Portable Image: Wheel Aligner

PORTABLE IMAGE
WHEEL ALIGNER
Service Manual
All information contained or disclosed in this document is con-
sidered confidential and proprietary by Snap-on Equipment. All
manufacturing, use, reproduction, and sales rights are reserved
by Snap-on Equipment and the information contained herein
shall not be used in whole or in part without the express written
consent of Snap-on Equipment.
Revisions
Release A
Date Changes Page
05/07/08 Original Release
Release B
05/13/08 Added Rear Target 12 o’clock..................................................................................................3-3
05/13/08 Removed LH/RH Identification.................................................................................................3-5
5/29/08 Added Backup/Restore information..........................................................................................3-7
6/5/08 Added warning to battery removal procedure..........................................................................2-8
6/12/08 Added PC TCP/IP settings.......................................................................................................2-3
Revision
This page is left blank intentionally

Table of Contents
INTRODUCTION
GENERAL........................................................................................................................................................... i
FUNCTIONAL DESCRIPTION............................................................................................................................ i
Maintenance Functions........................................................................................................................... ii
IMPORTANT SAFETY INSTRUCTIONS........................................................................................................... iii
LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE...................................................................................iv
ELECTRICAL SAFETY PRECAUTIONS...........................................................................................................iv
HANDLING STATIC SENSITIVE PCB’S............................................................................................................v
SERVICE GUIDELINES.....................................................................................................................................v
CHAPTER 1 Component overview

AC theory of operation........................................................................................................................ 1-1
AC DISTRIBUTION................................................................................................................................... 1-1
component identification.................................................................................................................... 1-1
Main Board............................................................................................................................................ 1-1
Camera Module................................................................................................................................... 1-3
Strobe/Radio Module....................................................................................................................... 1-3
Toe Sensor Module........................................................................................................................... 1-4
Inclinometer/Encoder Module.................................................................................................... 1-5
component location.............................................................................................................................. 1-6
block Diagram........................................................................................................................................... 1-7
Wiring Diagram......................................................................................................................................... 1-8
CHAPTER 2 checkout and maintenance

General....................................................................................................................................................... 2-1
unit checkout procedure ALL VERSIONS........................................................................................ 2-1
Verifying components.......................................................................................................................... 2-2
Powering Up the PODS........................................................................................................................... 2-3
charging system..................................................................................................................................... 2-4
Sidewinder wheel clamp assembly & Maintenance.................................................................... 2-5
master pod reset.................................................................................................................................... 2-8
battery replacement............................................................................................................................ 2-8
CHAPTER 3 cALIBRATION
Calibration................................................................................................................................................. 3-1
CALIBRATION functions........................................................................................................................... 3-4
Pod identification.............................................................................................................................. 3-4
Calibration factors......................................................................................................................... 3-6
Calibration history.......................................................................................................................... 3-6
Calibration utilities......................................................................................................................... 3-7
CHAPTER 4 diagnostics
Data Examination Mode.......................................................................................................................... 4-2
firmware download........................................................................................................................ 4-4
pod extended diagnostics.................................................................................................................. 4-5
pod extended diagnostics (page 2)............................................................................................ 4-6
pod power supply data.................................................................................................................... 4-8
pod runtime data................................................................................................................................ 4-9
pod charge information............................................................................................................... 4-10
pod toe diagnostics............................................................................................................................. 4-11
toe ext data........................................................................................................................................ 4-12
toe cal data........................................................................................................................................ 4-13
strobe/radio diagnostics.................................................................................................................. 4-14
POD ENCODER CAMBER/SAI..................................................................................................................... 4-15
Encoder calibration data............................................................................................................ 4-16
encoder cam/sai data..................................................................................................................... 4-16
WAP diagnostics..................................................................................................................................... 4-17
pod camera diagnostics..................................................................................................................... 4-18
pod power options............................................................................................................................... 4-19
INTRODUCTION
GENERAL
The “Portable Image Wheel Aligner” system consist of two targets attached to a vehicle’s front wheels and
two companion, battery powered sensor pods attached to vehicle’s rear wheels. Each pod is composed of a
metal housing and five intelligent modules; Main board, Camera module, Strobe/Radio module, Toe Sensor
module, and Inclinometer/Encoder module. Each module is somewhat self-contained in regards to assembly,
testing, calibration and function. Each module is optimized for power consumption, effective communications
and operational reliability. Modules are designed with on-board controllers that take full advantage of deep
sleep states, consuming power only during brief moments to acquire and communicate data. All modules
communicate over the standard Serial Peripheral Interface (SPI) to one of two redundant master devices.
Each module’s SPI connects to the master through a custom SPI multiplexer (Mux) device. The SPI Mux is a
programmable logic device (CPLD) specially designed to ensure the isolation of each interface. In this way,
no one faulty module can cause signal contention and failure of the shared SPI interface to the master. In ad-
dition, the design allows the master device to control the power supply to each module therefore disabling any
module that has failed in such a way that could result in substantially shortened battery life. In the “off” mode,
all power supplies and modules are shutdown with the exception of a single low power “Supervisor” controller
which is placed in a deep sleep mode. When a key is pressed on the keypad or the external AC/DC power
supply is connected, the Supervisor controller wakes, runs extensive self tests and powers up the pod system
for operation.
The system design has also been optimized for communications to the user. The intent is to provide redun-
dant communications paths so as to insure that an operator is always informed about the state of the “Por-
table Image Wheel Aligner” system. The primary communications path is from each “Portable Image Wheel
Aligner” pod to the console via the Bluetooth radio on the Strobe module as well as 9 LEDs on the keypad
of each pod. An IR communications link is included across the rear cross toe path so that each pod may
independently share information with the other companion pod. This allows each pod to communicate the set
full information from both pods independently over each pod’s Bluetooth radio. In this way if one pod’s radio
is faulty then that pod’s information continues to be available via the other pod’s radio connection. Power is
supply to each pod through a 7.2Ahr rechargeable Lithium Ion battery pack design for at least 24 hours of
continuous pod runtime. The pod’s on board battery charger uses a standard 6 to 24 volt AC to DC adapter
to charge the battery pack within a maximum of 12 hours. The Main board includes a battery “gas gauge”
to continuously track and monitor the battery pack in order to very precisely provide critical battery informa-
tion such as remaining runtime, time to fully charge, and number of charge/discharge cycles incurred. The
battery pack is designed to provide a lifetime of at least 500 charge/discharge cycles or over 5 years of typical
use. The on-board charger can be controlled to adaptively charge the battery based on various predetermine
conditions; for instance the battery is only charged if the battery gas gauge indicates that a predetermined
discharge level has been reached.
FUNCTIONAL DESCRIPTION
The main menu (Advanced Software) of the aligner is the control

center for the unit. It offers the operator easy control of the basic
alignment features. Moving the mouse pointer over the icon gives
the operator a short description of the icon function. See the opera-
tors manual for a more detailed list and description of the many
features and functions of the aligner.
i
INTRODUCTION
The “Run Wizard” icon steps the operator through a complete alignment. The alignment ma-
chine offers many factory default wizards that can be edited by the operator to either add or
delete certain steps.
The “Vehicle Selection” icon allows the operator to select a particular vehicle for an alignment.
This selection can be made at any point in the alignment by clicking on the “Home” icon and
selecting the “Vehicle Selection” icon.
The “Vehicle Specification” icon allows the operator to view the specifications for the vehicle
chosen from the vehicle selection icon. The operator has the ability to edit the specifications
and save the edit specification to a custom specification database.
The “Inspection” menu offers a variety of inspection menu allowing the operator to perform
predetermined inspections. Six Inspection screen are available under Inspections as well as a
Diagnostics icon. These are Pre-Alignment Inspection, Tire Inspection, Brake Inspection, Under
Car Inspection, Under Hood Inspection, and Courtesy Inspection.
The “Measurement” icon offers quick access to several angular measurement screens such as
Caster, SAI, Steering Angles, and Vehicle Dimensions.
The “Adjustment” icon offers access to a variety of features that assist the technician with ad-
justment of alignment angles. Some of these features include Live Caster, A-Arm Adjust, Rear
Shim Programs, and Cradle Adjust.
The “Customer Data” icon offers the operator easy control for finding, adding or editing any
customer data that has been previously saved from past alignments. Information can then be
retrieved and sorted through a myriad of different options.
Maintenance Functions
The aligner offers diagnostic tools to assist in troubleshoot-

