels and Manual instructions before installing, operating and
maintaining the Wheel aligner. They are provided to remind the operator to exercise extreme
care while performing wheel alignment with this product to prevent personal injury and property
damage. Replace any label unreadable or missing on the Wheel aligner. Refer Part No. given
for each Label for ordering.
It is the Operators responsibility to have sufficient knowledge on the vehicle to be aligned and
to use proper service methods and perform wheel alignment in an appropriate and acceptable
manner that does not endanger safety of the Operator / others in the work area or the
equipment or vehicle being serviced.
Always keep the Manual in a prominent place for quick reference.
Injury to personnel and damage to property incurred due to non-compliance with these safety
instructions are not covered by the product liability regulations.

SYMBOLS
Failure to comply with instructions could result in personal injury
Failure to comply with instructions could result in property damage
Important information

2.1.

2.2.

INTENDED USE

Use the Aligner as described in this Operating manual only.

Use only the Accessories recommended by the manufacturer.

Carryout alignment by positioning the vehicle to be aligned on the Alignment pit /

Alignment lift only.

SAFETY INSTRUCTIONS FOR COMMISSIONING

1.
2.
3.
4.
5.
6.
7.

8.
9.
10.

11.

Ref.: CCDWA - OM

Only Authorised service personnel are allowed to install and commission the
Wheel aligner.
Aligner should not be installed outdoors or in moist rooms (nearer to car
washing).
To reduce the risk of fire, the equipment should not be installed at hazardous
locations or in the vicinity of explosives or flammable liquids.
The Aligner should be installed with adequate ventilation in case of working on
vehicles with internal combustion engines.
Keep the System away from high capacity Transformers, Electric motors and
other strong magnetic fields.
Use proper handling tools while installation of Aligner for safety of equipment.
The electrical main supply to the Aligner must be connected through a CE
certified Two pole, Type C, 6A MCB (Miniature Circuit Breaker). Proper Earthing
must be provided.
If an Extension power cord is required, a cord with correct rating equal to or more
than that of the equipment should be used.
Care should be taken to route the Power mains cord properly so that it is not
tipped over or pulled.
During installation of Third party products (like Desktop computer, Monitor,
Printer, Keyboard, Mouse, Speakers, Operating system software etc.) follow the
safety instructions provided in the respective OEM's Installation document.
Ensure the disposal of ecologically harmful substances in accordance with the
appropriate regulations.

2.3.

SAFETY INSTRUCTIONS FOR OPERATION

1.
2.
3.

4.
5.
6.
7.

8.
9.

10.
11.
12.
13.
14.
15.
16.
17.

18.

2.4.

Read the Operating manual thoroughly.

Only permit qualified personnel to operate, maintain or service the Aligner.
The operator should have thorough understanding of the vehicle systems being
serviced & sufficient knowledge on the operation and safety features of
alignment.
Always keep the Aligner and the surrounding work area clean and free of Tools,
Parts, Debris and Grease etc.
Do not operate, if the equipment has been dropped or damaged until it has been
examined by qualified service personnel.
Do not operate the equipment with damaged / twisted power cord.
Do not operate the equipment under direct sunlight. Even reflected sunlight
reaching the camera will result in erratic readings and the system will display
error indication.
Let the equipment to cool down completely before putting away.
Do not switch OFF the Main system switch, in order to charge the Sensor arms
continuously. The Power panel switch located at the rear side of Main cabinet
may be used to switch off the Processor unit alone.
Handle the Sensor arms carefully. Rough handling / shocks may cause damage
to the Sensor and optical components.
Do not move or turn the equipment while the System is in power up condition.
Ensure the Rotary plates are locked with Locking pins before parking the vehicle.
Do not keep heavy objects over the equipment.
Do not hammer or hit any part of the equipment with Tools when the equipment
is in ON condition.
Ensure the cables are not in contact with Rotary plates / moving parts / vehicle
tyre.
Keep hair, loose clothing, fingers & all parts of body away from rotating / moving
parts.
Always wear Eye Safety glasses while doing under chassis adjustments /
corrections from the Alignment pit or Alignment lift to avoid oil drops / dust
particles falling on to Eye. Use hand Gloves to avoid fire hazards from the hot
surfaces of vehicle.
Always comply with the applicable accident prevention regulations.

SAFETY INSTRUCTIONS FOR SERVICING

1.
2.
3.
4.
5.
6.
7.
8.

Ref.: CCDWA - OM

Inspect the Wheel aligner on daily basis.

Only authorized personnel are allowed to service the Aligner.
Turn OFF MCB and unplug the Aligner before doing any maintenance or repair
work.
Only certified engineers are allowed to service the parts of the equipment.
Do not remove / disable / override any safety device / assemblies.
Third party products should be serviced only by the OEM's authorised service
personnel. Refer the respective service policies provided.
The use of cleaning agents which attack coating or sealing materials could result
in equipment damage.
Use Manufacturer spare parts only to guarantee the reliable function and to
ensure safety of the equipment.

2.5.

SAFETY FEATURES
2.5.1.

2.5.2.

2.6.

POWER FAILURE DATA RECOVERY

During alignment, if the power goes off, the system has the facility to resume
the previous job without redoing the entire alignment again.
When the power resumes after Power failure, the system will prompt the
following message "Resume Old Job". If the previous job need to be
continued, press YES to continue with the old job or else, press NO to start a
new job.
CONTROL FUSES
Control fuses (F1 & F2) are incorporated in the Main processing circuit and
Sensor arms to protect the electronic components against high current. The
Fuse holders are mounted on the Power panel and Sensor arm cabinets
which can be easily accessed from outside for replacing the blown fuse.
Always replace the Control fuse with same type and rating of CE marked
Fuse.

SAFETY LABEL INFORMATION

CAUTION
Use only the charging facility available in
the system
Keep the Battery/Charging contacts away
from metal objects
Never heat the Battery or throw into fire

ATTENTION
It is the responsibility of End-User to
comply with the Battery (M&H) rules of
National regulatory authority and hand
over scrap batteries to the Authorised
collection centres

CAUTION
230V AC 10%,
50 Hz

Battery caution
indicator
(Part No. B2059)

Input supply
indicator
(Part No. B2126)

WARNING
NO USER SERVICEABLE
PARTS INSIDE.
REFER TO QUALIFIED
SERVICE PERSONNEL.

WARNING
DISCONNECT
POWER BEFORE
REMOVING COVER

Electrical safety
indicator
(Part No. B0807)

Electrical safety
indicator

(Part No. B0808)

Sticker, Connection
details
(Part No. B8034)

Ref.: CCDWA - OM

3.

FEATURES & SPECIFICATIONS

Sl.
No.
I

Description

Rpac
Rpac
Premium
Premium
Plus

Features

1 Simultaneous 4 wheel alignment using 4 Measuring heads

2 Suitable for LCVs of 12" 24" Wheel size
3 Windows based alignment program
4 Robust wireless communication in the 2.4 Ghz unlicensed ISM band
5 No external antenna required (Internal antenna only)
6 Covers 100 meters of distance (Line of sight)
7 Field programmable 15 RF channels
8 On-line correction facility for Camber, Caster, Toe & Thrust angle
9 Automatic tracking of Left & Right turns for Caster & Kingpin measurement
10 Push-Pull Runout compensation (without jacking up the vehicle)
11 Redo Runout option at the final stage of alignment
12 Display of Live Setback and Thrust angle reading
13 Setback and Thrust angle compensation
14 Display of Front & Rear Total Toe readings
15 Excess toe indication
16 Measurement of Rear wheel setback
17 Measurement of difference in Track width
18 Electronic On-line arms leveling (Front)
19 Toggle option for Front & Rear alignment
20 Battery powered Sensor arms with Auto-charging facility in idle condition
21 Included angle in printout
22 Customer address in printout
23 Customer data edit option provided before taking printout
24 Printout of Sensor calibration values
25 Export option for Data manager reports
26 Option for selection of Vehicle specifications during alignment
27 Power failure data protection
28 Save & proceed option (CTRL+S) during UPS power condition
29 Software upgradation through CD drive
30 TFT color display
II Special features
1 Sensor arms with unique design to work independently either in RF / Cable
2 Facility for enabling the optional features in the field itself
3 Data manager software for storing alignment results
4 Animated pictorial representation of all angles during alignment
5 Two color bar display for adjustment of all angles (Red/Green)**
6 Two color printout for indicating alignment condition (Red/Green)**
7 Unlimited databank of Indian / international vehicle specifications
8 Multi-lingual program
Selectable functions
8

Quick wheel alignment program

Adjustment of Camber in wheel raised position

Spoiler program

Display of Toe in "mm" / "degree"

Measurement of Toe curve

Four point Runout compensation in single rotation

3D pictorial printout of alignment angles

Ref.: CCDWA - OM

NA
NA

Sl.
No.

Rpac
Rpac
Premium
Premium
Plus

Description

III Optional features

1 International Vehicle data update (Refer scope of supply)
2 Voice prompts in English for operator guidance
3 Measurement of Lock Angle and Toe Out on Turns
Simultaneous auto-charging facility while the particular Sensor arm is operated
4
using Cable
IV Technical specifications
Measurement parameters
1 Front & Rear Camber
2 Caster
3 Kingpin
4 Front / Rear Toe
5 Total Toe
6 Front Wheel setback
7 Rear Wheel setback
8 Thrust angle
9 Front / Rear Runout
10 Included angle
11 Track width difference
12 Lock angle (Optional)
13 Toe Out on Turns (Optional)

Range
10 00'
20 00'
20 00'
05 00'
10 00'
05 00'
05 00'
05 00'
10 00'
30 00'
02 00'
60 00'
60 00'

Accuracy
00 02'
00 05'
00 05'
00 02'
00 04'
00 02'
00 02'
00 02'
00 02'
00 05'
00 04'
00 20'
00 20'

V Electrical specifications
Power supply :
Stabilised UPS (AVR Built-in) 230VAC 10%, Single phase, 50Hz, +N +PE
2 Power consumption
Battery :
3
7.2 AH, 6V x 1 Valve Regulated Lead Acid
4 Battery backup time
Control fuse rating
a) 3A, dia 5 mm x 20 mm, Slow blow type glass fuse (F1)
5
b) 5A, dia 6.35 mm x 31.8 mm , Slow blow type Glass fuse (F2)
c) 1A, dia 5 mm x 20 mm, Slow blow type glass fuse
1

VI General specifications
1 Operating temperature : 0 C to +50 C
2 Humidity : RH below 90%
3 Machine dimension Unpacked (WxDxH) in mm (With Monitor)
4 Machine dimension Packed (WxDxH) in mm (Without Monitor)
5 Machine weight Unpacked
6 Machine weight Packed
7 Desktop computer console dimensions (WxDxH) in mm (max.)
NOTE :
* - Applicable for PPR models only
** - Red
- Out of specification range
Green
- Within specification range

Ref.: CCDWA - OM

200W

200W

NA

NA

>12 hr.

>12 hr.

1130x630x1450
1) 780x695x1170
2) 770x420x1175
150 kg
200 kg
200x500x450

4.

INSTALLATION
4.1.

INSTALLATION REQUIREMENTS
Wheel aligner installation should be done only by qualified Service personnel.
Provision of handling means such as Forklifts etc. is the owner's responsibility

4.2.

LOCATION
The Wheel aligner should not be installed outdoors, in moist rooms, at hazardous
locations, or in the vicinity of explosives or flammable liquids.
The location should have adequate ventilation in case of working on vehicles with
internal combustion engines.
Choice of a suitable location is the owner's responsibility

4.3.

SPACE REQUIREMENTS

Installation area should have roof.

Floor should be of good concrete flooring and should be leveled surface.
Proof of safe floor load capacity is the owner's responsibility

The clearances from side walls and roof should be adequate for the operator to
move around and perform wheel alignment / maintenance.
Alignment can be carried out either on Alignment pit or using Alignment lift.
Choice of suitable alignment platform is the owner's responsibility

4.3.1.

ALIGNMENT PIT DIMENSIONS

Pit for Rotary plates and Rear wheel sliders (Optional) are necessary to carry
out alignment. Both the pits should be in the same plane. However the main
pit is intended only for the operator to go underneath the vehicle easily and
carryout the required corrections. The length of the main pit can be made
depending upon the availability of space. The Rotary plate / Slider plate
locating pit can be finished with Granite or Marble purely by owner's choice.
Slider & its pit are not necessary for Heavy Commercial Vehicles
(HCV). However alignment pit with provision for Slider placement can
be used for alignment of Light Commercial Vehicle (LCV) using the
same pit
Choice of finish of pit is the owner's responsibility

A Rail using MS flat (50 mm x12 mm) for Trolley should be partly embedded
on the edge of main pit with specified height from floor level. This is required
for placing the Jack over the moving trolley platform to lift the vehicle while
carrying out Runout. A centralised single Hydraulic jack or Dual pneumatic
jack is recommended.
The floor level between the Left and Right rotary plate pits should be same.
The area adjoining the Main pit (except Rotary plate & Slider pits) should be
maintained at even level.
The surface over which Rotary Plates are kept must be perfectly leveled using
Spirit level. Also, perfect leveling must be ensured on both the sides of pit.
Otherwise it will affect the alignment results.

Ref.: CCDWA - OM

PIT DIMENSIONS Maximum Wheel base 3.2 metre

Fig. 1

Ref.: CCDWA - OM

PIT DIMENSIONS Maximum Wheel base 4 metre

Fig. 2

Ref.: CCDWA - OM

4.3.2.

ALIGNMENT LIFT DIMENSIONS

SCISSOR LIFT DIMENSIONS Maximum Wheel base 4 metre

Fig. 3

Ref.: CCDWA - OM

10

FOUR POST LIFT DIMENSIONS Maximum Wheel base 4 metre

Fig. 4

4.4.

POWER REQUIREMENT
Stabilised UPS 230V AC 10%, Single Phase, 50 Hz + N + PE
The supply to the Wheel aligner must be connected through an UPS of minimum 1KVA
capacity with AVR circuit using a CE certified Two Pole, Type C, 6A MCB. Proper
Earthing must be provided. Also ensure that Live phase is on the right side point of the
wall socket.
Neutral to Line Voltage should be 230V AC 10%
Line to Earth voltage should be 230V AC 10%
Neutral to Earth leakage should be less than 3V AC
It is strongly recommended to use 1KVA UPS with AVR (Automatic Voltage
Regulation) provision only.

Ref.: CCDWA - OM

11

5.

WHEEL ALIGNMENT PARAMETERS

WHEEL ALIGNMENT refers to a set of wheel angles which are responsible to distribute the
weight of the automobile over the suspension system and the four wheels uniformly when the
vehicle is in motion. Proper distribution of the weight results in uniform tyre wear and effective
steering control. Every vehicle manufacturer furnishes the Wheel Alignment specification for
the vehicles manufactured by them.
The process of bringing and adjusting the vehicle's Geometric angles and common adjustable
parameters such as Caster, Camber and Toe to its original position as per the vehicle
manufacturer specification is called Wheel alignment.
WHEEL ALIGNMENT ANGLES
i)
CAMBER
ii)
TOE
iii)
CASTER
iv)
KINGPIN INCLINATION
v)
THRUST ANGLE
vi)
FRONT WHEEL SETBACK
vii)
REAR WHEEL SETBACK
viii)
WHEEL RUNOUT
ix)
INCLUDED ANGLE
x)
TRACK WIDTH DIFFERENCE
xi)
LOCK ANGLE
xii)
TOE OUT ON TURNS

Wheel angles
Steering axis angles

These are unwanted angles which

sometimes prevail in a vehicle

Each wheel alignment angle has a specific purpose and function. If they are not set properly,
the effects will be uneven tyre wear, loss of steering control, pulling to one side while driving,
jerking on travel, etc.
It may not be possible to correct all the above angles in a vehicle. Depending upon the design
of suspension, some angles are adjustable at workshop level and some are not adjustable (Set
in Factory) which may require parts replacement to get the specified value.
The Parameters Wheel Runout, Set Back & Thrust Angle will affect the wheel angles ie.,
Camber & Toe. Therefore, it is very important to identify, measure and correct or
compensate these angles. Otherwise, proper Wheel alignment cannot be achieved.
System takes all the above factors into consideration in its design and offers total
solution by compensation in the respective parameters

5.1.

