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FCAR FD505 Wheel Alignment System User Manual

Technical parameter:

Measure item

Measure accuracy

Measure range

Camber angle

±0.01°

±8°

Caster angle

±0.03°

±19°

Front wheel inclination angle

±0.02°

±19°

Toe

±0.01°

±2°

Rear wheel thrust angle

±0.02°

±2°

Rear wheel axle deflection

±0.02°

±2°

Wheelbase difference

±0.02°

±2°

Front set back

±0.02°

±2°

Rear set back

±0.02°

±2°

Summary of Contents for FD505

Page 1: ...05 Wheel Alignment System User Manual 1 FD505 Wheel Alignment System User Manual Service and support FCAR TECH USA Phone 443 380 0088 Address 7090 Golden Ring Rd Suite 107 Rosedale MD 21237 Web www fcarusa com ...

Page 2: ...NCTIONS AND FEATURES 9 2 SELECTION AND USE OF SUPPORTING TOOLS 10 2 1 THE USE OF CORNER PLATE 11 2 2 SPECIAL FIXTURES AND TARGETS 11 2 3 5D FOUR WHEEL ALIGNMENT SYSTEM INSTALLATION METHOD 12 2 3 1 Target selection 13 3 PREPARATIONS BEFORE WHEEL ALIGNMENT OPERATION 14 3 1 PREPARATION BEFORE OPERATION 14 3 2 FIXTURE TARGET INSTALLATION 15 3 3 DEVICE CONNECTION 17 3 4 HOST ON OFF AND FUNCTION MENU MA...

Page 3: ...ATION 45 6 SYSTEM SETTING 46 6 1 PRINTING INFORMATION SETTING 47 6 2 TARGET TYPE SETTING 47 6 3 DATA UNIT SETTING 49 6 4 SET THE FRONT POSITION 49 6 5 SET CAMERA PARAMETERS 50 MAINTENANCE AND MAINTENANCE STORAGE ENVIRONMENT 51 APPENDIX 53 APPENDIX 1 REGULAR PROCEDURE FOR WHEEL ALIGNMENT 53 APPENDIX 2 BASIC OVERVIEW OF THE ALIGNER 58 FOUR WHEEL ALIGNER COMMON PROBLEMS AND SOLUTIONS 68 WARRANTY 69 ...

Page 4: ...ners should not tamper with the computer Regularly check the level of the car s positioning ground to ensure correct testing and personnel safety Remove obstacles around the car s location area to prevent impact on operations The equipment structure and supporting tools in this manual should be read carefully before installation and commissioning Avoid switching the computer host frequently It is ...

Page 5: ...el alignment system is the product and platform of FCAR self developed vehicle four wheel alignment combined with the application feedback of 3D aligner users and the lack of 3D products Field precision transportation installation shunting etc Through more than 5 years of research and development and test verification it has launched an era based landmark four wheel aligner product Since then the ...

Page 6: ...ng knuckle and the front axle with the frame should maintain a certain relative position This positional installation is called steering wheel alignment also known as front wheel alignment Previously used wheel alignment referred to front wheel positioning and now vehicles require rear wheel positioning in addition to front wheel positioning The front and rear wheel positioning of the vehicle is t...

Page 7: ...Measure item Measure accuracy Measure range Camber angle 0 01 8 Caster angle 0 03 19 Front wheel inclination angle 0 02 19 Toe 0 01 2 Rear wheel thrust angle 0 02 2 Rear wheel axle deflection 0 02 2 Wheelbase difference 0 02 2 Front set back 0 02 2 Rear set back 0 02 2 ...

Page 8: ...FD505 Wheel Alignment System User Manual 8 Tablet structure diagram Serial number Name Description Power Indicator Charging indicator Microphone port Voice input Light sensor External light intensity sensing ...

Page 9: ...or power supply RJ45 interface For network connection USB interface B shape Device interface used to connect computers and use tablets as USB drives USB interface Host interface for tablets to connect to other devices or to connect to USB drives HDMI interface Standard HDMI interface used to connect HDTV output Power switch For on off tablets or for locking screens 1 4 Product functions and featur...

Page 10: ...ted by rotating the target to perfectly solve the measurement site limitation Intelligentization It can adapt to multi port synchronous display such as Android tablet Android TV and subsequent Android mobile phone dynamic loading display stereo display is more intuitive Practicality Applicable to all kinds of lifting platforms double columns four columns small scissors large scissors it solved the...