ing. The maintenance menu is accessed from the “Main Menu”
screen by clicking on the “Maintenance” tab.
The “Calibration” icon steps the user through a

simple calibration.
The “Measurement Data” icon is the location for

troubleshooting. The screens within this subsys-
tem will aid a technician in the proper diagnosing
and trouble shooting of all of the wheel sensors.
ii
INTRODUCTION
IMPORTANT SAFETY INSTRUCTIONS
When using this equipment, basic safety precautions should always be followed,
including the following:
1. Read all instructions.
2. Do not operate equipment with a damaged power cord or if the equipment has been
damaged until it has been examined by a qualified authorized service technician.
3. If an extension cord is used, a cord with a current rating equal to or more than that of
the machine should be used. Cords rated for less current than the equipment may
overheat. Care should be taken to arrange the cord so that it will not be tripped over or
pulled.
4. Always unplug equipment from electrical outlet when not in use. Never use the
cord to pull the plug from the outlet. Grasp plug and pull to disconnect.
5. To reduce the risk of fire, do not operate equipment in the vicinity of open
containers of flammable liquids (gasoline).
6. Keep hair, loose fitting clothing, fingers and all parts of the body away from moving
parts.

7. Adequate ventilation should be provided when working on operating internal combus-
tion engines.
8. To reduce the risk of electric shock, do not use on wet surfaces or expose to rain.
9. Do not allow unauthorized personnel to operate the equipment.
10. Use only as described in this manual. Use only manufacturer’s recommended
attachments.
11. ALWAYS WEAR Safety Glasses. Everyday eyeglasses only have impact resistant
lenses, they are NOT safety glasses.
SAVE THESE INSTRUCTIONS
iii
INTRODUCTION
LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE
1. Notify all affected employees that a lockout or tagout system is going to be utilized and the reason
thereof. The authorized employee shall know the type and magnitude of energy that the machine or
equipment utilized and shall understand the hazards thereof.
2. If the machine or equipment is operating, shut it down by the normal stopping procedure (depress the
stop button, open toggle switch, etc.)
3. Operate the switch, valve, or other energy isolating device(s) so that the equipment is isolated from its
energy source(s). Stored energy (such as that in springs, elevated machine members, rotating flywheels,
hydraulic systems, and air gas, steam or water pressure, etc.) must be dissipated or restrained by meth-
ods such as repositioning, blocking, bleeding down, etc.
4. Lockout and/or tagout the energy isolating devices with individual lock(s) or tag(s).
5. After ensuring that no personnel are exposed, and as a check on having disconnected the energy sourc-
es, operate the push button or other normal operating controls to make certain the equipment will not op-
erate. CAUTION: RETURN OPERATING CONTROL(S) TO “NEUTRAL” OR “OFF” POSITION AFTER
THE TEST [DE-ENERGIZED STATE].
6. The equipment is now locked out or tagged out.
ELECTRICAL SAFETY PRECAUTIONS

Make sure the aligner is unplugged before disconnecting any wires in preparation for replacing any boards,
cables or other items within the unit. Use the “Lockout and/or Tagout” procedure.
When working on this aligner, keep three points in mind:
!
THIS UNIT MUST BE PLUGGED IN TO A PROPER AC OUTLET FOR
THE UNIT TO OPERATE CORRECTLY. REFER TO THE UNIT ID
PLATE LOCATED ON THE BACK OF THE UNIT. EXTENSION CORDS
ARE NOT RECOMMENDED, BUT IF AN EXTENSION CORD MUST BE
USED, USE A CORD THAT IS LESS THAN 50 FEET WITH A 16 AWG,
OR ABOVE 50 FEET AND LESS THAN 100 WITH A 14 AWG.
1. Aligner voltages refer to the “return” (white) side of the AC line. Yet sometimes outlet wiring is reversed.
In that case, electrical neutral connects to the “hot” side of the line. The aligner operates normally, but the
PC board floats 110/220 VAC above safety ground. Assume that points inside the aligner console are
at 110/220VAC; observe all safety precautions. If you make measurements with grounded test equip-
ment, use an isolation transformer. An oscilloscope is an example of such test equipment.
2. The aligner is susceptible to power line spikes and noise. You must connect the equipment to safety
ground. Does your machine do “strange things” or exhibit intermittent problems? Check for a proper
ground at the machine and the power outlet. If you’re using an extension cord, check that, too. It must be
constructed of at least 16 gauge wire and under 50 feet long.
3. Schematic voltages refer to the “return” side of the line, not safety ground. When measuring voltage, use
the white wire on the line power terminal block as ground. Don’t use the third, center safety ground ter-
minal. Another place to access ground is at the shield. The black wire in the shielded transducer cables
also connects to the ground return.
iv
INTRODUCTION
HANDLING STATIC SENSITIVE PCB’S
Electrostatic discharge can destroy high impedance ICs if uncontrolled. Use the fol-
lowing techniques to avoid damaging ICs:
- Leave new circuit boards in their antistatic bags until ready for use.
- When replacing boards, proms, etc. be sure to turn off power to the machine first
- Use an anti-static wrist strap. Connect it to chassis ground on the equipment or to an available raw
ground.
- Touch the chassis of the equipment to put yourself at the same static potential as the equipment.
- Grasp the PCB from opposite sides using your fingertips. Do not grasp the components on the board.
!
USE STANDARD ANT-STATIC PROCEDURES
WHILE PERFORMING THESE INSTRUCTIONS
When inserting PCB’s:

- Place boards on a grounded static mat after removal.
- Remove the new PCB from the original package onto a grounded static mat. Save packaging to use
when returning defective boards.
- Remove power from the machine (un-plug from wall) before installing the PCB.
- Avoid handling components needlessly.
- Do not set PCBs on insulating surfaces such as paper, glass, rubber, or plastic.
- Static is generated by friction. The following actions promote static generation:
- Wearing silk or nylon clothing.
- Walking on carpets.
- Walking with rubber soled shoes.
Static generation is increased when certain environmental conditions exist. Conditions of low humidity com-
bined with wearing silks or nylons, walking on carpets, or walking with rubber soled shoes may create large
electrostatic charges on your person, capable of blowing a hole in the substrate of an IC.
SERVICE GUIDELINES
4. BEFORE REPLACING circuit boards, verify that the main power supply operates within specifications.
5. VERIFY that board connectors are fully seated.
6. NEVER remove boards or disconnect a connector with the power on!
7. MAKE SURE that you completely understand what the aligner does. (If it works, you can’t fix it!) Refer to
the Aligner Operator’s Manual, application notes, and flow diagrams.
8. BE CAREFUL when handling circuit boards! Wear an anti-static wrist strap.
9. WHEN TRANSPORTING circuit boards, use anti-static bags.
note: Relative humidity has a direct effect on static charge buildup. As humidity
decreases, static buildup usually increases.
v
INTRODUCTION
vi
CHAPTER 1
Component overview
AC theory of operation
!
DANGEROUS HIGH VOLTAGES
ARE PRESENT IN THIS EQUIPMENT
Always use the “One Hand Rule” when working with AC voltages by keeping one hand in your pocket or be-
hind your back. Before removing wires from the Aligner, always verify that the unit is “OFF”. Turn off the Main
Power Switch on the back and unplug the AC power cord from the AC outlet.
AC DISTRIBUTION
The primary voltage applies 110/220VAC, 60/50Hz AC to the ALIGNER via the hot side (Black Wire) of the AC
power cable. The Main Power routes to one power strip. The power strip distributes 115’/220V AC to the PC,
Monitor, Printer.
component identification
Main Board
The Main board is design to functions as the system master and contains the image processing DSP, the
“Supervisor” ARM processor, SPI bus multiplexer, connections for each module as well as power supplies for
each processor and module. Each power supply is designed and optimized for power conversion efficiency
greater than 95% in-order to provide extended battery life. The Main board can be thought of as two boards
or primary functions combined into one board. These two primary functions relate to the image processing
DSP and system management by the Supervisor. The Supervisor and DSP communicate through the DSP
Host Port Interface which gives the Supervisor complete access to the DSP’s on-chip registers and external
RAM and Flash memory space.
Main board; Supervisor (ARM 9 microcontroller)

