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Manual

JOSAM laser AM

Measuring system

ALIGNMENT OF

WHEELS AND AXLES

Summary of Contents for AM10

Page 1: ...Manual JOSAM laser AM Measuring system ALIGNMENT OF WHEELS AND AXLES ...

Page 2: ...aring play Unnecessary play in kingpins steering gear and the balancing arms support on support axle vehicles The attachment of the axles play in spring eye bolts shackles broken center rivets broken springs and loose spring straps Worn torsion bar bushings If any of the above mentioned points are not correct these should be fixed before procee ding with the measurements Check of bearing play and ...

Page 3: ...est Report Sheet 23 25 MEASUREMENT OF RIGID AXLES 26 36 With measuring scale 26 27 With sliding scale 28 29 Out of square axles the second axle 30 31 Toe in toe out 32 33 Out of square axles the first axle 34 35 Measurement of camber 36 MEASUREMENT OF FRONT AXLES 37 53 Wheel angles for front axles 37 Centering of steering box when it is marked 38 Centering of steering box when it is not marked 39 ...

Page 4: ...correctly placed with the straight side or cut side on the outside The frame gauge with stepless adjustable attachment for the hangers Gauge extension with bubble for checking the adjustment of horizontal for the frame gauges Measuring scale AM34 A Attach the gauge extension sight pin Sliding scale AM84 A Sliding scale attached to the measuring scale ...

Page 5: ... eyelet for gauge extensions and measuring scales Adapter for kingpin AM69 Attaches to kingpin for hanging the frame gauge Magnet bracket for frame gauge AM172 Attaches on sides of frame for hanging frame gauges Magnet bracket for frame AM1227 1 and 2 For hanging frame gauges on vehicles with short overhang ...

Page 6: ...able laser projector Attaches to the axle of the wheel adapter Wheel alignment gauge AM301 Measuring instrument for camber caster and KPI Attaches on the axle of the wheel adapter Spirit level AM542 For checking of the horizontal on axle or frame Hanger AM98 Magnetic hanger for the spirit level AM TOOL SET Tool set for the adjustment of the steering box AM TOOL SET ...

Page 7: ...oe out on turn as well as KPI and caster Compensation ramp AM931 For example compensation for height of the back wheel when turn plate AM585 is used Non friction plate AM268 To be placed under wheel when adjusting toe in or toe out Brake rod AM325 To be placed between the brake pedal and seat in order to brake the wheel during KPI measurement Calculation database software AM1515 for use in Windows...

Page 8: ...aximum turn toe out on turn and the fixed values for KPI and caster Measuring scales can slide along the base 1 The measuring scale s 0 line 2 The intersectional point of the 0 line For measurement using turn angle gauges AM135 the axles are lifted so that the wheel rolls freely approx 10 mm from the floor The caster value will be insignificantly altered ...

Page 9: ...dle of the wheel Position left and alternatively right wheel in a straight ahead position with the laser projector Equal values on the front and rear measuring scales Align turn angle gauges on both sides with laser dot on the 0 line of the measuring scale Move measuring scale along the profile and check at both ends that the laser dot hits the 0 line Turn wheel Align the laser dot on the 0 line 1...

Page 10: ...straight side or the cut side facing out They should hang at the same height Check that the numerical marks are aligned with the upper edge of the end piece Lock with the knob Move together the guide rails on the frame gauge Both ends should face toward the housing Check that the guide rails are easy to move back and forth on the housing ...

Page 11: ... hangers are hanging at the same height and are all uniformly facing forward and tightly fixed in towards the support rack Check also that the frame gauges hang at the same height and that there is a right angle between the frame gauges and the hangers Mount the gauge extensions Check the sight pins with a straight edge They should lie in a line The maximum allowable deviation is 2 millimeters Tur...

Page 12: ...the adapter On rims with corners the wheel adapter is attached according to figures A and B and tightened outwards On the rims shown in figure C or on aluminium rims like figure D the grip hooks are reversed and attached between the tire and the rim and tightened inwards During the clamping process check that the grip hooks are gripping properly on the rim edges figures A and B or gripping in betw...

Page 13: ...rojector parallel with the adjustment arm Rotate the wheel and aim the laser dot at the measuring scale Read the indicated value for example 95 Value A Write down the result B Rotate the wheel a half turn 180 and aim the laser dot at the measuring scale Read the indicated value for example 55 Value B Adjust with the white knob 1 so that the laser dot hits right between A and B at C The value is 75...