CAMBER
The CAMBER angle will affect the wear on the inner or outer edge of the tyre. Camber
is the inclination of the centerline of the wheel from the vertical as viewed from the front
of the vehicle. Camber angle is measured in positive or negative degrees.
POSITIVE CAMBER is the outward tilt of the top of the tyre.

Fig. 5

Ref.: CCDWA - OM

12

NEGATIVE CAMBER is the inward tilt of the tyre at the top.

Fig. 6

If a tyre was absolutely vertical, the degree of camber would be zero. Unlike the
Caster angle, Camber will change with vehicle load and ride height. With the weight of
the driver in the vehicle, front left Camber will increase and front right Camber will
decrease and vise versa for left hand steering vehicle. As rough road conditions are
encountered, the downward thrust of the vehicle body will cause front Camber to go
negative. As the vehicle body movement returns upward, front Camber will go positive.
A tyre with Positive Camber can influence the vehicle with a directional pull. The
vehicle will go towards the side that has the tyre with the most Positive Camber.
It is the normal tendency of the tyre to roll around the center of a circle when the top of
the tyre is inclined towards the center of that circle. Positive Camber tends to place
the tyre-to-road contact area nearer the point of load. This assists in easier steering
and forces the thicker inner portion of the spindle to carry most of the load. Modern
suspension design has reduced the need for considerable Positive Camber. Many
manufacturers specify a slight amount of Negative Camber. Some manufacturers
recommend an additional 1/4 to 1/2 degree Positive Camber on the right wheel to
compensate for road crown. The car will then pull toward the side with greater Positive
Camber. This will offset the pull effect of the road crown. Always set Camber within
specifications.
Rear Camber Angle - Front Wheel Drive
Rear wheel Camber angle is being relied on for improved steering and general
handling performance. In the past FWD vehicles and independent rear suspension
vehicles were most likely to have adjustable rear Camber. On vehicles currently being
produced, rear Camber adjustment capabilities are being found on all types of models
(Note : Always use full-floating tables under wheels whenever alignment is being done.
When alignment problems are reported on vehicles with fixed rear axles and no rear
wheel Camber adjustment capabilities, a thorough inspection of the rear suspension
should be made. Damaged or worn components can cause alignment and / or steering
problems. Replacing or repairing the defective components should bring the rear
wheel assemblies into specification.
On vehicles where rear wheel Camber is adjustable, all previous precautions apply. If
Camber adjustment requirements are excessive, a thorough inspection must be
performed. Replacing any defective components could bring the Camber into
specification and adjustment may become unnecessary. As with the front suspension,
DO NOT perform alignment on vehicles with damaged or worn components.
Rear Camber Angle - Rear Wheel Drive
On RWD vehicles, where rear Camber is usually not adjustable, Camber will normally
be fixed at zero. Even though this angle cannot be changed through adjustment, if rear
suspension abnormalities exist, a thorough inspection must be made. Not to be
overlooked are the rear springs. Worn or weak rear springs will alter riding height and
because of a reduction in tension, will bring the shock absorbers out of the optimum
range of their dampening ability. The result will be excessive tire movement. This
condition reduces operator control and contributes to abnormal tire wear. As in FWD
vehicles, replacing worn or defective components may bring rear wheels within
specification.

Ref.: CCDWA - OM

13

5.2.

TOE
Unlike Caster and Camber, which are measured in degrees, Toe is most frequently
measured in fractional Inches, Millimeters or Decimal degrees. An incorrect Toe
setting is one of the main alignment factors that cause excessive tyre wear. Front and
rear Toe are the same in definition, with the adjustment capabilities and procedures
being the only actual difference. TOE is the difference between the leading edge (or
front) and trailing edge (or rear) of the tyres.
TOE-IN is the measurement in fractions of an Inch, Millimeters or Decimal of degrees
that the tyres are closer together in the front than they are in the back.

Fig. 7

TOE-OUT is the same measurement, except the tyres are further apart in the front than
in the rear.

Fig. 8

Slight Toe-in is preferred to Toe-out on most vehicles because steering is aligned while
vehicle is stationary. When the vehicle is moving, linkage components flex causing a
change in alignment angles. This is classified as Running Toe. Running Toe should
be zero to maximize tyre life and achieve least rolling resistance.
The usual tendency is for the tyres to turn outward while the vehicle is in motion, so
most vehicles are designed with a static Toe-in setting. The static Toe-in setting will
become zero as the linkage flexes when the vehicle is in motion. Always set Toe to the
manufacturers specifications. On vehicles with Toe adjustment capability on the rear,
an alignment specialist can go beyond manufacturers specifications according to
vehicle usage and customer requirements. With the proper equipment, the rear axle
can be adjusted to perform aggressively toward demanding load and road conditions.
Vehicles with FWD and independent rear suspensions are more likely to have
adjustable rear Toe. As with rear Camber, properly adjusted rear Toe will contribute to
improved steering & handling characteristics. Full floating tables (Rotary plates) must
be used under rear tyres whenever Toe is to be adjusted. If rear Toe is out of spec a
thorough inspection must be done, whether or not rear Toe is adjustable.
Components found to be defective must be replaced. On vehicles that do not have
rear Toe adjustment capability and Toe is not within specifications, replacing defective
components may bring Toe within specifications.
Normally TOE is specified in mm or inch. That is by how much the front of
the Wheel Rim is IN or OUT compared to the rear side of the Wheel Rim. But,
System follows the unit of Degrees and Minutes. Even, if the TOE is entered in
mm or inch, it converts the same into corresponding Degrees and Minutes
Ref.: CCDWA - OM

14

5.3.

CASTER
CASTER is the angle between an imaginary line drawn through the upper and lower
steering pivots and a line perpendicular to the road surface (viewed from side of
vehicle). If the top of the line tilts rearward, the vehicle is said to have POSITIVE
CASTER.

Fig. 9

If the top of the line tilts forward, the vehicle is said to have NEGATIVE CASTER.

Fig. 10

Positive Caster can also be defined as when the spindle is tipped so that the pivot
support centerline intersects the road surface at a point in front of the initial tire contact.
Negative Caster would then be the center line intersection to the road surface behind
the initial tire contact.
Most vehicles produced today do not have adjustable Caster angle. Many early model
vehicles have adjustable Caster in which road crown is compensated for (along with
Camber). By setting the Caster angle on the Drivers side 1/2 degree less than the
passenger side for Positive Caster specifications or 1/2 degree more for Negative
Caster specifications, the road crown should not cause vehicle pull in either direction.
Vehicles equipped with manual Steering use very little Positive or Negative Caster.
This helps reduce the Steering effort at the Steering wheel.
The advantage of Caster adjusted toward Negative is greater maneuverability.
however, direction stability on open road driving is reduced. The advantage of Positive
Caster is the strong directional stability and the ease of returning the steering to a
straight ahead position. Caster will not cause tyre wear unless extreme mis-adjustment
or worn parts are involved. Always set Caster (if adjustable) to specifications and
within 1/2 degree from side to side. Keep road crown in mind and adjust as necessary
if a pull is present after a proper alignment has been completed.

Ref.: CCDWA - OM

15

5.4.

KINGPIN INCLINATION (Steering axis inclination)

Fig. 11

KINGPIN Inclination (also referred to as the ball joint angle or Steering Axis InclinationSAI) can be a difficult angle to understand. The easiest way to understand Kingpin
Inclination is to first define Steering axis. The steering axis is an imaginary line
intersecting the spindle support. In a conventional steering system, the spindle
supports are the upper and lower ball joints or the Kingpins. With MacPherson strut
systems, Steering axis is the angle beginning at the ball joint and extended through the
strut assembly. Viewed from the front of the vehicle, Kingpin Inclination is the angle
between the Steering axis and a true vertical line established through the tyre. The
Kingpin Inclination is a stability angle and is measured in degrees.
If these imaginary lines were extended to road surface, the area covered between them
would be identified as the point of load or scrub radius. The vehicle body will be
closest to the road surface when the wheels are pointed Straight Ahead as a result of
Kingpin Inclination.
A spindle with Kingpin Inclination will have the outer end of that spindle at the highest
point when the wheels are pointed Straight Ahead. Therefore, as the weight of the
vehicle pushes downward, the spindle will always attempt to move upward to return the
wheels to a Straight Ahead position. After a turn, the Kingpin Inclination helps to return
the tyres to Straight Ahead position. Kingpin Inclination also aids in vehicle directional
stability by resisting road irregularities that attempt to turn the wheels away from the
Straight-ahead position. This angle produces many of the same benefits that improve
steering stability as Positive Caster. Correct engineering of Kingpin Inclination can
reduce the need for high Positive Camber. The effect of Kingpin Inclination on
directional stability is usually greater then that of Caster. Some vehicles with Power
steering require a greater amount of steering wheel returning force than those with
manual steering. Kingpin Inclination is often used with Positive Caster on power
steering equipped vehicles to assist in steering wheel returnability.

Ref.: CCDWA - OM

16

5.5.

THRUST ANGLE

Fig. 12

THRUST ANGLE is the line that divides the total angle of the rear wheels. The rear
tyres are not just following the front tyres, they are actually establishing direction of the
vehicle. In doing so, a direction of thrust is developed. The Thrust angle created by the
rear wheels is used as a reference for aligning the front wheels. Ideally, the Thrust
angle should be identical to the geometric centerline of the vehicle. If Thrust angle and
geometric centerline are identical, the position of the tires would then form an absolute
rectangle and the front tyres could be aligned to the rear tyres, resulting in a perfectly
centered steering wheel. Because of unitized construction, factory tolerances and a
varying degree of damage and / or wear, it is increasingly unlikely that the axles will be
parallel. When the rear axle projects a different angle than the front axle, the driver will
need to turn the steering wheel to compensate in order to drive in a straight line.
On situations where the thrust line and geometric centerline are not identical, a
thorough inspection of the rear axle and suspension system must be done. Replacing
defective components should aid in positioning Thrust angle close to the geometric
centerline. If the Thrust angle is not identical to the geometric centerline and there are
no defective components, align the vehicle using the Thrust angle instead of the
geometric centerline. Aligning the front wheels to the Thrust angle is preferred to
aligning to the geometric centerline. The ability to do this is a significant advantage of
four wheel alignment. The result should be a straight steering wheel as the vehicle
moves straight-ahead.

Ref.: CCDWA - OM

17

5.6.

FRONT WHEEL SETBACK

FRONT WHEEL SETBACK or front end squareness is a condition in which one wheel
is rearward of the other. If Setback is present the turning radius will not be correct
when the vehicle turns. With this condition, the tyres will wear very much in the same
manner as if they were under inflated. Generally, Setback is the result of collision
damage. It is preferable to have the front tyres square with each other before
alignment is done. The most accurate way of checking is with four wheel alignment
equipment.
The measured angle will be displayed as Negative Front wheel Setback, if the Right
Rear wheel leads the Left Rear wheel.

Fig. 13

The measured angle will be displayed as Positive Front wheel Setback, if the Right
Rear wheel is behind with respect to the Left Rear wheel.

Fig. 14

Ref.: CCDWA - OM

18

5.7.

REAR WHEEL SETBACK

It is the condition of Rear axle with respect to the Geometric centre line ie., one of the
Rear wheel is rearward or forward with respect to the other wheel. The Rear Wheel
Setback is the angle between a line drawn through both the wheel resting points. A
line perpendicular to the vehicle geometrical line (thrust line) will be measured in
angles.
The measured angle will be displayed as Negative Rear wheel Setback, if the Right
Rear wheel leads the Left Rear wheel.

Fig. 15

The measured angle will be displayed as Positive Rear wheel Setback, if the Right
Rear wheel is behind with respect to the Left Rear wheel.

Fig. 16

Ref.: CCDWA - OM

19

5.8.

WHEEL RUNOUT

Fig. 17

TRUE VERTICAL

10' (MINIMUM)

50' (MAXIMUM)

30' (AVERAGE)

RUNOUT is one of the important factor which affects a good wheel alignment. Hence
Runout compensation is a critical parameter in wheel alignment.
Runout is the wobbling of wheel with respect to neutral axis ie., vertical axis of Camber
and the axis parallel to Geometric centre line in case of Toe. This wobbling affects the
Camber and Toe parameters. Runout exists even in new vehicles. But it will be more
in old vehicles due to wear and tear. Now let us see how Runout affects the Camber:

ROAD

Fig. 18

TRUE VERTICAL

35' (MINIMUM)

55' (AVERAGE)

75' (MAXIMUM)

Assume that there is a wobbling of 10' to 50' in a wheel and Runout is 40' (max. min.
reading). This means, when the vehicle is in motion, the wheel will have a varying
Camber of 10' to 50' during every rotation. This is inevitable. Logically the average
point has to be taken as the real Camber (ie., 30' in this case).
If the specified Camber for a vehicle is 55', then adjustments must be made in the
shims / Cam mechanism suitably to affect a wobbling movement of 25' to achieve the
average Camber of 55' (ie., 30' + 25' = 55').
After the adjustment, Average Camber = 55' (required)
Minimum Camber = 35
Maximum Camber = 75

ROAD

Fig. 19

Ref.: CCDWA - OM

20

Due to the above adjustments, Camber variations will be equally distributed in the
vehicle (in motion) at any point of time. The process of bringing the Camber to average
Runout position is called Runout compensation.
The equipment does the Runout compensation automatically without the knowledge of
technician.
In Jacked up Runout method, the Technician has to simply rotate the wheel as guided
by equipment for 90and drop the wheel on Rotary plate.
In Roll-on Runout method, the wheel has to be rotated only at 90 backward from the
parked position.
Rest of the calculations is automatic and average Runout compensation is achieved.
Above theory is also applicable for achieving the average Runout compensation in Toe
setting.
Once Camber & Toe Runout are compensated, best results can be expected in terms
of wheel alignment.

5.9.

INCLUDED ANGLE

Fig. 20

INCLUDED ANGLE is the angle formed between the Kingpin inclination and the
Camber. Included angle is not directly measurable. To determine the Included angle,
Kingpin Inclination is added to the Camber. If the Camber is negative, then the
Included angle will be less than the Kingpin Inclination. If the Camber is positive, it will
be greater. The Included angle must be the same from side to side even if the Camber
is different. If it is not the same, then something is bent, most likely the steering
knuckles.

Ref.: CCDWA - OM

21

5.10.

TRACK WIDTH DIFFERENCE

Track width difference is the angle between Front Left wheel resting point to Rear Left
wheel resting point & Front Right wheel resting point to Rear Right wheel resting point.

Fig. 21

The measured angle will be displayed as Positive angle, if the Rear Track width is
more than the Front Track width.
The measured angle will be displayed as Negative angle, if the Front Track width is
more than the Rear Track width.

Ref.: CCDWA - OM

22

5.11.