The Supervisor’s main functions are power conservation, data communications, system integrity and user
interface. The Supervisor continuously configures and initiates each phase of operation and then cycles the
pod through systematic sleep periods. By choreographing and limiting the precise time that each module as
well as the DSP is awake and consuming power, the Supervisor can dramatically extend the runtime from
each battery charge. The Supervisor can monitor angle change activity and reduce data acquisition frequen-
cy if no change has been detected for a pre-determined amount of time. In this way the pod can conserve
power if the user has walked away or forgotten to turn the system off. The data acquisition frequency can be
reduced on a schedule such that the longer the system senses no activity the longer the sleep state duration.
The moment any angle movement is detected the system can acquire data at full rate thereby maintaining
the responsiveness required for wheel alignment. The Supervisor may also be configured to reduce the data
acquisition frequency on a critically low battery condition thereby moderately sacrificing measurement read-
ing update rate for an extended battery life. The Supervisor monitors temperature, power supply voltages,
current, and communications data integrity to ensure that all systems are working properly. Data from the
DSP, modules, power monitoring systems, and keypad are consolidated, packetized and sent to the compan-
ion head via the IR link and to the console via the Bluetooth radio. All failures are reported to the user by
communications with the console (Bluetooth), companion head (IR Comm) and keypad (LEDs). The intent is
to validate any failures to the extent that the pod or system can indicate the need for service without fear or
1-1
CHAPTER 1 COMPONENT OVERVIEW
doubt of false failure indication. This operational confidence can also assist the user in discerning procedural
or training issues from real pod or system failure modes.
Main board; DSP Image processor (TMS320DM642)