Page 14: ...or any other purpose than that for which it is intended Function 1 The on off circuit breaker 2 The light indicates that the laser is on When the laser is turned on give it full light intensity After approx 10 minutes reduce the light intensity by one half 3 A circuit breaker is used for regulation of light intensity For full light intensity press on the upper part of the circuit breaker for reduc...

Page 15: ...f the front and rear sliding scales The laser dot should hit the O line on both scales Max allowable deviation 1 mm per 6 meters measured distance If the laser dot hits at an equal distance from the O line on the outside of both or on the inside of both scales then the laser beam is at the correct angle but has a parallel deviance that can be tolerated Example If the laser dot hits distance line 3...

Page 16: ...minutes minus values are marked in red On the outer part of the scale camber can be read by looking at the arrow on the base of the scale On the inner part of the scale caster and KPI can be read on the adjustable indicator The top bubble is for adjusting the vertical position The wheel alignment gauge should be attached to the wheel adapter spindle Attachment hole for KPI measurements Move the in...

Page 17: ...eel adapter spindle 6 Mount it the opposite way by pulling out the locking pin 7 Turn the measuring scale so that the measuring bubble shows a horizontal position Read the camber value If 0 50 is the reading the alignment gauge is correctly calibrated This is the same value as the first measurement but with the opposite sign i e instead of If different numbers come up the measuring level has to be...

Page 18: ...e on both sides Check that the hangers are at a right angle to the frame by comparing them with the cross member or spring mounting If it is impossible to hang the frame gauges all the way forward or all the way back then these can be hung behind the front axle and in front of the rear axle Hanging the frame gauges on a semi trailer Mount the adapter AM69 on the kingpin and hang the frame gauge on...

Page 19: ...n the measuring scale When the laser dot shows the HIGHEST value the gauge extensions are at a right angle to the tow bar Hang the rear frame gauge to the rear end of the front axle frame the dolly Rear axle s Hang the frame gauges front and rear on the frame side members of the truck frame Check that they hang at a right angle to the truck frame by comparing them with the crossbars or the spring ...

Page 20: ...JOSAM laser AM Measuring system 20 Toe in toe out Table mm per meter Total difference between front and rear measuring scales Distance in meters between the measuring scales Table mm per meter ...

Page 21: ... the manufacturer gives tolerances in degrees and minutes this table can be used for converting to mm m For example 10 3 mm m 1 17 4 mm m 3 0 05 0 9 6 0 10 1 7 9 0 15 2 6 12 0 20 3 5 15 0 25 4 4 18 0 30 5 2 21 0 35 6 1 24 0 40 7 0 27 0 45 7 8 30 0 50 8 7 33 0 55 9 6 36 0 60 10 5 39 0 65 11 3 42 0 70 12 3 45 0 75 13 1 48 0 80 14 0 51 0 85 14 8 54 0 90 15 7 57 0 95 16 6 60 1 00 17 4 1 60 in tenths ...

Page 22: ... in toe out Tolerance in mm per bead of rim Table mm m tolerance in mm per bead of rim In certain cases the manufacturer gives tolerances in mm per bead of rim in the middle of the bead of rim Compare with mm m tubeless A B mm Ø bead of rim ...

Page 23: ...JOSAM laser AM Measuring system 23 The Test Report Sheet The complete Test Report Sheet AM39 ...

Page 24: ... scale A in mm Value from rear measuring scale B in mm Measured value of location of front axle out of square position Rolling direction of left wheel mm m Rolling direction of right wheel mm m Rolling direction of wheel out of square position of rear axle s Left and Right Calculation of out of square and parallelism between the axles Calculated toe in toe out mm m C Calculated value between A and...

Page 25: ...easuring system 25 The Test Report Sheet Measured values of the front axle Camber KPI Caster Measured values of rear axle s Camber Measured value of Max turn Measured value on opposite side Output value Toe out on turn ...

Page 26: ...ort Sheet square B1 Rolling direction of wheel C5 is the difference between the readings of measuring scales A1 and B1 110 92 18 Divide the difference 18 by the distance between the measuring scales A1 and B1 D 6m Result of 18 6 3 mm m Write down 3 by C5 Dm and circle the sign Wheel C6 right side Aim the laser dot at the measuring scale A2 right front Read the value For example 96 Make a note on t...

Page 27: ...JOSAM laser AM Measuring system 27 Calculation Toe in toe out 3 2 1 3 2 6 2 3 96 108 6 12 110 92 18 6 Measurement of rigid axles ...

Page 28: ... on the sliding scale On the bottom row read off rolling direction of wheel 3 mm m Write down 3 at C5 Dm in the middle field and circle the sign Wheel C6 right side Aim laser dot at the measuring scale B2 right rear Read the value For example 108 Move the sliding scale on the measuring scale A2 right front and set the 0 line on 108 Aim the laser dot at the horizontal 6m distance line on the slidin...

