Bosch FWA 43 Series Maintenance Instructions Manual Download Page 1

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FWA 43xx / FWA 44xx

Maintenance instructions

Wheel alignment system

Summary of Contents for FWA 43 Series

Page 1: ...FWA 43xx FWA 44xx en Maintenance instructions Wheel alignment system ...

Page 2: ...g 18 9 Charging equipment MWA 20 9 1 Overview sensor 20 9 2 Connector pin assignment 20 10 Radio box 21 10 1 Radio module 433 MHz green 21 10 2 Radio module 2 4 GHz blue 21 11 Measuring element 22 11 1 Over view of measuring element 22 11 2 Conductor board charging electronics 23 11 2 1 Function 23 11 2 2 Verify and set charging voltage 23 11 3 Battery For radio version 24 11 4 Measuring processor...

Page 3: ...rogram Calibration 39 14 7 Save user individual data 39 14 7 1 Customer data and measuring protocol 39 14 7 2 Measurement report 39 14 7 3 Automatically created vehicle data 39 14 8 FlashWriter 40 14 8 1 Function 40 14 8 2 General operating instructions of the program process flow 40 14 8 3 Preparation of the program step 40 14 8 4 Check the connected equipment ver sion check 40 14 8 5 Version che...

Page 4: ...tentially dangerous situation that could cause personal injury or damage to property Important warns of a potentially hazardous situati on in which the FWA 43xx FWA 44xx the test sam ple or other object in the vicinity could be damaged In addition to these warnings the following symbols are also used Info i i In addition to these warnings the following symbols are also used Single step procedure i...

Page 5: ...t 1 8 Cable set for reading recorder 9 Wheel base 1 Disconnect the connectors Do not unscrew otherwise the connector will be damaged 2 The reading recorders are loaded when FWA is connected to the network irrespective whether the multiple socket is switched on or off Rear view SPtv Fig 2 1 Steering wheel clamps 2 Break lock 3 Multiple socket 4 Cable socket 5 Splitter box Cable or Messbox Wireless ...

Page 6: ...rements 3 3 Function Specification Measurement H x B x T 1 600 x 900 x 800 mm Weight Approx 105 kg Temperature and working 3 4 environment Function Specification Operating temperature 5 C 40 C Storage temperature 20 C 60 C Temperature gradient 20 C hour Relative operating humidity 10 90 40 C Relative humidity gradient 10 hour Maximum operating clearance 200 m 3 000 m Maximum transporting clearance...

Page 7: ...side of the PC Fig 3 1 Mouse PS 2 2 LPT 1 parallel Centronics 3 Network BNC RJ 45 10 100Mbit 4 COM 2 serial 9 pin 5 USB 6 Monitor VGA 15 pin 7 COM 1 serial 9 pin 8 Keyboard PS 2 9 On Off switch 10 Voltage converter 110 V 230 V 11 Network connection Operating system Operating system Windows XP Professional Multilanguage Version 1 01 Recovery DVD Fig 4 ...

Page 8: ...on of C button R R in the axial cutter program Measurement is not possible if the licenses do not match Connection 4 2 2 The dongle is fixed on the parallel interface LPT 1 at R R the back side of the computer For other dongles of other program or a connected R R printer is permeable and they do not affect further Hardware License number 4 2 3 The license number is a part of the serial number It c...

Page 9: ... Functional diagram FWA 43xx FWA 44xx 9 Robert Bosch GmbH 1 690 326 006 2008 8 25 en Functional diagram 5 Cable format 5 1 ...

Page 10: ...d mouse LPT 3 3 3 3 2 D3 P1 P1 PS2 Y1 D6 D8 D8 D8 D8 D1 personal computer D2 keyboard D3 mouse D4 sensor remote control D5 unit communication D6 dongle D8 measurement head D10 measure box D14 radio box Y1 D5 D10 2 X1 fuse 3 15A fuse frontside 2A A1 rack P1 monito r TFT X1 extension lead Y1 printer Y2 wall wart printer Y2 chargin g contacts emergency cable mode optional components D14 ...