The DSP executes firmware independent of the Supervisor and therefore operates autonomously. By imple-
menting the Host Port Interface (HPI) the Supervisor can coordinate when the DSP is active or in sleep mode
in order to conserver power. The DSP’s primary function is to acquire image data from the image sensor and
derive the target plane orientation using Snap-on proprietary image processing algorithms. In addition, the
DSP can perform many of the Supervisor’s functions as an alternate system controller, including radio com-
munications, in case the Supervisor has failed. As required, the DSP can take control of the system and
send all failure data to the user by communications with the console (Bluetooth), companion head (IR Comm)
and keypad (LED). In addition, the DSP can operate in a “limp mode”, performing all alignment functions,
although at a much greater current drain. This would allow the user to operate for a short time in-order to
complete an alignment should the Supervisor fail completely.
1-2
Camera Module
The Camera module implements the Omnivision OV9121 image sensor with 1280x1024 pixel image reso-
lution. The image sensor setup, exposure time, gain settings and image acquisition is controlled by an
on-board Freescale MC9S08 low power microcontroller. The MC9S08 communicates with the Main board
Supervisor ARM 9 microcontroller via the SPI communications bus. The Supervisor directs the MC9S08 and
thereby controls the image sensor operation. The Supervisor may command the camera to take both a back-
ground frame (no illumination) followed immediately by an illuminated frame or simply one or the other types
of frames. The image sensor data signals are connected to the DSP Video Port where images are acquired
at a rate of 24 or 48 MegaPixels/sec. The full image can be acquired at a 48 MegaPixels/sec rate in-order to
find the target at high speed then the image sensor can be switched to the 24 MegaPixel/sec rate for precise
image processing at lower image noise levels. The on-board controller can also monitor various functions of
the image sensor, temperature, image frame pixel count and power supply voltages to ensure proper opera-
tion. The image sensor can be commanded by the on board controller to generate an overlay test pattern.
The DSP can analyze this test image to evaluate the image sensor functional integrity. Any failures or vari-
ances from nominal will be reported by the Camera module controller to the Supervisor on the Main board by
the inter-module SPI communications interface.
Strobe/Radio Module
The Strobe/Radio module performs two independent functions; image illumination (strobe) and Bluetooth
communications. Each function has a dedicated on-board Freescale MC9S08 low power microcontroller for
independent operation. Image illumination is performed by two strings of six each, high efficiency, high output
Infrared LEDs. Two constant current power supplies can instantaneously deliver 300mAs of current to each
string independently for a maximum strobe duration of 10 milliseconds. In normal operation, only one string
of LEDs is required for a much shorter duration than 10 milliseconds, therefore each string can be used alter-
nately thereby increasing the lifetime of each string. In addition, failure of an LED or a string power supply will
only limit the use of the pod, not render the pod totally unusable. An MC9S08 microcontroller communicates
with the Supervisor ARM microcontroller via the SPI bus to setup and control image illumination. The strobe
signal from the Camera board is used to synchronize image illumination with the image sensor exposure
duration. In addition, a Class 1 Bluetooth module with an external Centurion D-Puck high gain antenna is
implemented on the Strobe/Radio module. A second MC9208 microcontroller bridges the standard Bluetooth
HCI UART interface of the Bluetooth module with the custom highly reliable SPI communications bus used for
all HawkEye inter-module communications. The Bluetooth module can be programmed to enter the Bluetooth
defined Hold, Sniff or Park modes to conserve power during times of low usage. The strobe section controller
monitors the various functions such as temperature, power supply voltages and LED current to ensure proper
operation. The radio section controller monitors various functions such as radio interface communications
and power supply voltages to ensure proper operation. Any failures or variances from nominal will be report-
ed to the Supervisor on the Main board.
1-3
Toe Sensor Module
Two toe sensors are used in the portable alignment system as a functional pair. One sensor is located in
each pod. The sensor has a +/-7 degree cone of operation. The sensors are placed across from each other
within each others cone of operation. The sensor reports the angle to the opposite sensor. This angle is
associated with the rear cross toe. The toe sensor uses a CCD imager to measure the position of the oppo-
site units toe LED. The CCD is exposed to light for a period of time called the exposure time. This number
is reported in the diagnostic screen with units of sensor clocks periods. Maximum exposure is 12000. Two
images are taken for each toe sample, one with the opposite LED on and the other with the opposite LED
off. The two images are subtracted one from the other to remove light from the environment. The image of
the LED that results from the subtraction is called a centroid. The position of the centroid in the sensor array
is used to calculate the angle to the opposite sensor. The centroid is checked for intensity and shape. If no
centroid is found, then the No Peak error is returned. If the centroid is distorted a Shape error is returned.
If the centroid is too small, a Low Exposure error is returned. If the centroid is too large, a High Exposure
error is returned. All of these errors can be seen in normal operation of the sensor. They represent a problem
with an individual sensor sample and the sensor will automatically take action to correct the error. If these
errors appear frequently or do not resolve themselves then they can be used to help diagnose toe faults. The
toe sensor has special operating modes to deal with high ambient light. If the sensor is compensating for a
high ambient light condition, the Sunlight condition is returned. If the CCD array is over exposed such that
no image can be recorded, it is said to be in saturation. If a portion of the image is saturated, then a Clipped
condition is returned.
The sensor uses an IR communication link to check the optical path between the two sensors. If the IR com-
munication link can not function the senor will report a Sensor blocked error. Within a pod the Toe sensor
communicates using a SPI interface. If there is a fault in the Toe SPI communications within the pod a SPI
Communication Fault is returned. Errors resulting from normal operation are reported in the CCD Error
flag. When the toe sensor is first turned on, it performs a self diagnostic. The results of this diagnostic are
reported in the Board Error and Arm Error flags. In addition to the error flags, when in the diagnostic screen
in the aligner live centroid images for both toe sensors are displayed. These can be used to visualize the er-
ror states shown in the CCD error flag. On the extended diagnostics screen the board error and arm error
flags can be viewed along with live voltage diagnostic data for the toe boards.
Left Rear
Reference
Front of
Vehicle
Toe Out Zero Toe Toe In
1-4
Inclinometer/Encoder Module
The Inclinometer module implements a MEMS type inclinometer. This device was selected due to the ex-
ceptional accuracy and repeatability specifications for a MEMS device. The MEMS type inclinometer is
a two plane sensor giving us the ability to measure both camber and pod pitch in the same device. Two
Texas Instruments MPS430 ultra low power microcontrollers each with a Sigma Delta 16 bit Analog to Digital
converter, integrated temperature sensor and integrated SPI communications bus interface was selected to
process and communicate the angle data from each inclinometer sensor outputs to the Main board via the
inter-module SPI communications interface. In addition, the specific controller dedicated to the inclinometer
pod pitch output can be made to operate in a pod wake-up mode. In this mode the inclinometer pitch output
is constantly monitored for change. If a predetermined level of change should occur, signaling vibrations or
activity around the vehicle, then the controller can toggle the SPI bus slave out data line (MISO) while the SPI
interface is not active in-order to interrupt and wake the Main board Supervisor from sleep. During low or no
activity (angle change) the Supervisor may successively reduce the frequency of the data acquisition cycles.
Between cycles the Supervisor and other modules may be in a sleep state for long periods of time. The in-
clinometer can detect very slight movements of the pod indicating potential activity around the vehicle. Upon
detecting this movement, the controller can signal the Supervisor to wake and quickly begin data acquisition
cycles.
A rotary potentiometer is used to encode the angle of the pod shaft relative to the wheel/wheel clamp assem-
bly. A third and independent MPS430 that will convert the pot position into shaft angle and communicate the
data to the Supervisor processor via the SPI bus.
An optional shock or drop detection circuit utilizing a digital smart MEMs device can detect a free fall and sig-
nal a fourth MPS430 to begin acquiring acceleration data from the smart MEMS device as well as record the
time duration of the drop. In this way, a drop can be detected instantaneously, the time of fall and/or peak ac-
celeration from the impact can calculated and used to evaluate the damage potential to the pod from the fall.
Factory and field calibration factors are calculated and stored in each MPS430 controller for each inclinom-
eter output as well as the rotary potentiometer output. Each controller monitors various functions of the board
including temperature and power supply voltages to ensure operation. The MEMS inclinometer can be placed
in a test mode that deflects the internal micromachined silicon beam by a constant amount. Evaluating this
deflection by measuring the angle output change can determine if the inclinometer is defective or out of cali-
brations. Any failures or variances from nominal will be reported to the Supervisor on the Main board.
1-5
component location
Keypad
Main Board
1-6
Toe Sensor Module
Inclinometer\Encoder
Battery
Camera\Strobe\Radio
HawkEye
Portable Pod
Keypad/LEDs EAP0263J70A
Block Diagram
Toe
Sensor
(Spilt Rx)
SDRAM IR
EAP0263J54A 4M x 64 Flash Comm
4M x 16 (Custom)
Flash
4M x16
Image Sensor VP
DSP SPI
1.3 MPixel
TI DM642 Supervisor SPI
1-7
(Omnivision) Memory Bus SPI Inclinometer
SPI
Mux (2 Plane) &
SPI Encoder
SPI
Strobe trigger EAP0263J64A
Strobe from camera
(12 LEDs) HDQ
Power Supply
Bluetooth
Radio
Antenna Charger Gas Gauge
Encoder
Chip (internal) EAP0263J50A
EAP0263J60A
Charging Batteries
Reset Switch Connector 3 x 2.4Ah
block Diagram
Wiring Diagram
1-8
CHAPTER 2
checkout and maintenance
General
An efficient and proper troubleshooting method of repair is to analyze the logical order of events. Recognition
of symptoms which naturally occur in a certain sequence (depending on failure) will aid in the quick location of
system errors. This method of logical deduction has been used for years by the most successful technicians.
During the power up sequence the aligner is first a computer, the software load transforms the machine into
an alignment instrument. Even as an aligner, things must execute in a certain fashion. When this order is
known we can determine the system malfunction easily by observing the symptoms.
The following checks (in order) will aid in determining which section of the aligner a failure occurs.
unit checkout procedure ALL VERSIONS
1. Check for 115VAC 220VAC Europe power at the wall outlet and at the terminal strip inside the back door
assembly. 230V 1ph 3amp - 115V 1ph 6amp
2. Power on check, listen for fail code beeps, system messages the unit should begin the boot up process
and load the alignment software.
Note: The ROM BIOS also contains a simple system check program which executes
just after turn-on. DOS/Windows Diagnostics software. This is a very good
as well as thorough microprocessor diagnostic tool.
3. Check 110-220 VAC power at the Power Supply PCB inside the Electrical Box P1 pins 1 and 2.
4. Check 10VDC power at the Power Supply PCB P2 pins 1, 2 and 3.
5. Aligner software download. Check to make sure that the alignment software loads both the Software sup-
port and the alignment database.
6. Communications..Check under the Network Connections to make sure that the WAP Pod is communicat-
ing with the PC.
7. Assuming all console display functions are OK, go to the Maintenance - Aligner Diagnostic - Rack Check
screen. Monitor the activity of the pods by turning on one pod at a time. See that the pod is communi-
cating with the console by looking at the “Pod connection Status”.
8. Continue by powering up the opposite pod and to verify communication from console to pod.
9. Verify Pod battery life by viewing the LED’s on each pod. Explanation of LED’s are explained later.
10. Move the pod in the camber plane to verify camber output.
11. Valid camber. With the pods on the calibration bar, check for valid camber. With the sensors mounted on
the calibration bar the camber output on the Raw Values only screen should not exceed ± 1.50 degrees.
12. Move one end of the calibration bar to the lower cutout on the calibration stands. Verify that the camber
reading changes 4 degrees in the direction of camber change. Repeat this step with the opposite side.
13. Valid SAI. With the pods on the calibration bar, check for valid SAI. With the sensors mounted and
leveled on the calibration bar the SAI output on the Raw Values only screen should not exceed ±3.00
degrees. Tilting the wheel sensor up should make the values go negative and tilting it down should make
the values go positive.
14. Valid CrossToe. Again with both front sensors mounted on the calibration bar check for a good cross
toe reading. Using the raw values only screen, and a level bar. The raw value should not exceed ± 2.00
degrees.
15. Validate rear camera operation by viewing the “Data Examination Mode” under the diagnostics.
16. Mechanical - Wheel clamps and turntables. Check for variances in camber readings as the clamps are
rotated. Note any camber change. Using the same wheel sensor mount a different wheel clamp to the
same tire and wheel in the same location and rotate the assembly 360 degrees and note any camber
change. Complete this procedure with all 4 wheel clamps using the process of elimination.
2-1
Chapter 2 Checkout and Maintenance
Verifying components
Before the unit can operate as alignment system it first has to be a working PC. This manual does not include
PC troubleshooting techniques. It is assumed that all service personnel working with these systems have
some basic PC skills.
The system uses a Wireless Application Protocol (WAP) that acts as a liaison
between the PC and the Pods.
The WAP component is powered by a standalone 9VDC power supply and

connects to the back of the PC’s Ethernet connection using and standard CAT
5 wire. With all connections made power can be verified by observing a green
and amber light that will illuminate.
Pod Charger
Ethernet
Power
1. To easily verify that the WAP is communicating click on the “Network

and Internet Connection under the control panel.
2. Click on the “Network Connections” Icon.
3. Double click the “Local Area Connection” icon.
4. Verify that the area connection status is both sending and receiving
data packets.
5. If the connection status is not both sending and receiving data check
to make sure that the PC’s “Internet Protocol” is set up correctly. This
setup procedure will also be used anytime a PC is replaced in a unit.
6. Click the “Properties” button in the “Local Area Con-

nection Status” box.
2-2
7. Under the “General” tab double click on the “Internet Protocol {TCP/IP} (blue arrow) button.
8. The radio button (red arrow) “Use the following IP address” should be selected with the following IP ad-
dress entered 192.168.0.61 after entering the IP address click the mouse in the Subnet mask, the PC will
auto enter 255.255.255.0. Click on the OK button to accept these values.
9. The user can also open a DOS prompt and ping the WAP by typing “Ping 192.168.0.50” and pressing the
<ENTER> key. The system will go out and ping the WAP and return packets.
2-3
Powering Up the PODS