Page 29: ...JOSAM laser AM Measuring system 29 3 2 1 2 6 3 96 108 6 12 110 92 18 6 With sliding scale AM84 A toe in toe out Measurement of rigid axles ...

Page 30: ...ht Write down the value 0 5 on the dotted line Put in the number 2 on the solid drawn line The out of square is 0 5 2 2 5 mm m Write down 2 5 and circle a sign in the square right Write down the out of square reading 2 5 at C6 on the lower picture and draw it with a solid line C5 C6 If there is an out of square position to the right note the value as a minus If the out of square position is to the...

Page 31: ...JOSAM laser AM Measuring system 31 Out of square axle Calculation Out of square axle 3 2 1 3 0 5 2 2 5 6 2 2 5 3 96 108 6 12 110 92 18 6 ...

Page 32: ...D 6m The result 24 6 4 mm m Write down 4 at C3 Dm and circle a sign Wheel C4 right side Aim the laser dot at the measuring scale A2 right front Read the value For example 108 Write down the result on the Test Report Sheet square A2 Aim the laser dot at the measuring scale B2 right rear Read the value For example 96 Write down the result in the Test Report Sheet square B2 Rolling direction of wheel...

Page 33: ...JOSAM laser AM Measuring system 33 Calculation Toe in toe out 3 2 1 3 0 5 2 2 5 6 2 2 5 3 Measurement of rigid axles 96 108 6 12 6 6 12 6 110 92 12 89 113 24 108 96 4 2 2 4 2 ...

Page 34: ...ine on the right scale Write down 2 on the solid line Out of square is 1 2 3 mm m Write down 3 and circle sign in the left square Write down out of square 3 at C4 on the lower picture and draw it with a solid line C3 C4 Axle C3 C4 is out of square 3 to the left Axle C5 C6 is out of square 2 5 to the right The difference between the axles is evident at wheels C4 C6 3 is added to 2 5 5 5 mm m When o...

Page 35: ...JOSAM laser AM Measuring system 35 Out of square axle Calculation Out of square axle 3 2 1 3 0 5 2 2 5 6 2 2 5 3 96 108 6 12 6 6 12 6 110 92 12 89 113 24 108 96 4 2 2 4 2 5 5 3 3 2 1 ...

Page 36: ...spring spacers between the axle and the springs Adjust unevenness by placing plates under one wheel until the axle is level If the floor is flat level check the measurement between the floor and the hub bead of rim or something similar with the axle lowered and the wheel on the floor Attach wheel alignment gauge AM300 301 onto the spindle of the wheel adapter through the hole for camber and caster...

Page 37: ...ber The upper part of the wheel leans inward negative camber Measurement in degrees º and minutes Caster The backward or forward inclination of the kingpin as seen from the side The upper part of the kingpin inclines backward positive caster The upper part of the kingpin inclines forward negative caster Measurement in degrees º and minutes KPI kingpin inclination The upper part of the kingpin incl...

Page 38: ... the rear measuring scale B and read the value If the values are the same on both measuring scales the center point of the steering box is in agreement with the straight ahead position of the wheels If the values on the measuring scales A and B do not agree check the deviation The normal deviation between the middle position of the steering box and the straight ahead position is 1 per meter 1 17 5...

Page 39: ... the wheel then from the outside and in toward the middle until light resistance is felt Read the value on the measuring scale For example 100 The center point is 115 which is halfway between 130 and 100 Position the wheel with the laser dot on the front measuring scale A at 115 Aim the laser projector at the rear measuring scale B If the values are the same on both measuring scales the center poi...

Page 40: ...square on the Test Report Sheet Rolling direction of wheel C1 The difference between the measuring scales A1 and B1 158 151 7 Divide 7 by the distance between the measuring scale D 7m 7 7 1 mm m Write down 1 in the middle of the Test Report Sheet at C1 Dm and circle a sign Draw the rolling direction of wheel with a solid line Wheel C2 right side Aim the laser dot at the measuring scale A2 right fr...

Page 41: ...JOSAM laser AM Measuring system 41 Measurement of front axles Calculations Toe in toe out 7 14 7 158 151 7 140 154 1 2 1 1 2 ...

Page 42: ... on the measuring scale A1 front left and install the 0 line on 151 Aim the laser dot on 7m on the horizontal distance line of the sliding scale On the bottom row read the rolling direction of the wheel 1 mm m Write down 1 at C1 Dm in the middle part of the Test Report Sheet and circle a sign Draw in rolling direction of the wheel with a solid line Wheel C2 right side Aim the laser dot at the meas...