Page 11: ...splitter box or mess box Radio devices have KP built in the mess box The R R mess box also serves for loading the batteries In emergency cable operation Breakdown radio i i the measuring element can be connected to the mess box KP is installed in PC in case of cable equipments R R A splitter box manages the connection possibilities of the measuring element The KP in case of radio or cable devices ...

Page 12: ... 12 FWA 43xx FWA 44xx Communication processor 1 690 326 006 2008 8 25 Robert Bosch GmbH en Functional diagram of cable splitter box 6 4 ...

Page 13: ... sockets for the connecting cable At the same time the 8 V for the connecting cable is protected using fuse protection 1 6 AT The splitter box is always connected to power supply R R The device protection with 2 x 3 15 AT is found in R R the splitter box A looping of 240 V AC is made for switch able R R multiple sockets Configuration of front side Fig 8 Delay fuse for 8 V DC 1 6 A Configuration on...

Page 14: ...data cables and voltages Looping of data i R R n radio operation Measurement box in cable operation R R splitter box emergency cable mess box Looping of voltages 8 VDC for Battery charging R R 8 VDC for cable operation R R 5 VDC for radio module R R There are only conductor paths and clips on the i i board no electronic components Measurement box Radio 8 Element 8 1 Measurement box Fig 13 Radio ve...

Page 15: ... Measurement box Radio FWA 43xx FWA 44xx 15 Robert Bosch GmbH 1 690 326 006 2008 8 25 en Functional diagram of mess box 8 1 2 ...

Page 16: ...ng on the temperature Communication processor R R The communication processor requires 5 VDC for separate operation and for radio model Which he himself from the 8 VDC power supply board generated It is data manager between CCD server and the i i measuring processors in the measuring elements Splitter board R R see 7 2 2 Configuration of front side of mess box Fig 14 1 Delay fuse for 8 VDC 2 AT Pi...

Page 17: ... board with potentiometer R 16 Tadj See also potentiometer setting power supply board Power supply board 8 5 Connector pin assignment Fig 17 1 input supply voltage 2 connection san approx 12 VDC 3 output 8 VDC for KP 4 output 8 VDC for splitter board Tasks Supply of 8 VDC and 12 VDC Functional description The power supply board transforms the supply voltage110 V 230 VAC voltage in 15 VAC and conve...

Page 18: ...ing condition Temperature between R R 20 C 30 C no load Breaking point MP2 on C6 Pin 1 to GND MP1 R R Vadj 8 00 V 0 04 V 0 25 0 00 V i i 2 Iadj R11 Setting of operational amplifier input Safety switching to prevent overloading of power supply by short circuit or simultaneous battery charging and cable operation The power supply is only covered on battery charging or cable operation Setting locatio...

Page 19: ...8 4 266 5 5 258 4 6 250 4 7 242 5 8 234 7 9 226 9 10 219 3 11 211 8 12 204 3 13 197 0 14 189 8 15 182 6 16 175 6 17 168 6 18 161 8 19 155 0 20 148 4 21 141 8 22 135 3 23 129 0 24 122 7 25 116 6 26 110 5 27 104 5 28 98 6 29 92 9 30 87 2 31 81 6 32 76 1 33 70 7 34 65 4 35 60 3 36 55 2 37 50 2 38 45 3 39 40 5 40 35 8 0 0 50 0 100 0 150 0 200 0 250 0 300 0 0 5 10 15 20 25 30 35 40 T C mV ...

Page 20: ...direction of front side of the vehicle Mount receptacle MWA short on right side Fig 21 breadth length in direction of front side of the vehicle Connector pin assignment 9 2 Connector pin assignment Fig 22 connection for splitter board 8 V DC Cable white Connection for splitter board measure Cable brown The charging contact must be mounted only on the i i radio version During mounting the plus pole...

Page 21: ...ion to MWA R R Data receipt from MWA R R Communication with MWA R R Function The radio modules transmit on 433 MHz or 2 4 GHz the measuring commands to measuring element MWA and receive the determined measuring values from them Power supply The radio modules are supplied a voltage of 5 V DC R R The supply is taken from the splitter board R R 5 V DC is generated on the communication processor R R C...

Page 22: ...d off and converted to 2 charging operation during inserting the measuring element MWAS in the charging voltage See functional diagram charging electronics The green power LED goes out and the red charging 3 LED lights After taking out the measuring element MWA 4 from charging socket the red charging LED goes out charging is completed The measuring element MWA is switched off By pressing the ON bu...