Page 11: ...order to make the wheels to rotate freely during the caster measurement the locking pins on both sides of the corner plate must be removed Note When getting in the car make sure the wheel is at the center of the turntable 2 2 Special fixtures and targets This fixture is a four claw special fixture designed for the testing of 5D four wheel alignment system It has beautiful appearance and flexible u...

Page 12: ...hod FCAR 5D four wheel alignment system breaks through the limits of the field and is suitable for a variety of lifting platforms two columns four columns small scissor and large scissors The following are installation options Note The small scissor installation scheme is similar to the large scissor ...

Page 13: ...FCAR FD505 Wheel Alignment System User Manual 13 2 3 1Target selection Please refer to the table below to select the target type according to different lifting platforms ...

Page 14: ...e locking pin to prevent it from rotating 2 When driving the car ensure that the tire is at the center of the corner plate After stopping the car tighten the handbrake to ensure that the car does not move and the personnel are safe 3 Check the rim size and tire pressure the wear of the tires the components status of the steering system and the suspension system such as the tie rod ball head shock ...

Page 15: ...e in the left and right direction refer to the 5D four wheel alignment installation method The front wheel should install two short rod targets separately and the rear wheel should install two long rod targets separately How to install fixture target The fixture has been locked to the center position before leaving the factory There is no need to adjust the center and the fixture installation step...

Page 16: ...amp to the rim position Figure 3 2 1 Fixture installation The physical photo is shown below Note When assembling the fixture the claws should keep away from the lead block on the rim please make sure that the four claws are in full contact with the rim Installed long and short target object as shown below ...

Page 17: ...FCAR FD505 Wheel Alignment System User Manual 17 3 3 Device connection The interfaces on the back of the main unit are as shown below ...

Page 18: ... configuration as shown below Connect the power plug to the standard three terminal power socket The power supply requires 110 240V Turn on the power switch to start the two hosts 3 4 Host on off and function menu main interface After the host is started turn on the tablet Since the tablet has been connected to Wi Fi of the router built in the host computer at the factory the program can connect t...

Page 19: ... whether the Wi Fi name is correct Figure 3 4 1 system main interface The functions represented by each icon are shown in the table below Icon Icon name Function description Target monitoring Before wheel alignment camera monitoring must be carried out to ensure that all targets are clearly within the visual range of the camera Select model Select the model of the vehicle to be tested and then dir...

Page 20: ...ocess Before testing the wheel the target should be monitored to ensure that the target is complete clear within the camera viewable range After the target monitoring is completed the vehicle pushing compensation and the caster measurement can be performed If the measured result does not meet the requirements of the standard database the corresponding adjustment should be made After the adjustment...

Page 21: ... for users The following two measurement modes are introduced separately 4 1 Target monitoring Before performing four wheel positioning no matter which measurement mode is used target monitoring is required first Select Target Monitoring on the main interface of the system as shown in figure 4 1 1 and4 1 2 to ensure that all four targets are clearly within the visible range of the camera ...

Page 22: ...FCAR FD505 Wheel Alignment System User Manual 22 Figure 4 1 1camera monitoring Figure 4 1 2 Target monitoring and lifting mode ...

Page 23: ...efore entering the target monitoring please make sure that the target type and front position are set correctly For details see Chapter 6 System Setting 4 2 Ground mode General measurement flow of ground mode Model selection Push compensation adjust Back tilt measurement adjust Test drive Save measurement data View print results the operation flow and method of general measurement will be describe...

Page 24: ... 1 Custom Models You can add a model to your custom models through the following operation Select a model then press the Copy To Custom button in the Select model interface and the model will be added to your custom models When you select Custom models menu you can see your custom modles list Through the Add or Delete button in the upper left corner of this page you can add or delete a ...

Page 25: ...t add it at will You cannot delete any of the system models 2 Update Database You can add the model data in batch through this function FCAR provides the new model data regularly The detailed steps are as follows a Press the button Update database in the Select model interface the system will pop up the dialog as shown below ...

Page 26: ...k with data packge cardb zip to F7 series tablet c Click Select file you will see ES File Explorer d Open ES File Explorer and the system will pop up Choose path dialog then click the arrow to return to the homepage of folder e Click mnt usb_storage to open the USB disk ...

Page 27: ...FCAR FD505 Wheel Alignment System User Manual 27 f Open the data package cardb zip g Select the first way ...

Page 28: ...FCAR FD505 Wheel Alignment System User Manual 28 h Wait for the system reading and updating the data i Click Restart to restart the host after completing the data updating ...