Page 43: ...JOSAM laser AM Measuring system 43 With sliding scale AM84 A Toe in toe out 7 14 7 158 151 7 140 154 1 2 1 1 2 Measurement of front axles ...

Page 44: ...s out of square by using a tape measure Use the tape measure to measure the distance between the locating eye to a common reference point on the axle i e from the spring eye grease fitting to the u bolt hole on the axle Write down the value on the Test Report Sheet Maximum allowed difference is 5 mm Example Left side 865 mm Right side 860 mm Difference 5 mm ...

Page 45: ...98 Look for a place on the axle that is machined Do not measure on the underside of the springs if there are different size spring spacers between the axle and the springs Adjust any unevenness by placing plates under one wheel until the axle is level If the floor is flat level check the measurement between the floor and the wheel hub bead of rim or something similar 1 Put the wheel in a straight ...

Page 46: ...Measurement of caster Caster The inclination of the kingpin backward or forward as seen from the side When the kingpin s upper part inclines backward it has positive caster When the kingpin s upper part inclines forward it has negative caster Measure in degrees and minutes from the vertical line ...

Page 47: ... for both the left and right sides with a centered scale and in the middle of the wheels Put the left wheel on left steered or the right wheel on right steered vehicles in a straight ahead posi tion with the laser projector Equal values on the front and rear measuring scales Align the turn angle gauges on both sides with the laser dot on the 0 line of the measuring scale Move the measuring scale a...

Page 48: ...bubble and lock with the bottom knob 4 Rotate the measuring scale so that the measuring bubble shows a horizontal position 5 Place the moveable pointer on 0 at the inner measuring scale 6 Rotate the left front wheel 20 inward utilizing the turn angle gauge Measurement of front axles 3 5 4 1 8 7 6 2 Left 20 inwards Left 20 outwards Place the wheel alignment gauge level using the top bubble and lock...

Page 49: ... horizontal position 4 Place the moveable pointer on 0 toward the inner measuring scale 5 Rotate the right front wheel 20 inward utilizing the turn angle gauge Place the wheel alignment gauge level using the top bubble and lock with the lower knob 6 Turn the measuring scale so that the measuring bubble shows a horizontal position 7 Read the caster value at the pointer on the inner measuring scale ...

Page 50: ...ent of front axles V Vertical line A Kingpin inclination V A Measurement of KPI kingpin inclination Kingpin inclination The upper part of the kingpin inclines inward when seen from behind Measurement in degrees and minutes from the vertical line ...

Page 51: ...or a place on the axle that is machined Do not measure on the underside of the springs if there are different size spring spacers between the axle and the springs It is easy to make the axle level with the help of two jacks When the axle is level place the turn angle gauges AM135 on the floor for both the left and right sides with the scales centered and lined up with the middle of the wheels Plac...

Page 52: ...osition using the upper level and lock it into place with the upper knob 3 Turn the measuring scale so that the bubble indicates a horizontal position 4 Position the moveable pointer on 0 toward the inner scale 5 Turn the left front wheel 20 inward to the right utilizing the turn angle gauge NOTE The measuring gauge should not be placed in a horizontal position 6 Turn the measuring scale so that t...

Page 53: ... indicates a horizontal position 4 Position the moveable pointer on 0 toward the inner scale 5 Turn the left front wheel 20 outward to the right utilizing the turn angle gauge NOTE The measuring gauge should not be placed in a horizontal position 6 Turn the measuring scale so that the main bubble shows a horizontal position 7 Read the KPI value at the pointer on the inner measuring scale in degree...

Page 54: ...turn angle gauges AM135 on the floor for both the left and right sides with a centered scale and in the middle of the wheels Put the left wheel on left steered or the right wheel on right steered vehicles in a straight ahead posi tion with the laser projector Equal values on the front and rear measuring scales Position the turn angle gauges on both sides with the laser dot on the 0 line of the mea...

Page 55: ...ight ahead posi tion with the laser projector Equal values on the front and rear measuring scales Position the turn angle gauges on both sides with the laser dot on the 0 line of the measuring scale Turn the wheel out as far as possible Aim the laser dot on the 0 line of the measuring scale Slide the scale until the laser dot hits the intersection point on the 0 line Aim the laser dot on the outer...

Page 56: ...T 25 1 0010 This instruction is issued by JOSAM Maskingatan 5 Box 419 S 701 48 ÖREBRO SWEDEN Phone 46 19 30 40 00 Fax 46 19 32 03 16 E mail info josam se Internet www josam se Representative ...

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