Diagnostics
On top of both Pods are a series of LED’s. These LED’s
are multifunctional. During different times of an alignment
LED’s will either 1) Remain illuminated 2) Flash 3) Flash Runout
Rapidly 4) Turn OFF.
Power
Battery
It’s possible for the batteries to reach a level that will not
allow a pod to run and operate any components inside the
pod. Should this occur none of the LED’s will illuminate.
A hard reset is necessary to reset the system. Plug the
charging wire into the pod and press and hold the reset
button located on the side of the pod for 10 seconds. The
reset process will take approximately 3 minutes. After the
pod resets the lowest charging light should begin to blink.
Allow the pod to fully charge before using.
By clicking on the “Sensor Voltage” icon on the toolbar the

user can quickly obtain valuable information about the bat-
tery voltage.
Battery Power
Battery 100% to 80%
Battery 80% to 60%
Battery 60% to 40%
Battery 40% to 20%
Battery 20% to 10%
If flashing 10% remains

and must be charged
2-4
charging system WAP

The Aligners WAP system is equipped with a charging system. Each
POD contains a Lithium Ion Battery. Lithium-ion batteries are popular
because they have a number of important advantages over compet-
ing technologies:
1. They’re generally much lighter than other types of rechargeable

batteries of the same size. This light weight transfers to the POD Charging
making them much lighter than previous sensors. Ports
2. They hold their charge. A lithium-ion battery pack loses only
about 5 percent of its charge per month, compared to a 20 per-
cent loss per month for NiMH batteries.
3. They have no memory effect, which means that you do not have
to completely discharge them before recharging, as with some
other battery chemistries.
4. Lithium-ion batteries can handle hundreds of charge/discharge
cycles.
Every shop is different and there is no way to say how often a POD
should be charged. Because the batteries are lithium ion it does not
hurt to charge them at the end of every day. It will not affect the life
of the battery charging them daily nor will it affect them or help them
by totally discharging them. To charge the batteries plug the charger
into the side of the POD and place the opposite end of the charging
cable into either of the charging ports on the WAP.
Charged 90%
Charged 70%
Charged 50%
Charged 30%
Charged 10%
2-5
Sidewinder wheel clamp assembly & Maintenance

The Sidewinder wheel clamp requires little maintenance however the correct assembly is important so that
it will be able to attach to most wheels on the market today. In the past most service calls were to correct is-
sues with components after they were dropped. The portable aligner is no different, however the Sidewinder
wheel clamp was designed to absorb most of the impact should the Pod assembly get dropped. The guide
rod bracket in most cases be the part that would absorb the impact of a accidental drop and would probably
break before other components. Should the guide rod bracket break remove the parts listed below to replace
the guide rod.
6
4
1. Snap Ring
2. Guide Rod
3. Spacer Ring
4. Washer
5. Screw
6. Knob
3
4
5
2-6
Both the upper and lower bracket on the wheel clamp contains a brass threaded bushing that allows the
upper/lower grabbers to move up and down the threaded rod. There is an upper and lower bushing so if
replacement is required make sure that the correct bushing is ordered. The bushing is a split bushing (2
pieces) that must be replaced as a set. When the bushings are made they are made as one and then cut at
the factory to make it a split bushing making it a matched set.
1. Remove the components listed in the illustration on the previous page.

2. Remove the bushing cover and slide the cover (red arrow) towards the center of the clamp.
Bushing Cover
3. Slide the lower/upper part of the bracket (blue arrow) off of the brass bushing.
4. Measure the distance from point A to point B of the opposite end of the wheel clamp and place the new
bushing end at the measured distance.
Point A
Point B
2-7
5. Place the split bushing on the threaded rod at the same distance from the end as measured in step 4.
The castle part of the bushing goes towards the center of the wheel clamp.
Point A
Point B
6. Slide the lower/upper part of the wheel clamp up over the bushing and re-attach the bushing cover.
7. Install all hardware in figure below.
1. Snap Ring
2. Guide Rod
3. Spacer Ring
4. Washer
5. Screw
3
4
5
2-8
master pod reset

Each POD has a reset button located on the back side of the POD opposite charging side. This reset button
should never have to be used but has been installed in case a major malfunction occur. Just as if a hand held
palm device requires a reset so does the POD. To execute the reset, press and hold the button for at least 3
seconds. All LED’s on top of the POD will flash at the same time and then the power only LED will come on
and remain on until the entire reset process has taken place. A grid file located on the camera PCB is re-writ-
ten to the main processor. This reset takes from 2 to 4 minutes. This reset only resets the firmware on the
PCB’s. A re-calibration or POD identification is not needed after a hard reset.
battery replacement
The batteries used to power the pods are Li-Ion. These batteries have a great track record in many devices
that are used in everyday applications. Follow the steps below should replacement of the batteries be re-
quired.
1. Remove the rubber bumper from the bottom side of the pod.
2. Remove the two screws securing the battery.
3. Carefully extract the battery from the pod.

warning: do not attach the charging cable with the
battery removed as this will cause damage
to components inside the pods.
4. Un-plug the harness connected to the pod making sure that the har-
ness does not fall back into the pod.
5. Remove the Velcro strap securing the battery.
6. The battery is secured using double sided tape.
7. Reverse procedure for installation. Follow the charging instructions to
fully charge the batteries before alignment use.
2-9
Page left blank intentionally
2-10
CHAPTER 3 cALIBRATION
Calibration
Before an alignment is performed it is highly recommended that the unit be calibrated to the rack that align-
ments are done on. Although the unit is shipped from the factory calibrated to zero we can not assume that
all racks are exactly level in the field.
1. Raise the alignment rack to a comfortable working height.

2. From the Main Menu select the “Maintenance” Icon.
3. Select the Calibration button from the Maintenance menu.
4. Select the “Pod Calibration” button from the Calibration menu.
5. A “Warning” message appears instructing the user that the

calibration process should be performed by trained individuals.
Click on “OK” to continue.
Page 3-1
Chapter 3 Calibration
6. Place the calibration bar and stands on the rear of the rack as
shown in the figure.
NOTE: IT WILL BE NECESSARY TO INSTALL THE CALIBRA-
TION BAR ADAPTER (EAK0289J42A)ON THE END
OF THE CALIBRATION BAR WITH THE FLAT SPOTS.
THIS WILL ENSURE A SMOOTH ROTATION OF THE
BAR DURING CALIBRATION.
7. Place the left pod on the calibration bar so