Page 29: ...ensation After finding the model to be tested click OK to automatically enter the pushing compensation measurement interface If the target positioning is not accurate there will be corresponding adjustment prompts as shown in figure 4 2 2 1 or other prompt information Adjust the target respectively until the prompt disappears ...

Page 30: ...ly enters the car pushing interface as shown in figure 4 2 2 2 How to perform vehicle pushing compensation 1 According to the pushing prompt drive the car slowly and evenly backwards about 15CM the steering wheel is centered Note Before pushing the car you must ensure that the steering wheel is horizontal and lock it with the steering wheel mount ...

Page 31: ...ackward pushing 2 When the following interface is prompted please stop pushing backward and the rubber pad can be used to stuck the wheel Figure 4 2 2 3 Stop pushing 3 When the following interface appears move slowly and evenly forward according to the screen prompts ...

Page 32: ...g interface is prompted stop pushing forward At this time the system may take a few seconds to calculate please wait Figure 4 2 2 5 Stop pushing 5 If the measurement is successful the system will automatically jump to the measurement result interface as shown in figure 4 2 2 6 The measurement data of ...

Page 33: ...ange Red font measured value beyond the standard range Green font measured value within the standard range Precautions 1 During the measurement process the object or person between the camera and the target should be removed to prevent the target from being blocked and affecting the measurement results 2 Before measuring be sure to center the steering wheel and fix it so that the steering wheel do...

Page 34: ...t is for the front wheel including the inclination angle and the caster angle The inclination angle distributes the vehicle weight evenly over the bearing protects the bearing from damage and makes the steering force average and the steering light The presence of the caster angle allows the intersection of the steering axis and the road surface to be in front of the grounding point of the tire and...

Page 35: ...st be held before the caster measurement and shunting How to perform the caster measurement 1 According to the interface prompt first turn the steering wheel to the right about 80 When the scroll bar is close to the edge stop turning the steering wheel Figure 4 2 3 2 Right turn steering wheel 2 According to the interface prompt turn the steering wheel to the left about 80 When the scroll bar is cl...

Page 36: ...eel Alignment System User Manual 36 Figure 4 2 3 3 Left turn steering wheel 3 At this point according to the prompt slowly return to the right steering wheel about 00 or so Figure 4 2 3 4 Back to the steering wheel ...

Page 37: ...ther the current measured value is within the standard range Red font measured value beyond the standard range Green font measured value within the standard range Black font current measured value without reference range 4 3 Lift mode General measurement procedure for lift mode Model selection Lift the vehicle push compensation adjust back tilt measurement adjust Test drive Save measurement data V...

Page 38: ... click Lift up the vehicle in the upper left corner the software automatically switches to the lift measurement mode and the target monitoring mode is also automatically switched Figure 4 3 1 four wheel data interface 2 When the software pops up the following prompt please operate the lift and Lift the body slowly ...

Page 39: ...face1 3 If the frames of target graphics are red the targets are not the correct position Need to lift the body or adjust the elevation angle of targets When the frames turn green stop lifting the body and click to complete the lift mode setting Figure 4 3 3 Off the floor interface2 ...

Page 40: ...ehicle in the upper right corner to start the cart compensation measurement Figure 4 3 4 four wheel data interface in the lifting mode 5 The push compensation interface is shown in Figure 4 3 5 First slowly turn the left rear wheel backwards according to the prompt until the yellow reference line reaches the green dot position as shown in Figure 4 3 6 stop rotating Note Do not touch the target whe...

Page 41: ...t System User Manual 41 Figure 4 3 5 push compensation interface1 Figure 4 3 6 push compensation interface2 6 According to this method the rotation is reversed left rear wheel right rear wheel right front wheel left front wheel ...

Page 42: ...ement result is as shown below the measurement data of the legend is only for operation instructions and has no reference value Figure 4 3 8 four wheel data interface In order to make the user more intuitive to understand the condition of the vehicle the result display interface uses different color fonts to indicate whether the current ...

Page 43: ...the steering wheel and fix it so that the steering wheel does not rotate during the cart which will affect the test results 4 4 Vehicle adjustment In the measurement result interface select Adjust the rear wheel Adjust the front wheel or Adjust the caster to enter the adjustment interface as shown in figure below The general adjustment order of the wheels First the rear wheel and then the front wh...