Page 23: ...or is operated with battery voltage A charging process over Night is sufficient for R R approx 10 hours operation The durability of the battery consists of approx 5 years In mode emergency cabel radio MWA with cable is i i no battery charging Connector pin assignment Fig 29 1 Connection battery 2 Connection to measuring processor 3 Connection to the charging contacts 4 Breaking point ST 5 5 Breaki...

Page 24: ...ed battery voltage with Ni Cd cells gives i i no statement about the charge state full or half full To prevent deep discharge monitors the proces sor measuring the battery voltage and switches at 4 2 V to the relay Measuring processor 11 4 Connector pin assignment Fig 30 Front side 1 Keyboard 2 Keyboard radio status 3 Not configured is used for programming in plant 4 Radio module 5 Turn tilt plate...

Page 25: ... Measuring element FWA 43xx FWA 44xx 25 Robert Bosch GmbH 1 690 326 006 2008 8 25 en Functional diagram MWA 11 4 2 ...

Page 26: ...m Flash writer Reading the software information and error messages is done with service tool System monitor Reading reflecting the adjustment values 11 4 6 On every switch on reset of the measuring element MWA a check sum comparison is undertaken between the contents of EPROMS of measuring processor and the camera If there are any differences the adjustment values correction values and null point ...

Page 27: ...is R R illuminated by the pendulum on CCD line The tilt of camera is represented on its own CCD R R line using the pendulum swing The diodes are quickly switched on and again R R switched off in succession for determining the angle This happens in a specific time system Dark shots Ambient light and light shots LED are R R undertaken during each measuring The fixed time system results from the expo...

Page 28: ...racy 20 angular seconds Temperaturdrivt none Long term stability extremely high Alteration cannot be measured Sign measuring range up to 23 degree Sign difference measurement by 20 degrees using camera possible without electronic turn tilt plate Intelligent camera integrated micro controller Sign LED Fig 33 The sign LED sends the sign beam to the opposite i i measuring element Flexible camera boar...

Page 29: ...lues in case of camera change and R R annual maintenance as well as in case of servicing are locally determined by the service technician with the menu driven adjustment program The zero point adjustment values are stored on an EPROM of camera board and also stored permanently on the measuring processor board Reading reflecting the adjustment values 11 5 7 On every switch on reset of the MWA a che...

Page 30: ...Rim shock compensation button 3 Save button 4 Radio transmitter receiver display 5 Display of runout compensation 6 Display of save 7 Display on 8 Display battery off Battery OK flashing Battery reserve operation on Battery charging operation Keyboard board cable 11 5 12 Function 11 5 13 Keyboard function R R LED display on position R R LED display runout R R LED display button of save R R Keyboar...

Page 31: ...n and possible errors are read with service tool System monitor Change in transmission channel of 12 2 measuring element Using key combination MWA 12 2 1 Switch on measuring element MWA using R button R R The green power LED lights Quickly press R key and the rim shock key middle R R key simultaneously to switch off All LEDs go out They are now in channel change R R mode The device completely swit...

Page 32: ...urement Serial cable PC KP 13 4 Connecting cable PC COM2 for communication processor KP Line filter power supply board 13 5 PIN 1 orange cable PIN 2 black cable PIN 3 blue cable PIN 4 orange cable Communication processor KP 13 6 splitter board PIN 1 yellow cable data cable PIN 2 red cable 5 V PIN 3 green cable data cable PIN 4 brown cable measurement PIN 5 white cable 8 V PIN 6 brown cable measure...

Page 33: ...low cable data PIN 3 brown cable measurement PIN 4 white cable 8 V Splitter board 8 00 V DC 13 12 Protection 1 6 AT splitter board PIN 1 white cable 8 V DC Key measuring processor board 13 13 Measuring processor Fitting socket 13 14 Turn tilt board Charging electronic Measuring 13 15 processor PIN 1 white cable 8 V PIN 2 pink cable 5 V PIN 3 red cable Vcc 5 V f measuring processor PIN 4 red cable ...