that the boom faces the rear of the rack.
8. Place the right pod on the calibration bar
so that the boom faces the rear of the rack.
9. Place the targets on the front turn plates
and orient them so that they are facing
Step 1
the pods. It will be necessary to leave the
targets mounted to the wheel clamps.
10. Select the appropriate rack for calibration
Rack A, Rack B or Floor
11. With the Pods secured on the bar (needle 12 o’clock) rotate
the bar forward 90° to align the needle within the green area.
A Stop sign will appear indicating to hold the position until
instructed.
12. Continue through the process stopping at each location until
the rear pods have been calibrated. Proceed to the next step
to complete the target calibration.
Step 2
Step 3
Step 4
3-2
TARGET CALIBRATION
13. Place the targets in the bar so that the targets face the rear of
the rack (needle 12 o’clock).
14. Place the Pods on the rear of the rack so that the boom of the
pod points towards the rear of the rack.
15. The unit will prompt the user to rotate the bar so that the tar-
gets rotate forward 25°. A stop signal will appear.
16. After the information is taken the user will be prompted to rotate
the targets 25° backwards from vertical.
17. When the calibration is complete the user will need to press
<OK> button to store the calibration data.
18. CALIBRATION COMPLETE
3-3
CALIBRATION functions
The calibration menu incorporates other utilities to assist the operator. Below are a list of those utilities.
• Pod Identification
• Calibration Factors
• Calibration History
Pod identification
The portable alignment system uses very sophisticated pods that may periodically require replacement due to
failures. In this event a set of pods may need to be exchanged in the field. The alignment system uses “scan
and find” process called “pod identification. The Pod Identification is used to marry the pods with the align-
ment system. Followed the steps listed to marry a set of exchanged pods to an alignment system.
1. Select the Pod Identification button.
2. The user is instructed with a WARNING that this process

should be performed by trained individuals. Click on the <OK>
button to proceed.
3. Make sure that the pods to be identified are powered up and

ready to be located. If multiple aligners are used in the shop it
is not necessary to power them down to complete this process.
Click on the <OK> button to to activate the scanning process.
4. Using Bluetooth® technology the WAP searches for any

aligner pod in the area. Please be aware that it’s possible
for the system to find a pod that may be located at the shop
across the street. This will not interfere with the pod identifica-
tion process.
3-4
5. As the system acquires the different pods in the area it will start
displaying the MAC numbers on the screen. For instructional
purposes only the system has located 4 pods in the area, this
could happen if there are two or more aligners in the area.
6. Once the system has finished finding all the pods the system
will then begin the process of marrying the pods to the aligner.
This process will start at the top of the list working it’s way
down. The system will highlight a pod number and ask the user
if the LED’s on any of the pods are flashing.
7. Look at both pods. If the LED’s on any of the pods are flashing
click on <OK>. The system will automatically identify the Pod Manual Entry
as either the Left Hand or Right Hand Pod.
8. The system will proceed to the next pod that was located.
Each time the system will ask the user if any of the lights are
flashing on the pods to be identified. If there are no lights flash-
ing click on <NO> and the unit will advance to the next pod.
9. If the system does not locate 2 pods the user is instructed to
power down both pods and press the scan button again.
10. If after 3 attempts the system does not locate the pods it will be
necessary to manually enter the POD MAC numbers located MAC
on the tag behind the rear rubber bumper of each Pod. ID
11. Press the cancel button to abort automatic pod location. Once
cancel button is pressed the “Manual enter Pod ID” button
appears.
12. Once entered press the <OK> button. The system will load the
the calibration to the new pods.
3-5
Calibration factors
13. Select the “Calibration Factors” button from the calibration
menu.
14. Each line item represents the current calibration factor being
used by the system during the alignment process. It is impor-
tant to note the location of the calibration factors, the choices
are Rack A, Rack B or the Floor.
Calibration history
This function is very useful to see how each Pod and Target has maintained consistency from 1 calibration to
the next. If either a Pod or Target shows a significant jump or drop on the History line, it may indicate a cata-
strophic failure such as a drop to either a Pod or a Target or it may indicate that an incorrect calibration was
done at that time.
1. Select the “Calibration History” button from the calibration

menu.
2. Using the Radio buttons on the left side of the screen choose
LF, RF, LR or RR. The graph will show the amount of change
from one calibration to the next. The system will only report
back one calibration per day. Click on the “Camber” or “Toe”
button to see any special note that may have been entered
during calibration.
3-6
Calibration utilities
The alignment software has a calibration backup utility that is
recommended after a new calibration is done. The user must be
aware however should a the restore function ever be used that it
will over write all calibration and user setup data. An 1¼ floppy disk
is required to perform this function.
1. From the Calibration menu select the “Calibration Utilities” icon

on the tool bar (F6).
2. To backup the calibration/user information select the “backup”

button.
3. The user is instructed to insert a floppy disk into the drive and
press <OK> to continue.
4. After the data is backed up to the floppy it is highly recom-
mended that the date be written on the label of the floppy.
5. To use the “restore” function the user can simply insert the
backup floppy into the drive and select the “restore” button. All
calibration/user information will be over written. There is no
recovery of the data that is over written.
3-7
Page left blank intentionally
3-8
CHAPTER 4 diagnostics
The software has a diagnostic screen to help troubleshoot and determine possible failed components. It can
also be used to help determine operation errors.
1. From the Splash screen choose the “Diagnostic” icon.
2. Choose the “Aligner Diagnostic” Icon from the Mainte-

nance menu.
From here the technician has a host of utilities to help trou-

bleshoot the aligner. To simplify the troubleshooting process
we will only outline and explain data useful to a technician
for determining aligner problems. As the aligner develops
more explanations will be expanded in this manual. Howev-
er most of this information will be used in the factory depot
for more extensive and in depth troubleshooting of compo-
nents on the PCB’s.
4-1
Chapter 4 Diagnostics
Data Examination Mode
The Portable aligner has a quick reference utility to view target information. This utility should be used as a
quick reference to target and camera information.
From the Maintenance screen choose the “Data Examination” Icon.
1. RMS - (Root Mean Square) should be .06 or

less
2. Target Blobs - Number of Fids seen by cam-
era, should be no more than 33.
3. Distance - Distance measured from the cam-
era lens to the center of the target.
4. Number of Planes - Total number of valid
pictures taken by the camera.
4-2
Left/Right Pod Data Serial Number inside of Pod

Error 0=Target acquired - 1=No Target
Gain: The amount gain depends on the brightness of the image. The brighter the
image the lower the gain value will be.
0 to 45
Strobe: 20 to 255 Brightness of the LED’s (How long the LED’s are on)
nFids Used: Number of Fids used to generate readings
npBlobs Number of Fids seen by camera. Should be no more than 33. If anymore
than 33 the camera is seeing other data. Check for additional spare targets.
Flags To Be Removed
RMS Background noise, should be .06 or less, .15 is maximum.
Charge The amount of percentage battery is charged.
Time Left on Battery (min- The amount of calculated battery life. Depends on power consumption of
utes) pod at that time. (Metered screen pods are busy.)
Camber Calibrated Camber Data
SAI Calibrated SAI Data
Encoder Calibrated Angle of encoder (Wheel Clamp angle)
Toe (Cross) Cross toe angle (Raw Data)
Connected Pod / WAP connection
Pod Connection Status 1 = POD not communicating with WAP
2 = POD and WAP communicating
SCANS Number of attempts to connect to pod.
roiX 384 Horizontal pixel location of the top corner of the Region of Interest (area where the target
is located)
roiY 270 Vertical pixel location of the top corner of the Region of Interest (area where the target is
located)
roiNX 308 Horizontal width of the Region of Interest
roiNY 330 Vertical height of the Region of Interest
roiX
roiY
roiNY
roiNX
4-3
ccX -3.28 Location of the target relative to the camera X (or horizontal)
ccY -2.83 Location of the target relative to the camera Y (or vertical)
ccZ 100.27 Location of the target relative to the camera Z (or away)
PS Power saving mode aligner is currently in.