Page 44: ...an be eliminated but the old car or the car with the aging condition can only be used as a reference 4 5 Data saving When you click the button after completing the vehicle adjustment the system will automatically pop up the following prompt select Save Data fill in the vehicle related information on the maintenance record interface click OK to save all test records can be viewed or changed in the ...

Page 45: ... User Manual 45 Figure 4 2 6 1 Data saving prompt Figure 4 2 6 2 Save measurement data 5 Maintenance information Select the maintenance data icon on the main function interface to view modify delete create print etc the service records ...

Page 46: ...nting device keyboard mouse monitor and the printer driver on the host computer through the USB port or the corresponding port 6 System setting Select the system settings Icon on the main function interface to view store information language settings synchronization settings model rendering settings print settings and more ...

Page 47: ... Settings 6 1 Printing Information Setting You can set the title the workshop name the address etc for the test report Figure 6 1 1 Printing information setting 6 2 Target type setting Different installation schemes as shown in Table 1 select the corresponding target ...

Page 48: ...cissor installation scheme large scissor installation scheme Double column target Double column installation four column installation Big target 5 5 Not applicable Not applicable Small target 5 5 Not applicable Not applicable Tip For the installation plan of each platform please refer to the 2 3 5D Four wheel alignment system installation method section of this manual ...

Page 49: ...the display unit of the test report Figure 6 3 1 Data unit setting 6 4 Set the front position The user can set the front position according to his own detection environment and detection habits Once the front position is set please do not change it at will Figure 6 4 1 Car front position settings ...

Page 50: ...ode the tail is aligned with the four wheel alignment host 6 5 Set camera parameters When the measuring environment is too dark or too bright which is not conducive to the target to provide the target graphics reflection the camera exposure can be adjusted In general if the targets graphics reflection is too dark add the exposure value if too bright reduce the exposure value The actual application...

Page 51: ...esponding position Maintenance and maintenance storage environment Environment requirement a The machine is suitable to work between 0 and 40 If your working environment temperature is higher or lower than this temperature the machine may not work properly Please take measures to ensure the working environment ...

Page 52: ... avoid glare or sunlight interference during use otherwise it will not work properly 2 It should be placed in a ventilated and dry place after use 3 The surface of the reflector should be regularly cleaned with a soft cloth 4 Do not vibrate impact or slip the reflector to avoid damage to the sensing element 5 Do not open and change the original structural parts Equipment maintenance a The surface ...

Page 53: ...y you should go to the test vehicle to make a rough judgment on the possible causes of the vehicle failure Second step Inspection and maintenance of steering and suspension systems After the inquiry or vehicle test is completed the next step should be to check all steering and suspension components Maintenance technicians should establish the notion that relying solely on the vehicle positioning s...

Page 54: ...d the direction of the off rack is unchanged repeat the same process for the left and right wheels of the rear axle 4 If the off track direction remains the same after the rear wheel is aligned it can be determined that the off track is not caused by the side slip Four wheel positioning measurement must be performed to further find out the cause Fourth step Four wheel alignment measurement and res...

Page 55: ...ack The front wheel caster angle left and right is asymmetrical and the deviation exceeds 0 5 The vehicle deviates to the side with the small caster angle The front wheel camber angle left and right is asymmetrical and the deviation exceeds 0 5 The vehicle deviates to the side where the camber angle of the front wheel is the largest The rear wheel camber angle is asymmetrical and the deviation exc...

Page 56: ...r the front wheel toe is adjusted the deviation is occurred or deviation is increased It is easy to attribute this phenomenon to the toe adjustment when actually not Because when the vehicle going straight it is always in a position that the left and right toe is equal thus the front wheel toe itself does not cause a deviation However if the front wheel toe is not right the friction between the ti...

Page 57: ...ad centerline 2 The tire pressure is too low and both tires are worn at the same time 3 Chassis part problem 3 The vehicle is floating the caster angle is close to zero or the caster is negative 1 Steering wheel sinking 1 The caster is too large 2 The camber angle is wrong 3 The suspension parts after the violent bumps are slightly deformed or stiffened 2 Poor steering wheel alignment capacity 1 C...

Page 58: ... two wheels rear wheel camber angle rear wheel toe 2 Then the front axle two wheels If toe out on turn is not right replace the steering arm caster angle for vehicles with engine brackets always adjust the engine bracket first camber angle toe the steering wheel horizontally positive lock at present Appendix 2 Basic overview of the aligner 2 1 Wheel centerline A straight line formed by the contact...