LOCK ANGLE

Fig. 22

LOCK ANGLE is the angle measured in degrees by which the front wheels of a vehicle
move to the extreme left or right from the straight ahead position when steered.
Left wheel Lock Angle : The maximum degrees to which the left front wheel can
(Internal)
turn when the wheels are steered to the left side.
Left wheel Lock Angle : The angle turned by left wheel when the right wheel is
(External)
steered to max. right is called Lock Angle External (Left).
Right wheel Lock Angle : The maximum degrees to which the right front wheels can
(Internal)
turn when the wheels are steered to the right side.
Right wheel Lock Angle : The angle turned by right wheel when the left wheel is
(External)
steered to max. left is called Lock Angle External (Right).
Lock angles for the right and left side are controlled by stoppers provided on both
sides. Lock angle also determines the minimum turning radius of a vehicle.
The Lock angle varies from 35 to 42 depending upon the make of the vehicle. The
Lock angles may get disturbed due to the following factors:
i.
When Steering linkages are bent due to the vehicle meeting with any accident.
ii.
Improper adjustments of stoppers.
Iii.
Incorrect setting of steering rack, pitman arm and tie rod lengths.
Lock angles are measured to ensure that the front wheels turn equally on both sides
(right & left) as per manufacturers specification.

Ref.: CCDWA - OM

23

5.12.

TOE OUT ON TURNS

When the front wheels of a vehicle are steered to left or right, the angle turned by each
wheel at any instant is not equal. When the left wheel is turned towards left side by 20
from the Straight ahead position the right side wheel would have turned lesser than
20. If the Toe is measured at this instant, it will always be in Toe-out condition.

Fig. 23

The difference between the angle turned by left and right wheel is responsible for the
Toe-out condition.
Let a = the angle turned by left wheel. i.e., the angle made by the rear axle centre
line produced and a line drawn perpendicular to the plane of the left wheel
from its centre.
Let b = the angle turned by right wheel. i.e., the angle made by the rear axle centre
line produced and a line drawn perpendicular to the plane of the right wheel
from its centre.
(a - b) = rL is the difference in angle turned by left and right wheels.
Similarly when the right front wheel is turned 20 towards right side, the left side wheel
would have turned less than 20 because of the Ackerman principle employed in the
steering system.
The difference in angle turned by the front wheels during left turns (rL) and right turns
(rR) should be equal or within allowable tolerance.
If rL & rR are not equal or not within limits, then it indicates
i.
Bent Steering link
ii.
Wrong positioning of pitman arm in the Steering box
iii.
Not centralizing the rack in the steering box in the straight ahead position
Ref.: CCDWA - OM

24

6.

DESCRIPTION OF MAIN PARTS

The equipment consists of Main Cabinet, Display unit, RF Transceiver unit, Sensor arms, Arm
resting brackets, Keyboard, Mouse and Standard accessories. The Optional accessories
indicated will be supplied only against order.

6c

11

8
9

6a

6d

10
3
6b
1
7

2
Fig. 24

Sl.No.

Description

Sl.No.

Description

Main cabinet

Arm resting brackets

Desktop computer (refer scope of supply)

Keyboard (refer scope of supply)

Interface box

Mouse (refer scope of supply)

Display unit (refer scope of supply)

10

Color Inkjet printer (refer scope of supply)

RF Transceiver unit

11

Multimedia speakers (refer scope of supply)

6.a

Sensor arm-Front-Left

6.b

Sensor arm-Front-Right

6.c

Sensor arm-Rear-Left

6.d

Sensor arm-Rear-Right

Ref.: CCDWA - OM

25

6.1.

MAIN CABINET
Main cabinet is the housing for Desktop computer, PC Interface unit with Power panel
& Printer (Optional). The Display unit is mounted on a Monitor column over the top of
Main cabinet. The RF Transceiver unit, Keyboard, Mouse & Multimedia speakers
(Optional) are located on the respective slots in Main cabinet top cover.
The Arm resting brackets are provided on the sides of Main cabinet for placing the
Sensor arms when not in use.

6.2.

DESKTOP COMPUTER (refer scope of supply)

The Desktop computer is a Commercial branded computer integrated with our Aligner
and housed inside the Main cabinet for processing / executing the alignment program
and data storage. The location of Desktop devices and peripherals connection ports
may vary depending upon the manufacturer. However the following user end devices
and connection ports available commonly in all models are used for our application:
Device / connection ports

Location

Purpose

Optical drive

Front side

For loading / upgrading software

3 Pin AC socket (Male)

Rear side

AC input to Desktop

VGA out

Rear side

For Monitor

PS/2 ports

Rear side

For Keyboard & Mouse

Serial port (COM1)

Rear side

For communication with PC interface unit

USB ports

Front / Rear side

For communication with PC Interface unit,

Keyboard, Mouse, Printer, Speakers

Audio output

Front / Rear side

For Multimedia Speaker

Keep the Desktop away from radiators and heat sources

Desktop contains Optical drives which have built-in laser devices. To prevent
any risk of exposure to laser radiation, do not open the desktop / drives
Ensure that none of the system air vents are blocked. Blocking them would
cause serious thermal problems
Clean the Desktop with a soft & clean cloth using water and then remove
moisture from the surface quickly. Long term exposure to moisture may
damage the surface
The location / functions of Desktop devices / connections may vary depending
upon the make of Desktop supplied. Refer Desktop manual / Soft media

6.3.

INTERFACE BOX
Interface box is used for distributing & regulating the power supply required for the
Aligner and also to interface the Desktop computer (Processing unit) with alignment
system assemblies like Sensor arm & RF Transceiver unit.
Connectors, Ports and sockets are provided in at the rear side of Interface box for
connecting the RF Transceiver unit, Sensor arm cables, Arm resting brackets, Desktop
computer and peripherals like Monitor, Printer, Speakers. The locations are shown in
the Fig.25 & 26 below.
The ON/OFF switch provided in the Interface box can be used to switch OFF
the Processing unit alone

Control fuses are provided in the Interface box as described below:

Control fuse - F1 is provided for protection of all electronic components in PC I/F unit
Specifications 3A, Dia 5mm x 20mm, Slow blow type Glass fuse
Control fuse - F2 is provided for protection of Monitor, Printer & Speaker
Specifications 5A, Dia 6.35mm x 31.8mm, Slow blow type Glass fuse

Ref.: CCDWA - OM

26

Interface box - Front view

1

OFF
SW1

ON

PC

5 Amps
F2

230V AC
50 Hz
INPUT
USB
MONITOR POWER

F1

3 Amps

Fig. 25

Interface box - Rear view (inside the Main cabinet)

10

CAUTION
230V AC 10%,
50 Hz

SERIAL PORT

11

12

11

Fig. 26

Sl.No.

6.4.

Description

Sl.No.

Description

RF Transceiver unit connector

AC input for PC Interface unit

Sensor arm connectors

Fuse F1 for PC Interface unit

ON/OFF switch (Processing unit)

USB port for Desktop computer

Fuse F2 for Monitor & Peripherals

10

AC output for Printer & Speaker

AC output for Monitor

11

Charger connectors

AC output for Desktop computer

12

Serial port for Desktop computer

DISPLAY UNIT (refer scope of supply)

The Display unit is a High resolution Color Monitor to display the alignment screens
and functions. It contains a Power indicator LED, Power ON/OFF switch and various
adjustments. Refer the Monitor manual / Soft media provided along with the equipment
for adjustments.
Ensure that none of the Monitor air vents are blocked. Blocking them would
cause serious thermal problems
Clean the Monitor with a soft & clean cloth using water. Remove moisture
from the display quickly and keep the display dry. Long term exposure to
moisture may damage the display
The location of Monitor power indicator and controls may change depending
upon the make of the Monitor supplied. Refer the Monitor manual / Soft media

Ref.: CCDWA - OM

27

6.5.

RF TRANSCEIVER UNIT
The RF Transceiver unit has a built-in Hardware lock for protecting the alignment
program against un-authorised usage and also for enabling the Optional features in the
field itself by providing the activation code acquired from Manufacturer with respect to
the Machine Serial Number.
A Transceiver module is housed inside RF Transceiver unit to interface with processing
unit & Sensor arms by transmitting & receiving commands / alignment data for process.
Wheel aligner has an exclusive provision for programming its RF channel (upto 15
channels) in the field itself to avoid any external co-channel interference from other
equipments.
Indicators are provided in the RF Transceiver unit for power status and direction of data
flow as given below:
Indicator

Fig. 27

LED
color

Status

Power

Red

Availability of power supply

TX

Red

Data transmission from RF

Transceiver unit

FL

Green

Data received from Front Left

Sensor arm

FR

Green

Data received from Front

Right Sensor arm

RL

Green

Data received from Rear Left

Sensor arm

RR

Green

Data received from Rear

Right Sensor arm

The equipment radiates Radio Frequency @ 2.4 GHz. Usage of this equipment
in residential / commercial area may cause interference to some appliances. In
such case the user can contact our Service personnel for re-programming the
Aligner's RF channel or else the user should take whatever remedy required to
correct the interference on his own expense. The manufacturer is not
responsible for any claim
RF channel setting should be done only by authorised Service personnel
DO NOT disturb the location / orientation of the RF Transceiver unit. It will
directly affect the data transmission to Main processing unit, leading to
improper data communication

6.6.

SENSOR ARMS
Front and Rear Sensor arms contain High precision Inclinometers and CMOS Camera
to measure and acquire required alignment parameters from the Vehicle being aligned.
A Spirit level is provided in each Sensor arms for ensuring its horizontality.
Handle the Sensor arms carefully. Rough handling / shocks may cause
damage to the Sensors and optical components
Dropping / rough handling of Sensor arms may cause deviation in calibration.
User should take atmost care to handle and maintain the Sensor arms in good
calibrated condition

The data acquired by each Sensor arms are transmitted to the RF Transceiver unit
through Transceiver module in each Sensor arms using Radio Frequency of 2.4 GHz.
Auto charging batteries are provided inside the Sensor arm tubes for storage of DC
power required for carrying out alignment.
Ref.: CCDWA - OM

28

Battery specifications : 7.2 AH, 6V x 1 Valve regulated Lead Acid

Backup time
: >12 hours
Provision (5 Pin BSM type connector) is available in the Sensor arm cabinet for
operating each Sensor arms independently using Sensor arm cable also, which is
provided as Optional accessory.
While operating a particular Sensor arm using the Optional cable, the Sensor arm will
get charged simultaneously.
Control fuse is provided in all Sensor arms for protection of all electronic components
Specifications 1A, dia 5 mm x 20 mm, Slow blow type glass fuse
Never heat the Battery or throw into fire. Keep the Battery / charging contacts
away from metal objects
DO NOT try to clean or disassemble the Battery as it could result in the leakage
of sulfuric acid resulting in acid burns
Scrap batteries should be stored in non-reactive acid resistant containers. It is
the responsibility of End-User to comply with the Battery (M&H) rules of
National regulatory authority and hand over scrap batteries to the Authorised
collection centres
Sensor arm batteries should be replaced with same model only by qualified
Service personnel, if required. Refer the Battery label for Make / Model details
Sensor arms should not be kept idle if alignment is not caried out. Failure to
comply may lead Battery lead deep discharge and Battery failure
If Sensor arms are kept idle & not placed in Arm resting brackets, a continuous
beep sound will be generated after 10 minutes with 2 minutes interval
When alignment is not carried out, the Sensor arms must be placed on the Arm
resting brackets for auto-charging the batteries fixed inside Sensor arm tube
Ensure that the Charging LED glows in Red color when Sensor arm is kept on
the Resting bracket or connected with Optional Sensor arm cable for charging
If Low battery is indicated, Sensor arm may not communicate data with RF unit
properly. Keep the Sensor arms on the Resting brackets for charging
DO NOT switch OFF the Main system switch, let the battery get charged over
night

SENSOR ARM INDICATORS & KEYPAD CONTROLS

Indicator

LED
color

Status

During usage, as soon as the

Green Sensor arm is lifted from Arm
Resting bracket
During charging of Sensor arm,
By placing it on the Arm
Charging
Red
Resting bracket (or)
Using Sensor arm cable
(Optional)
When battery level goes below
Low battery Red
its normal operating voltage
Power ON

Fig. 28

Keys

Functions

Enter

To proceed to next program

Prev

To skip current operation and

go to previous step

Next

To go to next window

Runout

To be pressed in each step of

RUNOUT

Runout

Audio
indication

Red

Indicator to press Runout key

for performing Runout
Indicator (after 10 min.) to
switch off Sensor arm during
Mains power supply cutoff (or) if
comm error occurs between RF
Transceiver unit & Sensor arms

The use of cleaning agents which attack coating or sealing materials could
result in Membrane damage
Ref.: CCDWA - OM

29

During RUNOUT program, "PREV" key also is used to redo the RUNOUT

6.7.

Front / Rear Sensor arms

(Rpac Premium Plus models)
Sensor arm
knob

Rear Sensor arms

(Rpac Premium models)

Fig. 29

Fig. 30

ARM RESTING BRACKETS

Arm restring brackets are provided on the sides of the Main cabinet for resting the four
Sensor arms when it is not in use.
Resting brackets have charging facility for charging the Sensor arms. Sensor arms
should be charged for minimum 6 to 8 hours for un-interrupted alignment operation.
Never heat the Battery or throw into fire. Keep the Battery / charging contacts
away from metal objects
DO NOT short the Charging pins in Resting bracket which may lead to
malfunction of charger

6.8.

KEYBOARD (refer scope of supply)

A standard USB or PS/2 Keyboard is connected to Desktop computer and placed over
the Cabinet top cover. The Keyboard is provided for operating / navigating and giving
inputs during the alignment program.
The location of Indicators and functions of Keys may change depending upon
the make of the Keyboard supplied. Refer Keyboard manual / Soft media

The functions of active keys in the Wheel aligner program are given below. Functions
of a same key may differ depending on the program screen & context.

6.9.

MOUSE (refer scope of supply)

A standard Optical Mouse is connected to Desktop computer and placed over the
Cabinet top cover. The Mouse is provided for operating / navigating and giving inputs
during the alignment program.
The location / functions of Keys may change depending upon the make of the
Mouse supplied. Refer Mouse manual / Soft media

Ref.: CCDWA - OM

30

6.10.

STANDARD ACCESSORIES
Use only the Accessories recommended by the manufacturer and handle it
carefully. Failure to comply may cause injury to Operator
Frequently inspect the accessories and clean and lubricate

6.10.1. WHEEL BRACKET

Wheel
bracket
knob
Sensor arm
locking
knob

Fig. 31

This is a Self centering type Wheel bracket with quick clamping feature for
mounting the Sensor arm to Wheel rims The Wheel bracket is a versatile
design to accommodate LCV Wheel rims ranging from 12" to 24" of diameter.
The Inner PCD holes will cover from 12 to 20 sizes of rim & Outer PCD holes
will cover from20 to 24 sizes of rim.
Handle the Wheel bracket with care. The Locating pins may have
sharp edges
Wheel bracket must be mounted on the wheel at 12 O clock positions
(true vertical position) if the center block is slide down for spoiler
program. If not, it will measure wrong Wheel setback

Clamping of Alloy wheels

1.
Outer clamping is advised for Alloy wheel. Extend the clamp outward to
a size larger than the rim by turning the Wheel bracket knob in Anticlockwise direction.
2.
Place the upper Locking pins on the outside of the top of the rim. Push
the Locking pin in between the Tyre bead and the rim. It may be
necessary to "pop" the upper portion of the Wheel bracket with the palm
of your hand to seat well. Note that it is not necessary for the Wheel
bracket to be mounted perfectly vertical on the wheel.
3.
Push lower Locking pins into place. Again, it may be necessary to pop
them in further for security. Continue tightening knob until it is secured.
4.
Tighten the Wheel bracket by turning the knob in clockwise direction
until the lower Locking pins engage the rim.
5.
Ensure the mounting by pulling the Wheel bracket outwards. If it comes
off easily, re-mount the Wheel bracket properly.
Clamping of ordinary steel rim wheels
To clamp the wheel from the inside out using the outer lip of the rim, use the
following steps:
1.
Extend the Wheel bracket inwards to a size smaller than the rim by
turning the Wheel bracket knob in clockwise direction.
2.
Place the lower locking pins on the wheel lip at the bottom of the wheel.
It is not necessary to be perfectly vertical.
3.
Tighten the Bracket by turning the knob in anti-clockwise direction until
the upper Locking pins engage the rim. Continue to tighten until the
Wheel bracket is secure.
4.
Test the security by pulling the Wheel bracket outwards. If it comes off
easily, re-mount the Wheel bracket.
Ref.: CCDWA - OM

31

6.10.2. LCV ROTARY PLATE - 2 ton (Applicable only for LCV models)

Fig. 32

The Rotary plate consists of a freely rotating plate with load capacity of 2 ton
in each Rotary plate suitable for LCVs. The front wheels of the vehicle being
aligned should rest on these plates. The Rotary plate helps to free up the
wheel from the friction and relaxing the ball joint to its original condition. Lock
pins are provided to arrest the movement of rotation while parking the vehicle
over the plate for alignment. The Locking pins must be removed while taking
measurements.
(a)
The Rotary plates enable Left turn and Right turn movement required
for measuring Caster & Kingpin angles.
During Rear wheel alignment, the Rear wheels are to be rested on the Rear
wheel slider to accommodate the minor wheel movements.
Ensure the Top plate of Rotary plates are locked with Locking pins
before parking the vehicle
The Rotary plate must be maintained properly by user free from dust

6.10.3. LCV BRAKE PEDAL LOCK

Fig. 33

Brake pedal lock is used to keep the Vehicle Brake in pressed condition
(applied), so that the vehicle will not move during the Turn Left and Turn Right
programs, which is very important to measure the Caster and Kingpin.
Ensure the Brake pedal lock is pressed against the vehicle brake
Ensure the Brake pedal lock is pressed against the vehicle brake
during Caster & Kingpin swing to acquire readings

6.10.4. STEERING LOCK

Fig. 34

Steering lock is used to arrest the movement of Steering wheel, while

performing the Toe adjustment.
Do not keep your head nearer to the Steering while locking with
Steering lock to avoid get hit due to the spring tension
Ref.: CCDWA - OM

32

6.10.5. DATA MANAGER SOFTWARE

Data manager is a smart customised software package available with
alignment program for monitoring the condition of various vehicles aligned by
the equipment and the performance of Wheel alignment centre on the whole.
Reminder letters are automatically generated for existing customer base
periodically, which helps in increasing the revenue for the garage.