Page 34: ...lement 4 5 m 13 18 Connecting cable for measuring element Measuring processor CCD camera 13 19 tightly fitted in the camera Measuring connection using cable covering and screwed clamp on measuring processor Strip cable Measuring processor CCD camera Is moved and then secured in socket Charging cable measuring element 13 20 1 Brown cable measurement 2 White cable 8V Cabling diagram 13 21 There are ...

Page 35: ...repares to start After sometime the Windows XP Minisetup will 8 start To continue installation please select Next 9 Accept the license agreement and continue by 10 clicking on Next You will the Product Key on the underside of your 11 PC please enter it in the fields and continue with Next The installation shall be continued and ended In the path Start Programs FWA Tools sellang i i select the corr...

Page 36: ...tallation of every document is recorded If the program finds a valid license the data record R R in green is entered in the record with the note successful installed If a valid license is found for a data record this R R appears in red with the note Not installed incorrect invalid License After the installation process is completed this i i file is saved in the directory C Dokumente und Einstellun...

Page 37: ...nd the error cause i i There is information as to Logging the system configuration R R Logging the system start R R Information about e g non accessible sensors R R Information about e g interrupted working sections R R Logging user actions R R The tab Runtime displays the protocol of the i i current program runtime The log of the last 10 Program starts is saved under i i C program files FWA CCD W...

Page 38: ...ssor Transmitter power 0 adjustment and point blank 1 range Transmitter power 1 for close range 2 Transmitter power 2 for middle range and 3 Transmitter power 3 for long range 4 If the diagonally arranged camera determines i i that the infrared rays are not received then the transmitter power is shifted up automatically If the diagonally arranged camera determines i i overexposure light or infrare...

Page 39: ...e is out of tolerance in case of complaints Save user individual data 14 7 Customer data and measuring protocol 14 7 1 The customer data and the measuring protocol is i i saved in the following folder Path C program files FWA CCD WheelAligner Aligner General database Measurement report 14 7 2 The measuring protocol is saved in the folder i i Path C program files FWA CCD Wheel Aligner Aligner Gener...

Page 40: ...p document 6 Ends the FlashWriter program All function keys are not displayed every time Their i i availability is dependent on the corresponding program step Preparation of the program step 14 8 3 The axle measuring program and the CCD server 1 must not be in operation End the programs if they are running 2 You can close the CCD server in which you can 3 right click on the CCD symbol in the info ...

Page 41: ...ting the Firmware a green status button i i should be displayed for all the components Update of the communication processor 14 8 6 The communication processor shall be updated and 1 the result shall be displayed The step is executed only if the communication 2 processor can be updated and the firmware file receives a current version as already existing or the version check is deactivated Update o...

Page 42: ...ion field of the sensor Check the connected equipment result A subsequent check of the equipment is carried out and the result of the update is displayed Settings FlashWriter 14 8 10 The settings dialogue serves the following options R R and setting options Option list Language Enables the language option 1 for program user interface If the program is running for the first time a screen page appea...

Page 43: ...message can occur due to following reasons The file is not available is corrupt or is locked by other process The format of the file is invalid i e you cannot receive Firmware Images The communication processor can be be accessed If the communication processor and or the measuring box is not connected this message can have the following reasons The serial interface is not functioning or is blocked...

Page 44: ...th Read the content of the file is displayed in the current screen view Thereby the file suitable for currently selected screen view must be opened in other case it is not displayed With All all the equipments are selected with 5 None the option is reset completely Here different functions are provided partially it is 6 dependent on the screen view in order to effect the screen view or the provisi...

Page 45: ...Write Sensorhead Version Is available only in Service variants Writes the content of the field Version in the EEPROM of the selected measuring processors Options Tab 6 Register card Light exposure CCD line and transmitter LED must be configured optimally for exact measurement and must match The parameter used for it can be displayed here and if required can be modified The parameters are saved in ...

Page 46: ...erent display blocks compare colour scheme in case of Type and version info Camera specific parameter Fig 11 1 Coefficient for calculating track measurement value In case calibration sets the value Toe x 0 2 Coefficient for calculating camber measurement value In case calibration sets the value Camber x 0 3 Date of last calibration 4 Displays whether the fields Lens Corr and Pendulum Corr have a v...