Page 59: ...ont and rear axles of the vehicle B vehicle centerline also called the geometric centerline 2 3 Thrust Line The bisector of the toe angle of the vehicle rear wheel is called the thrust line and the angle between the thrust line and the center line of the vehicle is called the thrust angle ...

Page 60: ...he thrust or the vehicle centerline the toe angle is defined as a negative value Toe Out otherwise it is defined as a positive value Toe In 2 4 1 Function Reduce tire abrasion and rolling friction 2 4 2 Symptom judgment 1 Toe In too large will cause a Rapid wear on the outside For radial tire there will be wear patterns similar to those formed by too large positive camber angle Wear forms are serr...

Page 61: ... from the outside to the inside of the tire the inner edge of the tread has a sharp feeling b Steering unstable Poor straightness Wheel shaking 2 4 3 Front wheel toe adjustment method Adjust tie rod 2 4 4 Rear wheel toe adjustment method The original adjuster eccentric concave wheel eccentric bolt eccentric bushing and long hole gaskets 2 5 Camber Angle Wheel camber angle is the angle between the ...

Page 62: ...ire will wear abnormally and the car will also occur off track when driving 2 5 1 Function Adjust the vehicle load to act on the center of the tire to eliminate the deviation and reduce tire wear 2 5 2 Symptom judgment 1 Positive camber angle too large a Unilateral wear on the outside of the tire b Suspension system parts wear accelerated c The vehicle will be deflected towards the side with a lar...

Page 63: ...centric bushings and offset ball heads 2 6 Set back Set back refers to the angle between the line passing through the center of the two front wheels or the two rear wheels and the vertical line of the thrust If the right wheel is in front of the left wheel the angle is positive and vice versa When the wheelbase is known the set back can be expressed in mm 2 6 1 The cause of set back Manufacturer S...

Page 64: ...d vice versa 2 7 1 Function Affects steering stability and steering wheel automatic alignment capability 2 7 2 Symptom judgment Caster angle too small caused instability lack of steering wheel automatic alignment ability after steering when the vehicle speed is high it will float should pay full attention to this when driving on the highway Caster angle asymmetry caused deviation when the left and...

Page 65: ...pension as viewed from the front of the car The upper ball is positive inward and vice versa A reasonable kingpin inclination angle can make the car drive lightly reduce the impact of the road through the steering wheel to conduct the steering wheel and also have a certain automatic alignment function The kingpin inclination refers to the angle at which the kingpin is slightly inward on the front ...

Page 66: ...ion of the camber angle to the caster angle of the kingpin 2 10 Top Out On Turns The 20 top out on turn refers to the difference between the angles of rotation of the inner and outer wheels when the vehicle is turning 2 11 Thrust angle Thrust angle is the angle formed by the centerline of the vehicle and the thrust line When the thrust line is located to the left of the vehicle centerline it is po...

Page 67: ...oincide with the driving route of the front wheel This phenomenon is called rear wheel traverse When the thrust line is not directly in front the steering wheel must be turned to one side to ensure the straight line of the vehicle which causes the steering wheel to be unbalanced If the thrust line is neglected the accuracy of the positioning cannot be guaranteed which is the main reason for the fu...

Page 68: ...ew 2 11 3 The correction method of thrust angle Original car factory adjuster Install a wedge gasket between the axle and the tire Install adjuster behind concave wheel or other things Four wheel aligner common problems and solutions 1 The tablet cannot be synchronized with the computer program Check if the tablet port is connected to other networks instead of connecting to the aligner network the...

Page 69: ...y 1 Check if the cable is normal the battery is fully charged and charge the host header or tablet 2 Check if the HDMI cable connection between the TV and the host is normal 5 Daily attention Regularly clean the target filter use a soft cloth and avoid using rough cloth to wipe the surface of the filter and the dust on the lamp board will affect the receiving effect Warranty Respectful FCAR User W...

Page 70: ...ve purchased based on the valid purchase certificate and valid warranty card of this product if the product has performance failure caused by non human damage the whole machine is guaranteed for three years The first year is free of charge and the second and third years are paid for repair 6 In any of the following cases your product will not be covered by the free warranty 1 Failures defects or d...

Page 71: ...r and maintenance so as to get timely repair maintenance and prevent further loss 8 In the process of warranty service you will bear the cost of product delivery or delivery related costs including product packaging transportation insurance etc 9 The free warranty service you enjoy under this warranty is the only measure for the loss of the product due to defects in the product during the warranty...

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