6.11.

OPTIONAL ACCESSORIES
6.11.1. MECHANICAL ROTARY PLATE WITH ANGLE INDICATOR (For Toe Out
on Turns and Lock Angle measurement)

Fig. 35

Rotary plate consists of a freely rotating plate, an Angular scale and a Pointer
fixed to its centre axis of rotation. While carrying out alignment, the front
wheels of the vehicle being aligned will rest on these plates.
The functions of the Rotary plates are the following:
(a) Enables easy rotation of front wheels during Left turn and Right turn
movement required for measuring Caster and Kingpin angles.
(b) Measures the Toe out On Turns and Lock Angle for Front wheels.
The known angle is noted manually and given as input to the Main processing
unit for measurement
LCV Electronic Rotary Plate load capacity = 2 ton (each)
During Rear wheel alignment, the rear wheels are to be rested on the Rear
wheel slider to accommodate the minor wheel movements.
Ensure the Top plate of Rotary plates are locked with Locking pins
before parking the vehicle
The Rotary plate must be maintained properly by user free from dust

6.11.2. WHEEL BRACKET EXTENSION ADAPTER

This Adapter is very useful for clamping wheel rims of 10 to 26 dia., while
using along with Wheel bracket (whose clamping range is 12-24 dia). This
adapter eliminates requirement of a separate Wheel bracket for HCV wheels.

Fig. 36

Ref.: CCDWA - OM

33

6.11.3. FOUR SHAFT CALIBRATION KIT

Fig. 37

Calibration kit is a simplified tool meant for calibrating the all the Sensor arms
simultaneously and if necessary to correct it.
Calibration is a very important function. During this process, the
Calibration stand should not be jerked or moved

6.11.4. SINGLE SHAFT CALIBRATION KIT

Fig. 38

Calibration kit is a simplified tool meant for calibrating the System and if
necessary to correct it.
This Calibration kit is supplied in a dismantled condition along with 0 and 6
Spirit levels in a compact and portable casing.
Calibration is a very important function. During this process, the
Calibration kit should be leveled using the bubble level
Calibration is a very important function. During this process, the
Calibration kit should not be jerked or moved

6.11.5. RIM LOCKING PIN (HCV)

Wheel rim locking pin with 100mm Length is exclusively for clamping HCV
alloy wheels by fitting with the Wheel bracket unit.

Fig. 39

6.11.6. RIM LOCKING PIN (suitable for Run flat tyre rims)
This Rim locking pin of 64mm Lg. is developed for clamping different kind of
LCV Run flat tyre rim profiles, compatible with 24" Wheel bracket.

Fig. 40

6.11.7. RIM LOCKING PIN (suitable for Steel rims with fancy disc)
This Rim locking pins of 64mm Lg. is developed for clamping different kind of
LCV Steel rims with fancy disc, compatible with 24" Wheel bracket.

Fig. 41

Ref.: CCDWA - OM

34

6.11.8. REAR WHEEL SLIDER

Fig. 42

Rear wheel slider is used for Four wheel alignment. Rear wheels will rest on
these Sliders to enable lateral movement of wheels during Rear wheel
alignment.
The Rear wheel slider must be maintained properly by user free from
dust

6.11.9. LONGER REAR WHEEL SLIDER

Fig. 43

This Rear wheel slider is used to accommodate wide range of wheel base
(1800 to 2600mm) during Four wheel alignment. The Rear wheels will rest on
the Sliding top plate with Rollers underneath to facilitate carrying out the push
pull Runout & sliding movements in all the directions for easy adjustment of
Rear wheel Camber / Toe. Lock pins are provided to arrest the movement
while parking the vehicle over the Slider for alignment. The Locking pins must
be removed while taking measurements
The Rear wheel slider must be maintained properly by user free from
dust

6.11.10. SENSOR ARM CABLE KIT

The Sensor arm cables are a set of Shielded Multi-core cables used for
connecting the Sensor arms and Power panel with 5 Pin BSM type connectors
to perform the following functions:

To transmit data acquired by each Sensor Arms to Main processing unit.

To charge the Sensor arm batteries simultaneously during operation.

Ensure the cables are not in contact with Rotary plate / moving parts /
vehicle tyre
Store the Sensor arm cables properly without any twist when not in
use
DO NOT use damaged / twisted Sensor arm cables. It will directly
affect the data transmission to Main processing unit
datascope
transmission
to Main processing unit
6.11.11. PRINTERthe
(refer
of supply)
A Printer option is provided with the equipment for printing the alignment
reports in ISO A4 size paper. The User is provided with options for printing
the alignment reports in Ordinary or in 3D Graphical format as per the
requirement.
Use only original Ink/Toner cartridge, by indicating the respective
Cartridge Model No., Printer Make & Model No. to supplier. Failing to
comply may lead to Printer head damage / improper printout

Ref.: CCDWA - OM

35

Use only standard ISO A4 size papers (210 x 297 mm) recommended
by the Printer manufacturer and always ensure sufficient quantities of
paper is loaded in the Printer tray. Failing to comply may lead to
Improper printing / Paper jam / Printer head damage
Clean the Printer with a soft & clean cloth using water and then
remove moisture from the surface quickly. Long term exposure to
moisture may damage the surface
Location of Indicators and Control buttons may change depending
upon the make of Printer supplied. Refer Printer manual / Soft media

6.11.12. MULTIMEDIA SPEAKER (refer scope of supply)

Multimedia speakers (2 Nos.) are used for providing voice prompts to guide
the operator throughout the alignment program.
Location of Indicators and Control buttons may change depending
upon the make of Speaker supplied. Refer Printer manual / Soft media

6.11.13. INTERNATIONAL VEHICLE DATA (refer scope of supply)

This is an Optional feature to be activated via Built-in Hardware lock by
purchasing at extra cost. The readily available vehicle specifications that are
compiled and released by Third parties with License can be directly uploaded
in our system. These vehicle specifications are updated & released twice
every year at extra cost

Ref.: CCDWA - OM

36

7.

OPERATION
Only permit qualified personnel to operate, maintain or repair the Aligner
Handle the Sensor arms carefully. Rough handling / shocks may cause damage to the
Sensor and optical components
Do not move or turn the equipment while the System is in power up condition
Ensure the Top plate of Rotary plates are locked with Locking pins before parking the
vehicle
Always comply with the applicable accident prevention regulations
Do not hammer or hit any part of the equipment with service Tools
Do not operate the equipment under direct sunlight. Even reflected sunlight reaching
the Sensor arm camera will result in erratic readings
During mains power cutoff (or) if communication error occurs between Transceiver unit
& Sensor arms in idle condition, an audio indication will be given to switch off the
Sensor arms or to rest it on the Charging tray

7.1.

DEFECTS / MALFUNCTIONS
In case of defects or malfunctions, turn OFF the mains and contact qualified
Service personnel

7.2.

PRELIMINARY ALIGNMENT PREPARATION

1.
2.
3.
4.

5.
6.

It is vital to collect the required information / complaint on vehicle being aligned

from the vehicle owner prior to diagnosis for conducting a perfect alignment.
Perform a test drive to verify owners complaint.
Ensure that Top plates of Rotary plates are locked with Locking pins.
Position the vehicle on Alignment pit / Alignment lift
a)
For conducting alignment on Alignment pit, refer Chapter 7.2.1.
b)
For conducting alignment on Alignment lift, refer Chapter 7.2.2.
Inspect the vehicle tyres for correct size & for any signs of abnormal wear & tear.
Always check for correct tyre pressure in all the four wheels. The tyre pressure
must be uniform for both front wheels and for both rear wheels as per the
specification.
Unequal Tyre pressure may lead to improper alignment

7.

8.
9.
10.
11.
12.
13.
14.
15.

Ref.: CCDWA - OM

Inspect the vehicle parts like Front & Rear suspensions, Bearings, Steering, Ball
joints, Tie rod etc., thoroughly for any play / looseness / wear & tear. Replace the
defective parts if any.
Ensure that there is no excessive free play in steering mechanism and linkage.
Adjust the Wheel bearings if required.
Ensure that there is no excessive Runout in the wheels.
Place the Test loads in vehicle (if specified in Vehicle manual).
Mount the four Sensor arms on wheels using appropriate Wheel brackets. Wind
the Safety rope around Wheel bracket and hook both the ends to the Wheel rim.
Re-center the Steering wheel & re-adjust Front Toe if needed crooked Steering
wheels are the leading cause of customer dissatisfaction with wheel alignments.
Take a printout for comparing the results before and after alignment
Balancing of the wheels is also recommended before alignment.

37

7.2.1.

ALIGNMENT USING ALIGNMENT PIT

Park the Vehicle in the Alignment bay so that both the Front wheels rest on
exact centre of Rotary plates and the Rear wheels rest on Rear wheel sliders.

7.2.2.

ALIGNMENT USING ALIGNMENT LIFT

Secure the vehicle with the Alignment lift properly as instructed by
the Lift manufacturer. Failure to comply may lead to risk of crushing
or serious injury, if vehicle rolls off the lift
Leave Automatic transmission in park or Manual transmission in gear
unless equipment operation steps require vehicle in Neutral
Apply Parking brake unless equipment operation steps require wheel
movement
Use Wheel stopper whenever vehicle is positioned on the Alignment
lift
Follow the Alignment lift manufacturers safety recommendations
while lifting a vehicle. MANUFACTURER IS NOT LIABLE FOR

1.
2.

3.
4.
5.

6.
7.

Ref.: CCDWA - OM

ANY DAMAGES CAUSED due to non-compliance

Drive the vehicle over the Alignment lift and stop just before the Rotary
plates. Ensure the vehicle is centered on the bay.
Place the Vehicle in Park (or in Gear on a standard transmission), and
turn OFF the Ignition system. Press and lock the Vehicle brake using
appropriate Brake pedal lock.
Place Wheel chocks behind the tyres to prevent the vehicle from rolling
off the lift.
Position the Rotary plates as needed to insure the wheels are centered.
Bring the vehicle to Neutral condition and release Brake pedal lock and
move the vehicle forward to place over the Rotary plates. Now reposition
the Wheel chocks and change the vehicle transmission to Park and then
apply Brake pedal lock.
Raise the Lift to a solid, level lock position.
Place the Transmission in Neutral and release the parking brake just
before beginning the Vehicle positioning process.

38

7.3.

MAIN MENU
When the equipment is switched ON, Windows Operating System will boot up and then
the system will initialize all the devices. A Welcome screen will be displayed with
following options:

Fig. 44

START
ALIGNMENT

To conduct Wheel alignment

First, existing condition of Rear wheels will be measured & displayed.
Then the Rear wheel parameters are corrected and Thrust angle is
compensated in Front Toe during Front wheel alignment. It reduces
Tyre wear and improves the vehicle performance.
Refer Chapter 7.4 for details

SETTINGS

To go to Special options
Special Options is to perform all system related activities, such as
Vehicle specification entry etc. Since this a critical function dealing
with Calibration etc., a Password (Default password: supervisor) is
given to the customer to access Special options. Normally this
Password must be kept as a secret by a responsible person, say the
Owner of the Shop. If by chance the Password has come to others
knowledge, a Password modification provision is also given, using
which the owner can change the Password.
Refer Chapter 7.7 for details

HELP

To access On-line help

Online help can be accessed from all the screens by pressing F1 key
to guide the user while performing alignment

LANGUAGE
SETTINGS

To set the Language

User can select the preferred language out of the available options so
as to display the alignment screens and Voice prompts in their
regional languages
Refer Chapter 7.8 for details

DATA
MANAGER

To enter into Data Manager Software

Data manager is smart customised software for monitoring
condition of various vehicles aligned by the equipment and the
performance of the Wheel alignment centre on the whole.
Refer Chapter 7.6 for details

QUICK WHEEL This program can be selected in order to avoid elaborate alignment
ALIGNMENT
procedure and to save alignment time
Refer Chapter 7.5 for details.

SHUTDOWN

To Shutdown the program

To avoid damaging important files, it is necessary to shut down
Windows properly before turning OFF or restarting the aligner

Ref.: CCDWA - OM

39

SCREEN BUTTONS & ITS FUNCTIONS

To go to previous
screen

To redo Caster

To go to next screen

To view additional
parameter of Rear
wheels

To skip the current

operation

To view additional
parameter of Front
wheels

To go to Welcome
screen

To view Vehicle
specifications

To save the data

To view vehicle data

To print Data / Report

To add new Vehicle

data

To view the Report

To edit existing
vehicle data

To export as PDF
document

To export vehicle
data

Help

To save Vehicle
data

To select the Vehicle

To delete existing
vehicle data

To enter the Vehicle

data

To add User name

& password

To view / edit Vehicle

Inspection

To edit User name &

password

To redo alignment

To save User name

& password

To perform Runout

To delete User
name & password

To compensate the
uneven Lift platform at
different heights

Ref.: CCDWA - OM

40

7.4.

ALIGNMENT
Keep hands & other body parts away from jacking surfaces. Follow jack
manufacturers safety recommendations. Failure to comply may lead to injury
Press CTRL+S to save the data and come to Desktop during alignment
sequence
Battery status of all the Sensor arms will be indicated on Left & Right sides of
the Screen respectively
To view Battery & RF signal status, V key or RF SIGNAL & BATTERY STATUS
button can be pressed in any screen

If START ALIGNMENT button is pressed in the Welcome screen, User Login screen
will be displayed:

Fig. 45

Select the required User & key-in the password to enter into Vehicle selection screen:
Note: If no user ID is created, use Default user for further operation.

Fig. 46

Ref.: CCDWA - OM

41

7.4.1.