1 = WAP only
4 = All components on
charging battery = Battery is hooked to the charger.
Camber To be removed
Flag
SAI Flag To be removed
Encoder To be removed
Flag
Toe Error 0x01 No Peak No centroid found
0x02 Shape Centroid has bad shape
0x04 Exposure High Exposure level is to high
0x08 Exposure Low Exposure level is to low
0x10 Sensor Blocked IR communication interface is blocked
0x20 SPI Communication Fault A Fault occurred in the SPI communications
0x40 Sunlight Sensor has identified a high ambient light condition
0x80 Clipped A portion of the sensor array is saturated. Raw Toe Plot
Toe Expo- Sensor clock period (0 to 12000, high numbers normally) (Pg 1-4)
sure
Toe Rcvd 0 = No - 1 = Yes
DATA RCV Data being received back from the pods. Should be fairly close to number of SCANS
firmware download
As the unit progresses during different stages the hardware each PCB inside the POD’s will
require updates. This information is called firmware. These updates come in form of a CD as
this information is distributed to our customers. If mandatory firmware updates are required
these will be sent out to the field using a Technical Service Bulletin (TSB).
From the “Diagnostic” screen choose the “Firmware Update” icon from the toolbar.
After software (Alignment Operating System) is in-

stalled and the system determines components inside
the PODs have updates available these components
will display a “red” icon by the component. By simply
clicking on the icon the component will download
the firmware. NOTE: DURING THE DOWNLOAD-
ING PROCESS DO NOT DISTURB THE UNIT. After
all updates have been made the icons will display
a “green” check mark, meaning the system is up to
date with the current firmware.
note: the system will not execute a

download if the pod battery is
less than 40% charged.
4-4
pod extended diagnostics
Pod Extended Diagnostics
Raw Data - Engineering Use only
These values are accumulative faults during a power cycle. It is very normal that faults will happen, how-
ever faults that continually compile will indicate a possible failure on a component inside a pod. Values from
left to right pods should be relatively the same. Rebooting the system will restart the fault counts.
Pod Voltage checks while plugged into WAP (charger)

Minimum Maximum
Adapter Power .700 .950
Battery Power 3.000 4.300
PreReg Power 5.000 5.300
Power distribution to PCB’s inside of pods. Compare LH to RH, voltages should be relatively the same.
These simple checks should be done without the charger plugged in.
Minimum Maximum
DSP33 Pwr 3.250 4.300
DSP14 Pwr 1.35 1.450
Analog 4 Pwr 3.800 4.100
Analog 5 Pwr 5.100 5.300
4-5
pod extended diagnostics (page 2)
By clicking on the (next page icon) page 2 of extended diagnostics are displayed.
The information displayed on this screen is battery information. The areas outlined are helpful when trouble
shooting battery related information. The area outlined in the lower right side of this screen is firmware ver-
sions of each component inside the pods. As the product develops these version will change. This display
of versions will only update when using the “Firmware Download” described earlier in this chapter. With the
evolution of the product detailed diagnostics will be explained.
Temperature Temperature measured in the battery pack

Voltage XXX Battery voltage in Pod - Pods will only charge if volts below 3.89
Status Flags 0x0 Not charging, battery guage trained
0x1? Inaccurate but in a learning mode
0x8? charging and trained
0x9? battery charging and not trained
0x?2 battery drained low enough but did not drain enough with charges in
between
0x?4 Met condidtion to learn - finish charging
0x?6 Met conditions to learn but battery is low
0x?0 Not met conditions for learning.
State of Charge NAC / by Last Discharge
(REel)
4-6
Avg Current Average draw of current - battery empty and plug in charger should be high
because it is taking a charge.
Strobe Version 0x102 Firmware Version of components in Pod
Camera Version 0x102 Firmware Version of components in Pod
Encoder Version 0x101 Firmware Version of components in Pod
Camber Version 0x103 Firmware Version of components in Pod
SAI Version 0x103 Firmware Version of components in Pod
Toe Version 0x103 Firmware Version of components in Pod
Supervisor Ver- 0x106 Firmware Version of components in Pod
sion
DSP Version 0x102 Firmware Version of components in Pod
4-7
pod power supply data
Development stages - NOTE: By clicking on the icon the unit will retrieve all power
supply data and will not be usable until all information is obtained.
Pod Power Supply Data
4-8
pod runtime data
Pod Runtime Data
Intial Charge % Percent of Initial charge of Pod(s) before terminating charge

Time Between Charge Accumulative time between charging times
Average on Time Average time Pod(s) were powered on (Average of last 5 charge cycles)
Max on Time Maximum time Pod(s) were on
Cumulative on Time Total Time Pod(s) have been powered up (Reset to 0 after charge termi-
nated)
Cumulative off Time Total time Pod(s) have been powered off
4-9
pod charge information
Pod Charge Information
Last Battery Charge Information (Graphs will update after each charge cycle) X axis is equal to value
times 5. EX: 37x5=185 equivalent to 3.08 hours
Input Voltage (volts) Charging input voltage
Temperature Temperature of charge cycle
Charge Current (amps) Input amps - Should start high and decline during charge
Battery Votage (volts) Battery Voltage - Should start low and increase
Battery % Capacity Capacity of battery - Should start low and increase
4-10
pod toe diagnostics
note: toe errors common because of refresh time (red text)
Left Graph Shape of the centroid from the LH Pod (Should be a clean wave form) 12 to 170
Right Graph Shape of the centroid from the LH Pod (Should be a clean wave form) 12 to 170
Centroid Two images are taken for each toe sample, one with the opposite LED on
and the other with the opposite LED off. The two images are subtracted
one from the other to remove light from the environment. The image of
the LED that results from the subtraction is called a centroid.
Angle The position of the centroid in the sensor array is used to calculate the
angle to the opposite sensor
Exposure If the centroid is too small, a Low Exposure error is returned. If the cen-
troid is too large, a High Exposure error is returned. (0 to 12000)
Toe Error
Code Name Error
0x01 No Peak No centroid found
0x02 Shape Centroid has bad shape
0x04 Exposure High Exposure level is to high
0x08 Exposure Low Exposure level is to low
0x10 Sensor Blocked IR communication interface is blocked
0x20 SPI Communication Fault A Fault occurred in the SPI communications
0x40 Sunlight Sensor has identified a high ambient light condition
0x80 Clipped A portion of the sensor array is saturated. Raw Toe Plot
Raw Toe Plot Toe plot with ambient light (EXCELLENT to check if toe is seeing outside light source
4-11
toe ext data
Toe Ext Data
SPI Error count Reading will increase slowly over time - (will show up on toe error code)
IR Com Error Count Reading will increase slowly over time - (will show up on toe error code)
Arm Error
Code Name Error
0x01 Watch Dog Reset ARM core fault
0x02 End of Code Reached ARM core fault
0x04 UART Fault IR communication interface internal fault
0x08 UART break IR communication interface internal fault
0x10 UART framing IR communication interface internal fault
0x20 UART overrun IR communication interface internal fault
0x40 Calibration Checksum Calibration data is corrupted.
0x80 Memory Checksum Firmware download failure
Board Error
Code Name Error
0x01 Main Voltage Main 3.3V power is out of spec
0x02 CCD Voltage CCD Voltage out of spec
0x04 IR Communication LED fault IR communication LED current draw is out of spec
0x08 Toe LED fault LED current draw for toe strobe is out of spec
0x10 IR Communication Voltage fault IR Communication reference voltage is out of spec
0x20 CCD Fault CCD is damaged or dirty
0x40 Strobe Fault Power to strobe circuit out of spec
0x80 Raw Voltage Fault Power from Prism Main board is out of spec
IR Com Error Count Primary power supply on the board
VRAW Voltage coming to the PCB
4-12
toe cal data
Engineering use only
Toe Cal Data
Software Revision Software Revision on the PCB
4-13
strobe/radio diagnostics
Strobe/Radio Diagnostics
Status Flags 0x00 No strobes are turned on. No measurements done. (Strobe voltages not valid)
0x01 Only Strobe Bank 1 is on. No measurements done. (Strobe voltages not valid)
0x02 Only Strobe Bank 2 is on. No measurements done. (Strobe voltages not valid)
0x03 Both strobes on. No measurements done. (Strobe voltages not valid)
0x04 No strobes are turned on. Measurements done. (Strobe voltages valid)
0x05 Only Strobe Bank 1 is on. Measurements done. (Strobe voltages valid)
0x06 Only Strobe Bank 2 is on. Measurements done. (Strobe voltages valid)
0x07 Both strobes on. Measurements done. (Strobe voltages valid)
0x80 VSYNC was on longer than 20mS. No strobes are turned on. No measurements done.
(Strobe voltages not valid)
0x81 VSYNC was on longer than 20mS. Only Strobe Bank 1 is on. No measurements done.
0x82 VSYNC was on longer than 20mS. Only Strobe Bank 2 is on. No measurements done.
0x83 VSYNC was on longer than 20mS. Both strobes on. No measurements done.(Strobe volt-
ages not valid)
0x84 VSYNC was on longer than 20mS. No strobes are turned on. Measurements done. (Strobe
voltages valid)
0x85 VSYNC was on longer than 20mS. Only Strobe Bank 1 is on. Measurements done. (Strobe
voltages valid)
0x86 VSYNC was on longer than 20mS. Only Strobe Bank 2 is on. Measurements done. (Strobe
voltages valid)
0x87 VSYNC was on longer than 20mS. Both strobes on. Measurements done. (Strobe voltages
valid)
4-14
SPI Errors SPI retrys on the radio PCB