Page 47: ...ved in a file per camera at each time The files are in the directory C program files R R FWA CCD Wheelaligner CCD Camera A new sub directory is created here with the date R R and time in case of every backup The serial numbers of the cameras are used as file name Serial number as file name Fig 13 Recovery 14 10 3 Recovery of camera data Fig 14 Recovery of camera data in 3 steps Camera data file Se...

Page 48: ...d values R R Demo server D Provision of Demo measured R R values Licence server L Provision of licence data R R ILSV server Provision of language data R R TDE Solldateneditor i e target data editor R R RemoteControl IR Remote control program R R Function The main program serves as an interface between the user and the equipment The interface provides an operational platform here The main program r...

Page 49: ...erance 600 Equipment out of tolerance 600 10 angle minutes Tab 14 Only relevant settings are mentioned i i CCD server 14 11 3 CCD server Fig 16 Tasks Separate Program module R R Server for main program R R Provision of real time measured values currently R R measured in the vehicle Start before the main program R R In case of manual start begin before the main R R program Interface between the mai...

Page 50: ...e measured values between the individual adjustment steps Tab 17 Program functions Context menu The operation of the CCD server is carried out via i i a context menu which opens in the taskbar with a right click on the CCD server symbol Functions Fig 17 The functions Status Settings Channel Terminal R R About call a dialogue These functions can be accessed even within the opened dialogue A running...

Page 51: ... changed After saving the server shall be restarted Most of the relevant configuration settings can be i i edited in Settings Configuration settings in the file CCD INI Channel Channel enables to retrieve and set the system i i number Channel Fig 21 1 Display of channel number and selection of a device with the help of a radio button 2 Selection of a channel In case of 2 4 GHz wireless modules 4 c...

Page 52: ...nd can be switched on with the help of the key combination CTRL W 5 Display of sensor values The letters identify the following sensors A B G H cross toe C D E F long toe I K P Q Steering axis inclination sensor L M N O Camber sensor The display can be compared with the direct angle i i measurement in the main program There is no error handling and the measured values are uncorrected Thereby a bet...

Page 53: ... program files C program files FWA CCD WheelAligner Demo R R Demo exe R R Program start Auto Start Group R R File description DEMO exe Executable program file R R DEMO ini Configuration settings of the demo server R R Configuration settings DEMO ini Settings Entry Legend Port 1082 TCP IP Port number Tab 19 en Program functions Context menu Fig 25 Context menu The operation of the demo server is ca...

Page 54: ...cense server is a separate program module and provides the main program as server It provides the serial number of the wheel alignment gauge This serial number is provided in the dongle The dongle is inserted in the parallel port LPT1 The dongle shall be accessed by the license server via a driver The license server must always be started before the i i main program The main program asks for the s...

Page 55: ...am You will receive an error message The target databank shall be closed and a verification is possible only in demo mode License Status Fig 30 1 Displays the number of connections to the server during the entire runtime of the server after starting the program In normal case number amounts 1 Connection to main program 2 Displays the number of the queries of the main program to the license server ...

Page 56: ... i i the white program symbol register book in the right taskbar By right clicking on this symbol a dialogue opens with the following entries ILSV Status Fig 33 Displays the number of connections to the server 1 during the entire runtime of the server after starting the program In normal case number amounts 1 Connection to main program Displays the number of the queries of the main 2 program to th...

Page 57: ...g remote control This helps to forward the command forwarded by R R the Infrared receiver to the computer as well as to the program Wheel alignment system that this can be executed After starting the program a symbol appears in the R R taskbar The yellow symbol blinks while entering a function R R This takes place only if the command has not been recognised by the software Task With the help of th...

Page 58: ...1 690 326 006 2008 8 25 Robert Bosch GmbH en 58 FWA 43xx 44xx Instruction report Instruction report 15 ...

Page 59: ...1 690 326 006 2008 8 25 Robert Bosch GmbH Instruction report FWA 43xx 44xx 59 en ...

Page 60: ...Robert Bosch GmbH Diagnostics Franz Oechsle Straße 4 73207 Plochingen DEUTSCHLAND www bosch com bosch prueftechnik bosch com 1 690 326 006 2008 8 25 ...

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