VEHICLE SELECTION
Select the Vehicle databank from the following options in the screen:
1.
European Vehicle data
2.
United States Vehicle data
3.
Brazilian Vehicle data
4.
Indian Vehicle data
5.
User defined Vehicle data
6.
Unspecified Vehicle data
On selection of required Vehicle databank, following screen will be displayed:

Fig. 47

Vehicle specifications can be selected between "Initial measurement

completed" and "Alignment completed" screens

7.4.1.1 NORMAL VEHICLE SELECTION (Without Ride height spec.)

For normal vehicles without Ride height specifications, click alignment
specification button to see the vehicle specifications. Vehicle
parameters are grouped as
(i) Primary angles as shown below:

Fig. 48

(ii) Secondary angles as shown below:

Fig. 49

Ref.: CCDWA - OM

42

Required specifications for the particular model can be viewed by

selecting respective options.
Press NEXT SCREEN to go to Customer data input screen (Refer
Chapter 7.4.1.3).
7.4.1.2 RIDE HEIGHT BASED VEHICLE SELECTION
Most of the International vehicle specifications prescribed by the
Manufacturers are dependent on Ride height measurement.
Variations in ride height may alter required specifications.
For vehicles with Ride height specifications, following Ride height
input screen will be displayed:

Fig. 50

Measure the points shown in the Car illustration and enter the height
in the respective boxes.
If the ride height values are not entered or not within
manufacturer's specified range, following message screen
will be displayed:

Ride height input is very important. If the input is skipped,

the entire alignment specification will go wrong

Press NEXT SCREEN to go to Customer data input screen.

Ref.: CCDWA - OM

43

7.4.1.3 CUSTOMER DATA INPUT

After Vehicle selection, following screen will be displayed.

Fig. 51

Enter the required input.

All the above data will be recorded in the Alignment report which can
be taken from the printed after completing the alignment.
System will not proceed further without input of Vehicle
Registration number in Customer data input screen
Customer data or Vehicle specifications can be edited or
selected respectively between "Initial measurement
completed" and "Alignment completed" screens

Press NEXT SCREEN after entering all the data to go to Vehicle

Inspection screen.
7.4.2.

VEHICLE INSPECTION
Vehicle inspection is not a mandatory process during alignment.
However this is a selectable feature to provide value added service

The different parameters for Pre-alignment, Tyre, Brake, Under hood, Under
car & General conditions for the Vehicle will be displayed in this window.

Fig. 52

Ref.: CCDWA - OM

44

Fig. 53

Fig. 54

Fig. 55

Fig. 56

Ref.: CCDWA - OM

45

Fig. 57

Check the condition of each parameter for the Vehicle and select the required
data to record in the Alignment report.
Press NEXT SCREEN button to Wheel Runout screen. Press PREVIOUS
SCREEN button to go back to previous screen.
7.4.3.

WHEEL RUNOUT
The purpose of this program is to find out the Wheel Runout (wobbling) and
effect the "Runout compensation" automatically in the subsequent programs
while Camber and Toe are measured / adjusted.
While doing Runout, do not jerk the Vehicle or the Arms which may
cause abnormal Runout

The following screen will be displayed if pre-loading is not necessary:

Fig. 58

Following screen will be displayed if the Vehicle requires pre-loading

as specified in the Alignment specification. Load the amount of
weight at indicated locations as displayed in the screen:

Ref.: CCDWA - OM

46

Two types of Runout measurement are available in our alignment program as

given below:
1.
Push-Pull Runout method (Rapid Runout)
Push-Pull Runout is a simple way to measure the Runout of the wheel in
a very shortest time by just pushing or rolling the vehicle as guided by
the screen. Runout of all the wheels will be captured simultaneously
and compensated in the wheel alignment process.
In PPR models, User the option to choose either Push-Pull
Runout or Four Point Runout method by toggling the RUNOUT
button. The Runout method adopted during previous
alignemnt will be displayed by default

2.

Four Point Runout method

In Four Point Runout, Vehicle should be jacked up & Wheel runout to be
measured individually for every 90 of rotation as guided by the screen.
Four Point Runout method is a selectable feature in PPR
models. For other models Four Point Runout is alone applicable

7.4.3.1 PUSH-PULL RUNOUT METHOD (applicable only for PPR models)

Lock the Rotary plates with Locking pins before parking the
Vehicle over the Rotary plate
Ensure the Vehicle is in neutral position with Hand brake
released
Place Wheel chocks before & behind Front & Rear wheels to
arrest excessive movement of vehicle
While moving the vehicle in Forward / Backward direction as
guided by the screen, DO NOT move the vehicle beyond the
target region to avoid from rolling off. Manufacturer is not
responsible for any damage or loss due to non-compliance
During Push-Pull Runout, DO NOT switch ON the engine
which will give wrong Runout measurement

Press NEXT SCREEN button to proceed.

Fig. 59

Ref.: CCDWA - OM

47

Press RUNOUT key in Sensor arm keypad or START RUNOUT

button to start Push-Pull Runout measurement.

Fig. 60

Push the vehicle backward until ball matches with target region.
Following screen will be displayed:

Fig. 61

Once the data is acquired, bring back the Vehicle to the centre of the
Rotary plate as guided in the following screen to match target region:

Fig. 62

Then the system will acquire data for compensating Runout.

To redo Runout, press PREVIOUS SCREEN button. Otherwise
proceed further. After measuring Runout, tighten the Sensor arm
knob.
Tighten the Sensor arm knobs once the Runout
measurement is completed

Ref.: CCDWA - OM

48

7.4.3.2 FOUR POINT RUNOUT METHOD

Make the Gear lever to Neutral position if the vehicle being
aligned is Rear wheel drive
Remove the Locking pins in the Rotary plates and apply
Brake pedal lock before jacking down
Loosen all the Sensor arm locking knobs before Runout
measurement

Press NEXT SCREEN button to proceed.

Press RUNOUT key in Sensor arm keypad or F1 key for Four Point
Runout measurement.
Rotate the wheel in CLOCKWISE direction as indicated by the
Flashing Arrow and bring the Bracket knob to 90. Hold the Arm in
Horizontal position and press RUNOUT key. Rotation of the wheel
should be done only when the Arrow blinks. Otherwise the Runout
values will be wrong.

Fig. 63

Do the above procedure for 180, 270 & 360 respectively and now
Runout is completed. Completion of Runout will be indicated by a
Tick mark over the respective wheels.
After each activity of Runout, either RUNOUT key available in
Arm keypad can be pressed or F1 (for left Runout) & F7 (for
Right Runout) button in Alignment screen can be pressed

If any of the wheels are abnormal, press REDO RUNOUT (Arrow

indication) to redo Runout for the particular wheel. To redo Runout
for all wheels, press PREVIOUS SCREEN button. Otherwise
proceed further. After measuring Runout, tighten Sensor arm knob.
Tighten the Arm knob in Horizontal position.
After the data is acquired, bring back the Vehicle to the centre of the
Rotary plate and follow the on-screen instructions.

Fig. 64

Ref.: CCDWA - OM

49

Lower the Wheel & apply Hand brake. Jounce the vehicle to free up
the joints.
Apply Brake pedal lock and remove the Rotary plate & Slider locking
pins and then jounce the vehicle. Ensure the level of Sensor arms
using spirit bubble.
Press HELP button to get Help
Press PREVIOUS SCREEN to go back to previous screen
Press WELCOME SCREEN button to go to Home screen
Press NEXT SCREEN to go to next program.
Tighten the Sensor arm locking knobs once the Runout
measurement is completed
Remove the Locking pins from Rotary plate once the Runout
measurement is completed

7.4.4.

CASTER & KINGPIN SWING

Caster and Kingpin angles are differential angles and cannot be measured
directly. Hence a sequence of procedure is required to measure the
parameters.
Do not jerk or shake the Steering wheel during data acquisition
Hold the Steering wheel at the end of each move to acquire stable
measurement of Caster / Kingpin. Do not rush into turns
During Left turn/Right turn/Straight Ahead, if there is any obstruction
of light beam between the Sensor arms, an error screen with No video
signal message will be displayed until the error is cleared
While working on Power steering vehicles, switch ON the engine
before fixing the Steering wheel lock in Straight ahead position
(ensure that Gear is in neutral position). The engine may be switched
"OFF" after Straight ahead is completed

7.4.4.1 ARMS HORIZONTAL

Fig. 65

This screen is meant to instruct the User to make Sensor arms

horizontal and delivers the simulation of Arm movements in the
Wheel bracket. When the Arms are made to perfect horizontal
position, the Arm tubes in the Screen will be in GREEN color (ie., 0 or
upto 10 minutes). If RED color is seen, move the Arms up or down
till the color changes to GREEN.

Ref.: CCDWA - OM

50

After making the Arms horizontal, lock them firmly using the Arm
knobs. In the same screen, Camera status will be displayed. If the
camera path is obstructed by some objects, status bar of that Camera
will be displayed in Red color. In such case, choose the Spoiler
option to lower the arms equally down until the Status bar glows in
Green color.
Before doing Arms Horizontal, ensure that the wheels are
more or less straight ahead
Ensure that the Brake pedal lock has been fixed properly
Tilting of Arms downwards upto -3 30' equally will not affect
the measurement.
Ensure that the Camera status is in Green color. If it is in
Red color, then the camera path is obstructed.
Lock Arm knobs firmly after achieving equal readings & both
Camera status are in Green.

7.4.4.2 TOE OUT ON TURNS & LOCK ANGLE MEASUREMENT (Optional

feature using Mechanical Rotary plate with Angle indicator)
The TOT/LA button will be displayed in the screen only if the
Optional feature is enabled and operated using Mechanical
Rotary plate with Angle indicator

Press TOE OUT TURNS / LOCK ANGLE button and key-in the initial
Rotary plate scale values in the respective box as shown below:

Fig. 66

Press NEXT SCREEN button. Readings will be displayed as shown

below:

Fig. 67

Press NEXT SCREEN button to go to Turn Left screen.

Ref.: CCDWA - OM

51

7.4.4.3 TURN LEFT

Fig. 68

In this screen, a Steering diagram can be seen and a Flashing arrow

will indicate the direction in which the wheel is to be turned.
Steer the wheels to left until the moving BALL fully matches the left
GREEN region. After reaching the Left Green region, the system will
display "Stop " icon and measures the parameters. After data
acquisition, system will automatically go to Turn Right screen.
7.4.4.4 TURN RIGHT

Fig. 69

Steer the wheels to right until the moving BALL fully matches the right
GREEN region. After reaching the Left Green region, the system will
display "Stop" icon and measures the parameters. After data
acquisition, system will automatically go to Straight ahead screen.
7.4.4.5 STRAIGHT AHEAD

Fig. 70

Ref.: CCDWA - OM

52

This screen is to instruct the User to bring the Front wheels to

Straight ahead position. Steer wheels until the moving BALL fully
matches the centre GREEN region.
When Straight ahead position is achieved, "Stop" symbol will appear
and stop turning the Steering wheel.
If the Straight ahead is disturbed, the symbol will vanish and the
arrows will blink and guides to indicate in which direction to turn the
Steering wheel to get back the Straight ahead position.
Now adjust the Steering wheel straight manually for fine adjustment
till the Red ball in the Green region reaches the centre white region,
followed by a "Stop" symbol and then goes to next screen.

Fig. 71

Lock the Steering wheel in straight position visually and then press
NEXT SCREEN button to view the Alignment results of existing
condition of the vehicle in Live mode.

Fig. 72

In Straight ahead condition, If horizontality of any one of

both Sensor arms are disturbed after fixing the Steering
lock, system will automatically prompt the operator to make
the "Arms horizontal" and press NEXT SCREEN button.
System enters into Straight ahead screen

Ref.: CCDWA - OM

53

7.4.5.

ALIGNMENT PARAMETERS & RESULTS

Following procedure needs to be carried out for the adjustments as per
Manufacturers specification
First perform Camber correction and then do Toe correction
TWO COLOR REPRESENTATION
While doing Caster, Camber & Toe correction, pointing Arrow sliding
over the Horizontal bar indicates specification range using different
colors as indicated below:
Color Indication
Red
Reading is not within required specification.
Green Reading is within specification & preferred value
White Specification is not available / required for parameter
A Spanner image displayed over the Parameters image means it is
adjustable. Hence by clicking the Spanner image, an animated movie
or sketch to explain the adjustment methods of alignment parameters
can be viewed as shown below:

In case if the Spanner image is crossed, parameter is not adjustable

Initial measurement results of existing vehicle condition will be displayed:

Fig. 73

Printout of the measurement results can be taken by pressing PRINT button.

Press NEXT SCREEN button to go to Rear wheel parameters screen.

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54

7.4.5.1 REAR WHEEL PARAMETERS

By pressing REDO ALIGNMENT button, complete alignment
sequence from Wheel runout screen can be repeated

Fig. 74

In this screen, Live readings of Rear wheel Camber and Toe will be
displayed. Effect the corrections in the Rear wheels until the GREEN
color at the Horizontal bar with the Arrow point to that region.
In case of alignment using Lift, compensate the uneven level
in the Lift platform by pressing LEVEL COMPENSATION
PROGRAM button. The following screen will appear to raise
the lift to adjustable position:

Press NEXT SCREEN button to return to Rear wheel

parameters adjustment. Then proceed with Front wheel
parameters adjustment procedure and finally by pressing
LEVEL COMPENSATION button again, following screen will
be displayed to lower the Lift as shown below:

Result printout can be taken during the Level compensation

program or even after lowering the Lift platform. Press NEXT
SCREEN button to go Front wheel parameters screen

In case of any specific adjustments needs to be done, press

ADJUSTMENT TYPES button for On-screen guidance for Camber
and Toe in Wheel raised condition (refer chapter 7.4.5.4).
Tighten the Lock nuts.

Ref.: CCDWA - OM

55

Press ADDITIONAL PARAMETER button to view Rear wheel Total

Toe & Thrust angle as shown in the Rear wheel parameters screen.

Fig. 75

Press ADDITIONAL PARAMETER button to view the Rear Wheel

Setback & Track width difference as shown in the following screen
(This features is applicable only for Premium Plus models).

Fig. 76

The Track width difference will be displayed as Positive angle, if the

Rear Track width is more than the Front Track width and as negative
angle if the Front Track width is more than the Rear Track width.
Press PREVIOUS SCREEN to return to the Rear Wheel parameters
correction screen.
During Rear wheel Toe correction, if any obstruction exists
in between the two Sensor arms, following "Attention"
screen will appear until the error is cleared. Otherwise
alignment cannot be proceeded further

Ref.: CCDWA - OM

56

By clicking the Parameters image in the centre of screen, a

zoomed image of the respective reading will be displayed

NEXT key in Sensor arm keypad can be used to view next

screens. PREV key can be used to escape from Zoom option

After adjustment of Rear wheel parameters, press NEXT SCREEN

button to go to Front wheel parameters screen.
7.4.5.2 FRONT WHEEL PARAMETERS
By pressing REDO ALIGNMENT button, complete alignment
sequence from Wheel runout screen can be repeated

Fig. 77

This screen displays the Live readings of Caster, Camber and Toe.
Effect the corrections in the Front wheels until the GREEN color at
the Horizontal bar with the Arrow point to that region.
In case of any specific adjustments needs to be done, press
ADJUSTMENT TYPES button for On-screen guidance for Camber
and Toe in Wheel raised condition (refer chapter 7.4.5.4).
Press ADDITIONAL PARAMETER button to view Kingpin, Runout &
Setback values. Out of these three, Runout & Setback are having
compensation with Camber and Toe respectively.