Serial Errors Communication retries between micro controller to radio
Strobe 1 LED Voltage 2 strings of 6 LED's - 8.4v to 10.8
Strobe 2 LED Voltage 2 strings of 6 LED's - 8.4v to 10.8
Strobe Vcc Volts into the Strobe PCB 3.0 to 3.4
Temperature Temperature of the Strobe pcb
Strobe 1 Count Bumps every time the LED's count ( value is accumulative until rollover)
Strobe 2 Count Bumps every time the LED's count ( value is accumulative until rollover)
Pod Encoder Camber/SAI
POD ENCODER CAMBER/SAI

Development stages
Inclinometer SPI Errors 0 0
Encoder Internal VCC 23700 24700
Camber Internal VCC 44600 45200
Camber External VCC 44600 45200
SAI Internal VCC 44600 45200
SAI External VCC 44600 45200
4-15
Encoder calibration data
Engineering Use Only
encoder cam/sai data

Engineering Use Only
4-16
WAP diagnostics
Battery will only charge if below 3.90v or below 80%.
Volts In Volts in at the AC adapter - Min 8.00 Volts - Max 10.00 Volts
V Out 1 ± 1 volt of “Volts In” value
A Out 1 .300 Amps 3.00 Amps
V Out 2 ± 1 volt of “Volts In” value
A Out 2 .300 Amps 3.00 Amps
Temperature Temperature of WAP PCB
POT Adjust Engineering only
Bay Select Dip switches for each bay
Discover Number of Pod(s) located during the search mode
Configured Number of Pod(s) found and configured after search (should be 2)
POD1 Address (pod1)

Handle In Developement
Clock In Developement
Error In Developement
RSSI received signal strength from radio
4-17
pod camera diagnostics
Error Flags 0x07 - Camera power problem & I2C Errors from EEPROM & Camera
0x06 - Camera power problem & I2C Errors from EEPROM
0x05 - Camera power problem & I2C Errors from Camera
0x04 - Camera power problem
0x03 - I2C Errors from the EEPROM and the Camera
0x02 - I2C Errors are from the EEPROM
0x01 - I2C Errors are from the Camera.
0x00 - NO PROBLEM FOUND
Camera SPI Errors Retrys seen by camera (stable but will count up)
Camera 12C Errors Retrys seen by camera (stable but will count up)
Digital Voltage 3.3 supply to micro contoller (3.0 to 3.4)
Analog Voltage 3.3 to camera (3.0 to 3.4)
Camera 25V 2.5 to camera (2.2 to 2.6)
Temperature Temperature on the camera 15 to 25
Camera Pixel Rate 3700 to 3900
Camera Pixel count 131000 to 1310720
4-18
pod power options
The user has the capability to control the POD Power OFF
mode to conserve battery life. The software is very intuitive
and can be accessed by clicking on the battery icon on the
Diagnostic menu.
The following information is displayed.

Power Status:
• Percent of battery life.
• Operating time left on battery.
• Pod Mode.
• 1 = Power Save Mode
• 4 = All components running.
• Charging = Pod connected to charger.
Power Scheme: All components are programmed to be on,
after set time components will shut down for power saving modes.
Turn Pods Off: Radio Only All On
After 10 mins After 15 mins
Never Never
Depending on the setting the operator will be flagged on any screen that the pods are down to this percent-
age of operating time. It is suggested that the pods be plugged in for a full re-charge.
Warning Threshold: 10%
20%
30%
40%
4-19
Blank Page
4-20
Notice: The information contained in this document is subject to change without notice. Snapon Equipment
makes no warranty with regard to this material. Snapon Equipment shall not be liable for errors contained herein
or for incidental consequential damages in connection with furnishings, performance, or use of this material.
This document contains proprietary information which is protected by copyright and patents. All rights are re-
served. No part of this document may be photocopied, reproduced, or translated without prior written consent of
Snapon Equipment.
TEEWA557A (Rev B) 06/2008...rjh Printed in the U.S.A.

Portable Image: Wheel Aligner

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Portable Image: Wheel Aligner

Încărcat de

Drepturi de autor:

Formate disponibile

PORTABLE IMAGE

This page is left blank intentionally

CHAPTER 1 Component overview

CHAPTER 2 checkout and maintenance

The main menu (Advanced Software) of the aligner is the control

The aligner offers diagnostic tools to assist in troubleshoot-

The “Calibration” icon steps the user through a

The “Measurement Data” icon is the location for

IMPORTANT SAFETY INSTRUCTIONS

1. Read all instructions.

9. Do not allow unauthorized personnel to operate the equipment.

SAVE THESE INSTRUCTIONS

LOCKOUT AND/OR TAGOUT SYSTEM PROCEDURE

6. The equipment is now locked out or tagged out.

ELECTRICAL SAFETY PRECAUTIONS

When working on this aligner, keep three points in mind:

HANDLING STATIC SENSITIVE PCB’S

When inserting PCB’s:

Main board; Supervisor (ARM 9 microcontroller)

Main board; DSP Image processor (TMS320DM642)

Toe Sensor Module

unit checkout procedure ALL VERSIONS

The WAP component is powered by a standalone 9VDC power supply and

1. To easily verify that the WAP is communicating click on the “Network

2. Click on the “Network Connections” Icon.

3. Double click the “Local Area Connection” icon.

6. Click the “Properties” button in the “Local Area Con-

Powering Up the PODS

By clicking on the “Sensor Voltage” icon on the toolbar the

Battery 80% to 60%

Battery 60% to 40%

Battery 40% to 20%

Battery 20% to 10%

If flashing 10% remains

charging system WAP

1. They’re generally much lighter than other types of rechargeable

Sidewinder wheel clamp assembly & Maintenance

1. Remove the components listed in the illustration on the previous page.

7. Install all hardware in figure below.

master pod reset

2. Remove the two screws securing the battery.

3. Carefully extract the battery from the pod.

Page left blank intentionally

1. Raise the alignment rack to a comfortable working height.

3. Select the Calibration button from the Maintenance menu.

4. Select the “Pod Calibration” button from the Calibration menu.

5. A “Warning” message appears instructing the user that the

7. Place the left pod on the calibration bar so

1. Select the Pod Identification button.

2. The user is instructed with a WARNING that this process

3. Make sure that the pods to be identified are powered up and

4. Using Bluetooth® technology the WAP searches for any

1. Select the “Calibration History” button from the calibration

1. From the Calibration menu select the “Calibration Utilities” icon

2. To backup the calibration/user information select the “backup”

Page left blank intentionally

1. From the Splash screen choose the “Diagnostic” icon.

2. Choose the “Aligner Diagnostic” Icon from the Mainte-

From here the technician has a host of utilities to help trou-

From the Maintenance screen choose the “Data Examination” Icon.

1. RMS - (Root Mean Square) should be .06 or

Left/Right Pod Data Serial Number inside of Pod

PS Power saving mode aligner is currently in.