Fig. 78

Ref.: CCDWA - OM

57

In case of Toe Out on Turns & Lock Angle measurement is

opted during Caster & Kingpin swing sequence, following
screen will be displayed:

Key-in the final Rotary plate scale values after adjustment

(as explained in Chapter 7.4.5.4) in the respective box and
the final readings will be displayed
By clicking the Parameters image in the centre of screen, a
zoomed image of the respective reading will be displayed

NEXT key in Sensor arm keypad can be used to view next

screens. PREV key can be used to escape from Zoom option
While adjusting Caster, Toe may get slightly affected.
Similarly, while doing Camber & Toe, since both are Wheel
angles, one may get affected while adjusting the other.
Therefore, ensure all angles are OK before locking Lock
nuts & completing alignment. Otherwise, do some finer
adjustments to get everything OK
During Caster, Camber & Toe correction, if any obstruction
exists in between two Sensor arms, following "Attention"
screen will appear until the error is cleared. Otherwise
alignment cannot be proceded further.

For Caster correction, adjust the Caster by the method

specified by manufacturer

Ref.: CCDWA - OM

58

Live Caster is measured by detecting forward and backward

rotation of wheel. For that, it is important the arms are not
disturbed. If any mistake is done during this activity, you
may get wrong Caster values. To verify, press REDO
CASTER button to redo the Caster measurement again. Then
proceed to steps explained in Chapters 7.4.4.3, 7.4.4.4 &
7.4.4.5 to get the Caster values. System will come to Front
wheel parameters screen & will display new values of Caster
If Toe value to be displayed mm mode, click the mouse
pointer on the MM selector and feed the diameter of the RIM
size in inches. The display will be changed to mm. If the
display is to be changed to degree mode again, click on the
Deg selector
On cars with Rack and Pinion steering, a bump steer
condition is usually created by worn rack mounting
bushings that allow the entire rack to shift when bumps are
hit. Some vehicles have slotted Idler arm mounts to allow
correction of Toe curve change problems
In certain Cars where suspension work is done, Front wheels
may have excessive Toe setting. This may lead to problems
in achieving Straight ahead position. Operator is alerted as
shown below:

The procedure to be adopted in such a situation is to first

bring the Steering wheel to Straight ahead position and lock
it in that position using Steering wheel lock. Then proceed
with adjustment & set the required Toe in a single operation.
In cases where there is no excessive Toe, there is no change
in the procedure
During adjustment, when large corrections are made to
Caster, Camber or Toe, the Arms horizontality may get
disturbed in most cars. This results in inaccurate Toe
setting, since it is one parameter which depends very much
on how well the Arms are kept in horizontal position.
The Operator is alerted if such a situation arises by
displaying a message that the Arms horizontal has been
disturbed when NEXT SCREEN button is pressed after
correcting all the parameters.
Values in Horizontal bars are minimum & maximum values of
the corresponding Wheel parameters.
This message is shown only in conditions when the
horizontality of any or both Arms are lost by more than 20
minutes. The Operator is advised to make the Arms
horizontal and re-adjust the Toe to required values

Press NEXT SCREEN to complete alignment & go to Results screen.

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59

7.4.5.3 RESULTS
Data from alignment results are forwarded to the Wheel
aligner Data Manager only when HOME button is pressed at
the end of wheel alignment in Alignment completed screen

The following Reports are provided to print the alignment results:

1.
Standard printout - Results of Camber, Caster, Kingpin, Toe,
Thrust angle & Setback

Fig. 79

2.
3.

Additional printout - Results of Toe Out on Turns, Lock Angle

and Tyre & Bearing conditions
3D printout - Pictorial representation of Camber, Caster,
Kingpin, Toe, Thrust angle & Setback

Fig. 80

4.
5.
6.
7.
8.
9.

Pre-alignment inspection report - Present condition of

Vehicles recorded and stored
Tyre inspection report - Present condition of Tyre recorded
and stored
Brake inspection report - Present condition of Bake & related
parts recorded & stored
Under hood inspection report - Present condition of Vehicle
Under hood components recorded & stored
Under car inspection report - Present condition of Vehicle
Under car parts recorded & stored
General inspection report - Present condition of Vehicle
lightings & fittings recorded & stored

Printout of the Alignment results can be viewed or printed by pressing

PRINT button.
PDF file can be created and stored in the system using the SAVE TO
PDF icon.

Ref.: CCDWA - OM

60

Press HOME button and then select TICK mark to forward the
alignment reports to Data Manager program and return to Welcome
screen as shown below:

Fig. 81

This completes the Four wheel alignment.

7.4.5.4 ADJUSTMENT TYPES
The adjustment of vehicle parameters may vary depending upon the
vehicle construction. Following adjustment types are provided:

Fig. 82

Ref.: CCDWA - OM

Single Tie rod adjustment

Toe curve adjustment

Elevated Front Camber

Elevated Rear Camber

Elevated Front & Rear

Caster/Camber/Toe

61

1.

SINGLE TIE ROD ADJUSTMENT

Some of the earlier design of trucks and 80s generation of
vehicle have a single tie adjuster for Total Toe with no provision
for adjusting steering direction. For these type of vehicles,
select SINGLE TIE ROD ADJUSTMENT button and follow the
procedure given below:
Steer the Front wheels to bring the Toe reading to zero. Lock
the Steering wheel at this position. Once zero reading is
achieved, Total Toe readings will appear on top window.

Fig. 83

Adjust the Single tie rod to Total toe specifications displayed.

If Steering straight ahead is still not achieved, remove Steering
wheel from the steering column (see Vehicle recommended
procedures prior to removal) and re-fix it properly.
2.

TOE CURVE ADJUSTMENT

To measure the changes occur in individual Toe due to jounce/
rebound of suspension. An excessive amount of change in
individual Toe may cause early Tyre wear. Excessive change
on one side alone may cause the vehicle to rapidly change
directions when bumps are encountered.
There are no specifications prescribed by the Manufacturer for
the amount of change. The Toe changes should be fairly
minimum, and a comparison of Left and Right wheels will assist
in diagnosing the defective Steering system components.
Follow the on-screen instructions carefully to raise the
suspension to 60mm by pushing down / lifting up the
Suspension using a Scale or Measuring tape to observe the
proper amount of frame movement :

Fig. 84

Ref.: CCDWA - OM

62

The difference in individual Toe will be displayed as shown

below:

Fig. 85

Make the required adjustments / changes to bring down the

difference to fairly minimum and then bring the vehicle to
normal position.

Fig. 86

3.

ELEVATED FRONT & REAR CASTER / CAMBER / TOE

Keep hands & other body parts away from jacking
surfaces. Follow jack manufacturers safety
recommendations. Failure to comply may lead to
human injury
While jacking up the vehicle, the vehicle should be
stable and do not apply any external force which may
shake the vehicle and subsequently the readings will
be affected
In certain vehicles, the Left and Right wheels cannot
be jacked up simultaneously due to their construction.
In such vehicles, the Left and Right wheels have to be
jacked up individually and the Camber correction
should be performed for both wheels separately as
described above

Ref.: CCDWA - OM

63

Following screen will be displayed to jack up the vehicle:

Fig. 87

Press NEXT SCREEN button

Live values of Front / Rear wheel parameters can be viewed by
pressing FRONT PARAMETER / REAR PARAMETER button
respectively for further adjustment.
By default, Front wheel parameters will be displayed in the
screen. The values will automatically be set to the initial values
shown when wheels were resting on the Rotary plates or floor.

Fig. 88

Now adjust the Front wheel parameters to achieve the specified

value.
To adjust Rear wheels press REAR PARAMETER button. Live
values of Rear wheel parameters will be displayed in the
screen. The values will automatically be set to the initial values
shown when wheels were resting on the Rotary plates or floor.

Fig. 89

Ref.: CCDWA - OM

64

Now, adjust the Rear wheel parameters to achieve the specified

value and press NEXT SCREEN button. Jack down and
jounce the vehicle message will be displayed.

Fig. 90

Values that are adjusted during raised position will be restored.

4.

ELEVATED FRONT CAMBER

Following screen will be displayed to jack up the vehicle:

Fig. 91

Press NEXT SCREEN button.

Live Front Camber values will be displayed in the screen. The
values will automatically be set to the initial values shown when
the wheels were resting on the Rotary plates or floor.

Fig. 92

Ref.: CCDWA - OM

65

Now, adjust the Front Camber to achieve the specified value

and press NEXT SCREEN button. Then Jack down and
jounce the vehicle message will be displayed:

Fig. 93

Values that are adjusted during raised position will be restored.

5.

ELEVATED REAR CAMBER

Following screen will be displayed to jack up the vehicle:

Fig. 94

Press NEXT SCREEN button.

Live Rear Camber values will be displayed in the screen. The
values will automatically be set to the initial values shown when
the wheels were resting on the Rotary plates or floor.

Fig. 95

Ref.: CCDWA - OM

66

Now, adjust the Rear Camber to achieve the specified value

and press NEXT SCREEN button. Then Jack down and
jounce the vehicle message will be displayed:

Fig. 96

Values that are adjusted during raised position will be restored.

7.5.

QUICK WHEEL ALIGNMENT

Quick wheel alignment can be performed only in LCVs and HCVs with single
rear axle

Quick wheel alignment refers to alignment of a vehicle in the shortest possible time.
The normal alignment sequence is shortened by skipping some of the steps and
Attention screens in the alignment process and keeping only the required process.
User can customize the program sequence to their preference as explained in Quick
wheel alignment settings (Refer Chapter 8.1 of Service manual). Later, based on the
requirement user can choose the particular customised alignment program to proceed
with Quick wheel alignment.

Ref.: CCDWA - OM

67

7.6.

DATA MANAGER
This software will work only on Wheel aligner machine
Data from alignment results are forwarded to the Wheel aligner Data Manager
only at the end of wheel alignment in the Alignment completed screen

Data Manager is smart software developed for the purpose of managing alignment
results which are generated by Wheel aligner. This software runs under Windows
platform and provides menu driven, user friendly Graphical User Interface.
This software is designed to retrieve the stored alignment results and to generate
reports. The following screen is the Opening screen of this software.

Fig. 97

Four options will be displayed:

1.
Date based Alignment report
2.
Registration Number based Alignment report
3.
Year based Alignment report
4.
Technician based Alignment report
5.
Customer database
6.
Reminder to Customer
7.6.1.

DATE BASED ALIGNMENT REPORT

Upon selection of Date based Alignment report, a Date window will appear:

Fig. 98

Select the required From and To date between which Alignment results
have to be viewed and press NEXT SCREEN button.

Ref.: CCDWA - OM

68

Following screen will be displayed:

Fig. 99

Fig. 100

The list of alignments conducted within the provided date will be displayed Job
number wise. By selecting "Front" / Rear tab in the screen, results of
respective wheel parameters can be viewed.
Press VIEW button to view the Date based reports as shown below:

Fig. 101

Press PRINT button to print the report.

Ref.: CCDWA - OM

69

7.6.2.

REGISTRATION NUMBER BASED ALIGNMENT REPORT

This report helps the user in deciding the frequency of the alignment made for
the selected vehicle.
Upon selection of Registration number based Alignment report icon, a Pull
down list of Vehicle Registration Numbers for which alignment carried out so
far will be displayed as shown below:

Fig. 102

Select the required Vehicle Registration number and press NEXT SCREEN
button. Following screen will be displayed:

Fig. 103

Fig. 104

The list of alignments conducted for the selected Vehicle registration number
will be displayed based on Job number. By selecting "Front" / Rear tab in
the screen, results of respective wheel parameters can be viewed.

Ref.: CCDWA - OM

70

Press VIEW button to view Registration No. based reports as shown below:

Fig. 105

Press PRINT button to print the report.

7.6.3.

YEAR BASED ALIGNMENT REPORT

Upon selection of Year based alignment report icon, a Pull down list of year
for which alignment carried out so far will be displayed as shown below:

Fig. 106

Select the required Year and press NEXT SCREEN button.

Press VIEW button to view the Year based alignment report as shown below
which helps the user in getting the No. of alignments achieved in a year
(Month wise):

Fig. 107

Press PRINT button to print the report.

Ref.: CCDWA - OM

71

7.6.4.

TECHNICIAN BASED ALIGNMENT REPORT

Upon selection of Technician based alignment report icon, the available
Users list will be displayed:

Fig. 108

Select the required User, From & To date and then press NEXT SCREEN
button. Then press VIEW button to view the number of alignments
(consolidated) conducted by the selected User as shown below:

Fig. 109

Operator can also choose ALL USER to view the number of

alignments (consolidate) conducted by each user

Press PRINT button to print the report.

7.6.5.

CUSTOMER DATABASE
Upon selection of Customer database icon, a Date window will be displayed.
Select the required From and To date and press NEXT SCREEN button:

Fig. 110

Ref.: CCDWA - OM

72

Press VIEW button to view the date based Customer details as shown below:

Fig. 111

Press PRINT button to print the report.

7.6.6.

REMINDER TO CUSTOMER
This option is provided to the user to generate Reminder letters to his
customers on daily basis. The system followed is, when he runs this option on
a particular date, the system will automatically generate Reminder letter for
the vehicles aligned exactly 90 days back.

Fig. 112

Press PRINT button to print the report.

Press HOME button and then select TICK mark to exit from Data Manager
program and return to Welcome screen as shown below:

Fig. 113

Ref.: CCDWA - OM

73

7.7.

SETTINGS
You can enter into this Option by clicking SETTINGS in the Welcome Screen and by
providing the Password.

Fig. 114

The following Menu will be displayed:

Measurement units
Vehicle
specifications
Ref. Chapter 7.7.1 Ref. Chapter 7.7.2

Restore calibration
data
Ref. Chapter 7.7.3

Quick wheel
alignment settings
Ref. Chapter 8.1 of
Service manual

Push-Pull Runout
(PPR) calibration
Ref. Chapter 7.2 of
Service manual

Workshop
Passwords
information
Ref. Chapter 7.7.4 Ref. Chapter 7.7.5

Calibration history

RF Channel setting

Ref. Chapter 7.7.6

Ref. Chapter 8.2 of

Service manual

Electronic Rotary
plate calibration
Ref. Chapter 7.3 of
Service manual

User Login

Arm communication Calibration certificate Sensor arm board ID

Four shaft
check
calibration
setting
Ref. Chapter 7.7.7 Ref. Chapter 7.7.8 Ref. Chapter 7.4 of
Ref. Chapter 8.3 of Ref. Chapter 7.1.2
of Service manual
Service manual
Service manual

Reset Job number

Testing options

Camera testing

Ref. Chapter 7.7.9 Ref. Chapter 7.7.10 Ref. Chapter 8.4 of

Service manual

Ref.: CCDWA - OM

Left/Right Steering
wheel setting
Ref. Chapter 8.5 of
Service manual

Single shaft
calibration
Ref. Chapter 7.1.1
of Service manual

74

7.7.1.

VEHICLE SPECIFICATIONS
The Vehicle specification data must be entered by End user only.
MANUFACTURER IS NOT RESPONSIBLE FOR ANY INCORRECT OR
INCOMPLETE VEHICLE SPECIFICATIONS ENTERED / AVAILABLE IN
THE SYSTEM. No claim is entertained for any damage or loss

Fig. 115

7.7.1.1 EUROPEAN / BRAZILIAN / UNITED STATES VEHICLE DATA

Fig. 116

The readily available vehicle specifications that are compiled and

released by Third parties with License can be directly uploaded in our
system. These vehicle specifications are updated & released twice
every year at extra cost. These data are non editable but the User
can select the required vehicles from the list & export it by pressing
EXPORT TO USER DATA button to User data for edit & customizing
the specification.
Vehicle data can be exported to User data for modifying the
data while doing alignment for customised vehicles

7.7.1.2 INDIAN VEHICLE DATA

The Indian data contains specifications of known vehicles collected
by Manufacturer with update available at the time of despatch.
However Manufacturer is not responsible for any incorrect or
incomplete vehicle specifications available in the Indian data.

Ref.: CCDWA - OM

75

7.7.1.3 USER DEFINED VEHICLE DATA

The vehicle specifications collected by the User can be added /
modified / viewed using this option as given below:

Fig. 117

Following options are provided:

Add specification - To add new Vehicle specifications
Edit specification - To modify the existing vehicle specifications
Delete specification - To delete the existing vehicle specifications
Select the required options based on specifications to be entered:

Fig. 118

For HCV vehicles, specification for all the wheels will differ,
In such case, Individual specifications option can be
selected

COMMON SPECIFICATIONS (LEFT / RIGHT)

By selecting this option, screen displays the following Data sheet in
which the details of specifications are to be filled:

Fig. 119

Ref.: CCDWA - OM

76

The user has to keep ready all these information before starting to
add any Vehicle specifications.
1.
VEHICLE MAKE
Type Vehicle make and press ENTER to go to the next window.
2.
VEHICLE MODEL
Type Vehicle model and press ENTER to go to next window.
3.
TOE IN DEGREES / MM / INCHES (D,M,I) ?
The TOE values of the vehicle can be entered in degree (or)
mm (or) inch. To intimate the system about the TOE input
unit, enter "D" for Degrees, "M" for mm and "I" for inches.
Press ENTER to move to next window. This window cannot be
left blank. A beep sound will be heard it attempted.
4.
RIM DIAMETER
If the Toe unit is entered as mm or inch, then the Rim
Diameter of the vehicle has to be entered. If this window is not
filled, the system will not allow you to proceed further.
Alignment specifications
Each and every angle has been provided with four data entry
windows. First two for the Front` wheels and other two for Rear
wheels. Two windows are given for each wheel to enter the
Maximum and the Minimum permissible reading.
5.
CASTER
Enter the Minimum allowable Caster for that vehicle in first data
window. Enter the Maximum allowable Caster in second
window. As Caster is not applicable for Rear wheels, system
will prompt "N/A" in the other two Rear wheel windows, so you
can't enter any data in these windows.
6.
KINGPIN
Follow the same procedure as done in Caster. Kingpin is also
not applicable for Rear wheels, so "N/A" will be displayed in the
Rear wheel windows.
7.
CAMBER
Enter Camber readings as per procedure for both Front & Rear
wheels.
8.
TOE
There are three options for entering Toe readings. Any one of
the options can be chosen according to the requirement. i.e., if
'D' is entered in "Toe in degree / mm / inch (D,M,I) ?" Data
window, then Cursor will be taken to Toe in Degrees Data
window.
If "M" is entered, then the cursor will be placed in the Toe in
MM data window and for "I", it will be Toe in Inches data
window. The windows other than the selected will have "----" in
them.
9.
TOTAL TOE
For some vehicles only Total Toe values are only known. In
that case, enter the readings in these windows. Here also three
options are provided as in the case of Toe.
If the Toe / Total Toe values are entered in "mm" "Inches",
the system will convert it to "degree & minutes"
If Toe values are entered first, then Total Toe will be
calculated by the system itself from the entered Toe value &
displayed in Total Toe window and vice versa if Total Toe
value is entered first

Ref.: CCDWA - OM

77

INDIVIDUAL SPECIFICATIONS (Left / Right) (only for HCV

vehicles)
To add new specifications, select "Add Make/Parameter" as below:

Fig. 120

The screen displays the above Data sheet in which the details of
specifications are to be filled. The user has to keep ready all these
information before starting to add / modify any Vehicle specifications.
7.7.2.

MEASUREMENT UNITS
This option is used to change the measurement units like degree min" /
degree / mm" / inch and other angles in degree / degree min, kg lb

Fig. 121

7.7.3.

RESTORE CALIBRATION DATA

This option is provided to backup / restore the Calibration data between
alignment units & external devices, if the existing files are modified or
corrupted or in case of re-installation.
Following are the options provided:

Fig. 122

Ref.: CCDWA - OM

78

7.7.3.1 BACKUP CALIB DATA FROM PC TO SENSOR ARM

This option is used to backup the Calibration data from Desktop
Computer to Sensor arms
A backup is stored in local HDD of Personal computer.

Fig. 123

Select the respective Sensor arm in which the data backup is to be

done and click SAVE button. After taking backup, a tick mark will
appear in the respective Sensor arm.
7.7.3.2 RESTORE CALIB DATA FROM SENSOR ARM TO PC
This option is used to restore the Calibration data from Sensor arms
to Computer.

Fig. 124

Select the respective Sensor arm from which the calibration data is to
be restored and click SAVE button. After restoration, a tick mark will
appear in the respective Sensor arm.
7.7.3.3 RESTORE FACTORY CALIBRATION DATA TO PC
This option is used to restore the original Calibration data from the
Optical media provided by Manufacturer to Desktop Computer.
The system will prompt to locate the source of calibration files for
restoration. Files are provided along with Aligner in an Optical media
format. Also a backup is stored in local HDD of Personal computer.

Fig. 125

Ref.: CCDWA - OM

79

7.7.3.4 BACKUP CALIB DATA FROM PC TO OTHER LOCATION/DEVICE

This option is used to backup the Calibration data, User defined
vehicle data, International vehicle data, User settings & Data
Manager from Desktop computer to other locations in the HDD or
other external devices like USB drive or Optical media.
Choose the location in which data is to be saved & click SAVE button.
7.7.3.5 RESTORE CALIB DATA FROM OTHER LOCATION/DEVICE TO PC
This option is used to restore the Calibration data, User defined
vehicle data, International vehicle data, User settings & Data
Manager from other locations in the HDD or other external devices
like USB drive or Optical media to Desktop computer.
Choose the location from which data is to be restored & click SAVE
button.
7.7.4.

WORKSHOP INFORMATION
This Option is used to enter the Customer Name and address of the Alignment
Centre and password settings. Customer can also add Logo of their Service
centre to appear on the top left corner of the printout.

Fig. 126

After entering the data, click SAVE button on the screen to save the data.
7.7.5.

PASSWORDS
This option is provided to activate the optional features from field and to reset
the User password: The Optional features available in alignment programs
are controlled using built-in hardware lock. The user himself can activate the
required Optional feature by paying additional cost and sending the Hardware
lock number along with Machine Serial Number to Manufacturer. Upon
receiving the key code from Manufacturer, select the respective feature in the
screen and enter the Key code and then press SAVE button.
Following are options provided, if Passwords is selected from Settings menu:

Fig. 127

Ref.: CCDWA - OM

80

7.7.5.1 SETTINGS PASSWORD

This option is provided to set password for accessing the settings.

Fig. 128

Current password will be displayed. User will be prompted to enter

the new password. If password is correct, the operator will then be
prompted to enter the New password again for confirmation
If the re-entered password is not correct, "Re-enter.
Password does not match" message will be displayed

After re-entering the new password correctly, click SAVE to save the
password (Factory set default password is "supervisor").
7.7.5.2 VEHICLE DATA PASSWORD
This option is provided to activate the International Vehicle data that
are compiled & released by Third parties with License. These vehicle
specifications are updated & released twice every year at extra cost.

Fig. 129

This screen will display the status and then the Year of Vehicle data
update available in the system. To activate Vehicle data for the
displayed year, User can purchase the key code from Manufacturer
for that particular year & key-in for activation.

Ref.: CCDWA - OM

81

In case if User prefers to get the latest update available as of date,

first install the purchased vehicle data software as explained in
Chapter 6.2 (software installation) of Service manual and then enter
the key code provided along with the software and press SAVE
button.

Fig. 130

If the customer operates recently purchased Aligner (loaded with

latest vehicle data) with an old RF unit, user can either purchase/
provide the Key code for that latest update and activate the same or
install the RF unit compatible Vehicle data software & activate it.

Fig. 131

Fig. 132

Ref.: CCDWA - OM

82

7.7.5.3 ELECTRONIC TURN TABLE (ERP) PASSWORD

This option is provided to activate the measurement of Toe out On
Turns and Lock Angle for Front wheels using Electronic Rotary plate.

Fig. 133

This screen will display the status of availability. In case of activation,

User will be prompted to enter Key code obtained from Manufacturer.
7.7.5.4 RAPID / PUSH-PULL RUNOUT (PPR) PASSWORD
This option is provided to activate the Push-Pull Runout feature.
Push-Pull Runout feature is set at Factory itself for PPR
models

Fig. 134

This screen will display the status of availability. In case of activation,

User will be prompted to enter Key code obtained from Manufacturer.
7.7.5.5 MECHANICAL TURN TABLE (with Angle indicator) PASSWORD
This option is provided to activate the measurement of Toe out On
Turns and Lock Angle for Front wheels using Mechanical Rotary plate
with Angle indicator.

Fig. 135

This screen will display the status of availability. In case of activation,

User will be prompted to enter Key code obtained from Manufacturer.
Ref.: CCDWA - OM

83

7.7.6.

CALIBRATION HISTORY
The details of calibration done so far can be viewed in Calibration history.

Fig. 136

To take a printout, press PRINT button or to save it in the system, press SAVE
TO PDF icon in the screen.
7.7.7.

USER LOGIN
This option is used to create User accounts to operate the system. In this
user can also edit or delete the existing accounts.

Fig. 137

7.7.8.

ARM COMMUNICATION CHECK

This Option is provided to check & ensure the communication between the
Sensor arms and Computer.

Fig. 138

The data communication can be viewed by pressing the relevant Sensor arm
and enabling the Sensor data option. The status of the communication trials
will be displayed in the Status window.

Ref.: CCDWA - OM

84

7.7.9.

RESET JOB NUMBER

Job Number is a Serial number which is automatically generated by system for
each alignment job. This option is useful to reset the Job number to 0001. If
this option is selected, confirmation will be requested to reset Job Number. If
YES is selected, Job number will be reset. Press NO to skip current operation.

Fig. 139

7.7.10. TESTING OPTIONS

This option is provided to test the functions of Sensor arm keypad and Buzzer.

Fig. 140

7.7.10.1 KEYPAD TESTING

The function of Sensor Arm keys in the keypad can be tested by
pressing the keys and the respective key will blink in the screen.

Fig. 141

Ref.: CCDWA - OM

85

7.7.10.2 BUZZER TESTING

Buzzer function can be tested by selecting the respective Sensor arm
in the screen and audio can be heard from the respective arm.

Fig. 142

7.8.

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

Fig. 143

After setting the language, press SAVE button

Ref.: CCDWA - OM

86

8.

MAINTENANCE
Turn OFF the MCB switch and unplug the Aligner before doing any maintenance or
repair work

The equipment requires only minor maintenance to keep the equipment operating properly.
We recommend attention to the following points for getting maximum benefit out of the
equipment.
1.

Keep the area around the Aligner clean. Remove any tools or other items that are leaning
against the Aligner.

2.

Use only recommended Accessories / Spares. Accessories from other manufacturer may
not fit or function properly and may damage the equipment.

3.

For continuous protection against fire hazard replace the Control fuses only with same
type and rating of CE marked Fuse.
Control fuse F1
3A, Dia 5 mm x 20 mm, Slow blow type Glass fuse
Control fuse F2
5A, Dia 6.35 mm x 31.8 mm, Slow blow type Glass fuse
Control fuse in Sensor arm 1A, Dia 5 mm x 20 mm, Slow blow type Glass fuse

4.

Protect the System from direct sunlight.

5.

Do not attempt to open the System cabinet / Interface box / Sensor arms for any reason
as you may spoil the Electronic circuit and components. In case of any fault, please call
Service Engineer.

6.

Clean the System once or twice a day using a soft cloth. DO NOT wash the system using
Water.

7.

Clean the visible glasses in the Sensor arms regularly using a soft cloth.

8.

Clean the Sensor arm Keypad / Keyboard with Non-solvent, Non-abrasive cleaner. DO
NOT use cleaning agent which attacks the keypad and could result in equipment damage.

9.

Protect the Rotary plates from dust. Foreign particles / dust may affect the rotation,
leading to wrong Caster / Kingpin readings. Service the Rotary plates once in 3 months.

10.

Clean the Wheel Brackets periodically and lubricate for smooth functioning.

11.

DO NOT try to charge the batteries with any other Charging equipments.

12.

Replace the Batteries only with same Volts and current ratings.
Specifications: Type
: Valve regulated Lead Acid
Volts
: 6.0V
Ampere / Hour : 7.2 AH / 20 Hr
Terminal
: Snap on plug type
Dimensions
: 125 mm (L) x 32 mm (W) x 60 mm (H)
DO NOT try to clean or disassemble the battery as it could result in the leakage of sulfuric
acid resulting in acid burns.

13.

Keep the System covered when not in use to avoid dust.

14.

Keep the System away from Moisture.

Ref.: CCDWA - OM

87

9.

TROUBLE SHOOTING
The common troubles and error messages which can be attended by the users are listed in the
table given below.
For Troubles and Error messages other than that are listed in the table contact the Service
Engineer for Trouble shooting.
The Service Engineer may ask for information to help in diagnosing the service
concern. Conveying this information to the Service Engineer prior to servicing can help
to expedite service to your equipment

9.1.

HARDWARE TROUBLE SHOOTING

EQUIPMENT
Sl.
No.

Trouble

Causes

Remedies

When System is
switched ON, no beep
sound and No display

Power socket problem or

Insert the equipments Power
loose connection in the Power cord to another Plug points
socket plug point
power socket & check it

Still problem persists

Connect a Test lamp at the

UPS may be defective. i.e, No
output socket of UPS and ensure
output from the UPS
whether UPS is OK. If not
replace the UPS
Loose connection in Fuse /
Fuse may be blown off.

All the external

parameters have been
ON/OFF Switch or Power
checked. But the display supply board may be faulty
problem remains as it is

Check the status of Fuse and

replace it
Get the problem solved through
Service Engineer

When equipment is
Monitor may be switched OFF Switch ON the Monitor and
switched ON, only Audio
or Power supply to Monitor
Check the Power LED is ON. If
sound is noticed. But no
may got disconnected.
not, replace the Power cord.
display in Monitor
Monitor Power LED
2 blinking in Standby
mode. But no display

Loose connection in the

Monitor data cable

Monitor may be defective

No loose connection in
Data cable. Still the
display problem persists Computers Internal system
may be defective

Electrical Shock
observed in the system

Switch OFF the system, remove

the 15 Pin data cable and
reconnect it to the system with
correct polarity
Replace a monitor from other
computer and check for it
Get the problem solved through
Service Engineer

No Earthing or loose contact

Get the problem solved through
in the Earthing point of switch
Qualified personnel
board
Earth terminal in Power cord
may have intermediate cut

Replace the Power cord

Switch OFF the system and

Any keys in the Keyboard may
release the struck keys and
Keyboard error message be in pressed condition
again switch it ON
4 displayed when system is
Replace with any other PS/2 or
switched ON
Keyboard may be defective
USB type keyboard or get it
solved by Service Engineer

Ref.: CCDWA - OM

Camera obstruction
error signal displayed at
Turn left / right
screen(NV / MS error)

May be due to dust particle

deposition in Cameras dust
prevention glass. External
Sun light reflection/ Stone
guard self reflection

Clean the dust with a soft cloth

Enable the multiple spot
program in the settings option.

If the problem is still not

solved by cleaning the
Dust prevention glass

Camera path may be

obstructed due to Low body
vehicles or due to any
reflection

Spoiler program can be used to

overcome this problem

88

Sl.
No.

Trouble

Causes

Remedies

Battery voltage may be low.

IR LED (Light) just above the
The problem still persists
Recharge the Sensor arms by
camera may not be working.
even by using Spoiler
placing it in the Charging tray or
Not Enabled the multiple spot
program up to 3.5 down
get it solved through Service
program in the setting option.
Engineer

Arms Horizontal may got

disturbed

Correct the Arms horizontal and

to zero level.

May be due to any reflection

from the vehicle body

Select spoiler program and

complete the alignment

May be due to any external

light source affecting the
Rear camera operation

Block the external light source

to solve the problem.
Enable the multiple spot
program in the settings option.

May be due to dust

deposition in Rear cameras
Dust prevention glass

Clear the obstruction by

cleaning it with a soft cloth

Low Battery indication

always displayed

Sensor arms may not be

located properly on the
Charging tray

Once again rest the Sensor

arms properly on Charging tray
and ensure that the Charging
LED (Yellow) is ON. After
complete recharging of battery,
redo the alignment process

The problem persists

even after complete
charging

May be due to any technical

problem in the Sensor arms
internal circuit

Get the problem solved by

Service Engineer

Problem may be in Charging

tray

In alignment screen press

CTRL+V to view the charge
level. If the level is found to be
week, place the sensor arm
straight to the charging tray.

Battery may be defective

Replace the battery with same

specification

May be due to week signal

strength

Shift the Sensor arm to the next

Charging tray and allow it to
charge for 4 hours. If problem
is not solved, get it solved by
Service Engineer

Sensor arm fuse holder may

be having loose contact

Tighten Fuse holder manually.

Also, once the Sensor arms are
lifted from the Charging tray
ensure the Green LED is ON

At straight ahead
position, Unable to
match the ball.

During Alignment
camera obstruction
signal was noticed
intermediately

Always fast discharging

takes place in any one
of the Sensor arm
battery.
9
Battery charge level, for
all Sensor arms found
to be OK. But still
problem remains
unsolved

Autoretrieving data
from/Timeout error
(FLA, FRA, RLA, RRA)

Sensor arm may not get

charged properly. Check
whether battery low status
LED is on.

Still the Autoretrieving

data / Timeout error
occurs intermediately

External RF interference
Hi powered Wi Fi signal
presence

10

Ref.: CCDWA - OM

Due to power failure or

improper fixing of arms in
Charging tray, over night
charging may not happen.
Recharge it again
RF Transceiver / USB having Fix these connectors firmly.
loose contact in the interface
box
Check for high powerful
2.4GHz RF transmitter near by
area

89

Sl.
No.

Trouble

11 Multimedia speaker not

working

Causes

Remedies

Same RF channel used

wheel aligner presence in
within the area of 100meters
RF transceiver and sensor
arm is not in line of site
Technical problems in
Internal circuit boards

Change the RF channel above

10 in the wheel aligner.
Avoid too much of metal
obstruction between the RF
Transceiver and sensor Arms
.Get the problem solved by
Service Engineer

Input supply to speaker may

be disconnected

Remove the plug point and refix it properly and ensure that
the Green light in the Speaker
is switched ON

Ensure that the Audio output is

Audio output connection from
connected to the Green color of
Motherboard may be
Motherboard. Remove and redisconnected
fix it again
Multimedia Speaker may be
defective

Replace the Speaker

INTERFACE BOX
Sl.
No.

Trouble

Causes

All the battery charging

LEDs in the sensor arm
are not glowing when
putting in to the charging
1 tray
EMI Filter board faulty
No AC output power for
the PC/Monitor

RF Transceiver unit
disconnected

SMPS faulty

Remedies
Check physically for any loose
contact / damages in wire. If
found replace the wiring
Check & ensure the Filter board
is not burnt
Check the input supply voltage
(230VAC) at the I/P section of
EMI Filter board
Check the output supply voltage
(230VAC) at the O/P section
Replace the EMI Filter board
Check physically for any loose
contact / damages in wire. If
found replace the wiring
Check the input supply voltage
(230VAC) at I/P section of SMPS
Check the output supply voltage
(12VAC) at the O/P section
Replace the SMPS

DESKTOP COMPUTER & PERIPHERALS

Sl.
No.

Ref.: CCDWA - OM

Trouble

Causes

Remedies

Power cord may not be

connected properly or may
be defective

Ensure proper connection or

replace it

Faulty SMPS

Check for output voltages. If

not OK, then replace the SMPS

Power switch may not be

functioning properly

Check and correct / replace it

Power Connector is not

connected to the Board

Check and connect it

Not Powering ON

90

Sl.
No.

Ref.: CCDWA - OM

Trouble

Causes

RAM not fixed properly /

loose in the slot

This problem in Indicated by

beep sound for a duration of 12 seconds. If so check whether
the RAM module is firmly fixed
into the slot

Faulty RAM module

Replace the RAM

Faulty Mother board

Replace the Mother board

Faulty SMPS

Check for output voltages. If

not OK, then replace the SMPS

Loose VGA connector

Check whether the VGA

connector is connected
properly. If not connect it firmly

Monitor not switched ON

Switch ON the Monitor

SDRAM not fixed properly /

loose on the slot

Insert the SDRAM firmly into

the slot

CMOS setup corrupted

Switch OFF the system and

clear the BIOS by changing the
position of the CMOS jumper to
Clear CMOS by referring to
the Manual. After clearing the
CMOS on the system, power
ON the system and go to
CMOS setup and detect the
Compact Flash / Boot Device in
the BIOS

Faulty Mother board

Replace the Mother board

Loose Keyboard connector

Connect the Keyboard

connector firmly

Faulty Keyboard / cable

Replace the Keyboard

Processor over heated

Check whether hanging is

observed after specific duration
from power ON and whether
the Heat Sink is getting heated
on the Processor or the Coprocessor. Check the cooling
fans are running in good
condition

Faulty peripherals

If the system halts at a specific

point during Boot up, check for
the specific peripherals and
correct it

OS / application software
corrupted

If the hanging is observed when

booted to the OS and running
the application, check whether
the application or the OS has
got corrupted. If so, reinstall
the software

Booting Problems

No Display

Keyboard not detected

System hangs up

System hangs up

CMOS Checksum Error

Remedies

Faulty CMOS battery

Check for CMOS battery

voltage. It should always read
+3V. If not, replace the Battery

91

Sl.
No.

9.2.

Trouble

Causes

Remedies

Hard Disk Drive(HDD) not

detected

Insert the cables into its cable

slot

HDD become defective

Check whether the HDD is

detected in BIOS. (In BIOS,
detect for HDD). If not
detected, replace the HDD. If
the BIOS detects the HDD,
check whether there is a Disk
Partition and whether it is
formatted or due to booting file
corruption

Non-System Disk or
Disk boot failure

SOFTWARE TROUBLE SHOOTING

Sl.
No.

Trouble

RUN TIME ERROR 9:

Subscript out of range

RF Transceiver not
connected

Causes

Remedies

RF interference of two
Shift one Aligner to a different
Aligners at the same location location out of RF range
Existence of same RF channel
Change the RF channel number
No / frequency (of similar or
in the Aligner
different devices)
Fuse may be defective in
Interface box

Replace the Fuse located in the

Interface box

EMI Filter board may be

defective

Replace the EMI Filter board

SMPS may be defective

Replace the SMPS

No power supply to RF
Transceiver unit

USB port may be unplugged

from PC

USB port cable may be

defective

Replace the USB port cable

USB port may be disabled in

OS settings

Enable the USB port via device

manager option

USB software may not be

installed

Install the USB driver software.

Personality board may be

defective

Replace the Personality board

USB port section may be

Check the USB port option. If not
defective In PC Mother board working, replace Mother board
Error-1
RF Transceiver unit
3
connectivity disturbed
during alignment

RF Transceiver unit in
Ensure the connection is secure
unplugged / loose condition or and also tighten the BSM
loose contact in it's connector connector
Respective IR Led may not be Check the supply to IR Led
working
across connection
Obstruction between IR LED
& Camera

No Video (NV)
4 (common for all Sensor
arms)

Ref.: CCDWA - OM

Remove the obstruction

Dust particles Dust prevention Clean the glass with soft cloth or
glass
tissue paper
Zero Camera dia count in
Camera setting

Mount all Sensor arms in

Calibration kit and ensure Dia
value as tabulated in Chapter 8.4
of Service manual

Faded IR Filter

Replace IR Filter

Problem in Arm board

Replace Arm board

Problem in Camera

Replace Camera

92

Sl.
No.

Trouble

Causes

Remedies

External light/reflection on the Prevent external light falling on

Camera
the Camera
Multi-spot (MS )
(common for all Sensor
5
arms)

No Vertical Sync (NVS)

6 (common for all Sensor
arms)

9.3.

Camera Dia disturbed

Mount all Sensor arms in

Calibration kit and ensure Dia
value as tabulated in Chapter 8.4
of Service manual

Faded IR Filter

Replace IR Filter

Faulty Camera

Replace Camera

No power supply (+5V) to

Camera

Ensure +5V power supply to

Camera connector

Loose connection in Camera

connector

If required, solder the Camera

connector directly

Camera may be faulty

Replace the Camera

Defective Arm board

Interchange the Arm board from

other Sensor arm & conform

SELF DIAGNOSIS
Following message box will be displayed in case of any fault identified during alignment
sequence.

To diagnose the exact root cause, click Click here for Error diagnosis button and the system
will diagnose the error. User will be advised to wait for few minutes and DO NOT disturb the
system during self diagnosis.
Sl.
Error
Causes
Remedies
No.
USB cable may be
Ensure the proper USB
disconnected from PC connectivity

RF Transceiver unit
cable disconnected

Ensure the proper 4Pin

BSM connectivity

Fuse (F1) may be

blown in Interface box

Replace the Fuse with

correct rating

Check the Power LED

No power supply to RF glows in RF Transceiver
Transceiver unit
unit. If not, contact Service
technician

No supply to the
Charging tray

Check 12V supply in the

respective Charging pins in
Tray. If not, check &
ensure the Charger
connectors (2Pin) are
connected to the Interface
box properly (ref. Sl.No.11
of Fig.26)

Battery voltage is
<5.4VDC

Charge Battery for 8 hours

(min.)

Failure in battery
charging

Check the Battery voltage/

connections after 8 hours
of charging. If battery
voltage is below 6VDC.
Replace the Battery

Sensor arms are in

switched OFF
condition in charging
tray

Remove from Charging tray

and switch on the Sensor
arm

Ref.: CCDWA - OM

93

Sl.
No.

Error

Causes

Remedies

Sensor arm fuse

Tighten the Fuse on the
holder loose (no power Sensor arm, so that power
to Sensor arm)
is supplied to Sensor arm
Defective fuse

If Fuse is found to be
defective, replace the Fuse
with correct rating

Battery drained out in

the Sensor arm

Place the particular Sensor

arm in Charging
tray/connect cable

Same Arm board ID

programmed wrongly
in two Sensor arms
(two sensors arms
having same ID)

Connect only one Sensor

arm at a time to the
Interface box and select the
required arm board ID

Ensure that all the channel

Different RF Channel
numbers are same in
Nos. in RF Transceiver
Sensor arms & RF
unit and Sensor arms
Transceiver unit

9.4.

Defective RF
Transceiver board

Contact Service technician

Defective Arm board

Contact Service technician

RF Channel settings
are not same across
the Sensor arms & RF
Transceiver unit

Ensure that all the channel

numbers are same in
Sensor arms & RF
Transceiver unit

Same RF channel
used in nearby RF
aligner within 100ft
distance of same
premise

Ensure the Channel

numbers are set differently
for both the RF Aligners.
Same channel numbers
should not be used in same
premise

MIS-ALIGNMENT TROUBLE SHOOTING

Sl.
No.

Trouble

Causes

Remedies

Misaligned Rear axle (ie.,

unequal Rear Toe).
Check the Rear suspension for worn out
Rear axle is not perpendicular control arm bushings or sagged springs
to Geometric Centre Line
Setback

Check the position of the Front wheels are in

line

Improper Camber setting.

Car pulls sideway with more
positive Camber

Check for worn out ball joints or control arm

bushings and sagged or broken springs

Car pulling Uneven tyre pressure.

1 towards one Car pulls sideway with low
side
inflation

Check both tyres are with same pressure

Mismatched tyre sizes.

Both Front tyres must be of same size, same
Steering pull due to mixing of
design & should have approx. same amount
Radial & Normal tyres and
of thread wear
cross ply
Incorrect Caster setting

Caster must be same on Front wheels

Check for worn out Control arm worn strut
rod bushings

Dragging brakes and car pulls Check for corroded brake caliper piston and
sideway
misadjusted emergency brake cable
Ref.: CCDWA - OM

94

Sl.
No.

Trouble

Causes

Power steering problem

Check for uneven Steering balance of Front

wheels in jacked up condition and run the
engine. The steering should not turn one
side due to leak in Control valve. The
steering effort should also be equal in both
directions

Steering problem with tyre

Check for faulty tyre construction

Loose steering parts

Inspect Tie rod ends, Idler arm and steering

gear mountings

Worn out steering gear

2 Car wanders Vehicle skids while applying
brake

Tilt in
Steering
3 wheel even
after
alignment

Remedies

Adjust if possible. Else replace it

Check for worn out strut or Control arm
bushings

Loose Wheel bearings

Remove the loose bearing and inspect for

damages. If so, replace it

Toe not adjusted equally

Make the length of Tie rods equal

Misaligned Rear axle

Check the rear axle alignment, worn out Rear

axle mountings, Sagging springs or collision
damage

1.
2.
3.

If Runout Compensation 1.
skipped.
If Ride Height Value
2.
skipped.
After Caster adjustment, 3.
Redo process not carried
out

Runout compensation to be done

compulsorily
Ride Height Value should be entered

1.

Ensure wheel bracket rim locking pins

are clamped properly
All the Wheel brackets should be
clamped uniformly either at inner or
outer side of Rim

2.
Wheel bracket not fixed
properly

After Caster adjustment Redo process

should be carried out compulsorily

Ensure the wheel bracket is fixed on the rim

at 12 o clock position (While the wheel
bracket center block is slide down).
1.
Tilt in
Steering
wheel even
after
alignment

2.
Wheel bracket may be
defective
3.

1.
Uneven pit level

2.

If Screw rod is found to be bent, replace

the Wheel bracket
Fix all the Wheel brackets one by one in
another Wheel rim and ensure the
bracket motion is proper. If not, replace
the particular Wheel bracket
Fix all the Wheel brackets in a particular
wheel one by one and ensure the
readings are similar
Pit must be leveled properly within the
tolerance of 2mm
Zero level should be ensured diagonally
(ie., between Front Left & Rear Right
and Front Right & Rear Left) without
deviation

Tyre wear on outside shoulder Inflate the tyre to recommended pressure

due to excessive positive
and adjust the Camber as per the
Camber
specifications

Other
symptoms

Tyre wear on inside shoulder

due to excessive negative
Camber

Inflate the tyre to recommended pressure

and adjust the Camber as per the
specifications

Tyre wear on both shoulders

due to under inflated tyres

Check the tyre pressure is as per

recommended specifications

Saw tooth tyre wear due to too

Adjust the Toe as per specifications
much of Toe-in or Toe-out
Ref.: CCDWA - OM

95

Sl.
No.

Trouble

Causes

Remedies

Abnormal tyre wear due to

loose Steering system,
Correct the Steering system, align Front &
misaligned Front or Rear
Rear wheels and correct the suspension
wheels, defective suspension system. If necessary replace the parts
system or car is overloaded
Hard steering due to low or
uneven Tyre pressure, more
positive Caster or tight
Steering system or defective
Power steering

Check & inflate the tyre as per recommended

pressure and adjust the Steering system or
replace the Power steering

Tyre squeal on turns due to

wrong Toe Out on Turn angle
Align the Tie rod and adjust the Lock angle
from misaligned Tie rod, or
and check the tyre pressure
bent Steering arm. Low or
uneven tyre inflation
Unstable at high Speed due to
Adjust the Toe or replace the worn out
incorrect Front or Rear Toe or
steering components
worn out steering components

Ref.: CCDWA - OM

96

Manufactured by

All rights reserved. Any reproductions of this document, partial or complete, are not allowed without prior
consent of Manufacturer
All information, illustrations and specifications contained in this Manual are based on the latest information
available at the time of publication. Manufacturer reserves the right to make changes at any time without further
notice to any of its products to improve reliability, functions, design or whatever can be thought suitable