MANATEC Fox 3D Smart Mobile PT Service Manual Download Page 1

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3D WHEEL ALIGNER

PIT

(PT) model

DRIVE THROUGH

(DT) model

VARIABLE HEIGHT

(VH) model

IN-LIFT

model

AUTOMATIC VARIABLE HEIGHT

(AutoBoom) model

AutoBoom

AutoBoom X

AutoBoom V4

With Cabinet

SERVICE MANUAL

(Ver.1.8)

Summary of Contents for Fox 3D Smart Mobile PT

Page 1: ...WHEEL ALIGNER PIT PT model DRIVE THROUGH DT model VARIABLE HEIGHT VH model IN LIFT model 14 AUTOMATIC VARIABLE HEIGHT AutoBoom model AutoBoom AutoBoom X AutoBoom V4 With Cabinet SERVICE MANUAL Ver 1...

Page 2: ...figurations 33 4 4 4 IN LIFT MODEL USB3 0 configurations 34 5 DESCRIPTION OF MAIN PARTS 35 5 1 CAMERA BEAM COLUMN 35 5 1 1 CAMERA LH RH 35 5 1 2 IR LED BOARD 36 5 1 3 LED DRIVER BOARD HUB BOARD 36 5 2...

Page 3: ...D 85 9 2 INTERFACE BOX 86 9 2 1 EMI FILTER BOARD MOTOR CONTROL BOARD 86 9 2 2 SMPS 87 9 2 3 MOV BOARD Applicable only for AVH model 87 9 3 VERTICAL COLUMN Applicable only for AVH model 88 9 3 1 POWER...

Page 4: ...equipment is used for any purpose other than intended use 5 The equipment must be installed Indoor away from Sunlight rain moist areas Warranty ceases if the equipment is exposed to direct Sunlight R...

Page 5: ...rs Spanner set and Allen key set Measurement Tape 5 metre Marker Chalk liner for marking 0 Sprit Level Strip cutter to Open Carton Banding knife for opening Cartons Plastic cable Ties for proper routi...

Page 6: ...is intended only for the operator to go underneath the vehicle easily and carryout the required corrections The length of the main pit can be made depending upon the availability of space The Rotary p...

Page 7: ...L MAX WHEEL BASE REAR WHEEL MIN WHEEL BASE FRONT WHEEL CAMERA DISTANCE WHEEL BASE LEVEL THE PIT DIAGONALLY LEVEL THE RECESSES OF BOTH ROTARY PLATE SLIDER MAX WHEEL SLIDER OVERALL PIT DIMN OVERALL PIT...

Page 8: ...Ref 3DWA SM Ver 1 8 5 PIT DIMENSIONS Max Wheel base 3 2 4metre For DT model Fig 2 Set the verticality of Camera mounted Vertical columns using Jack screws provided in the Master base plate...

Page 9: ...Ref 3DWA SM Ver 1 8 6 PIT DIMENSIONS Max Wheel base 3 2 4metre For VH model Fig 3...

Page 10: ...ALL FOR 6 DEPTH REAR WHEEL MAX WHEEL BASE REAR WHEEL MIN WHEEL BASE FRONT WHEEL CAMERA HEIGHT H BRACKET PITCH HEIGHT P CAMERA DISTANCE D WHEEL BASE WB WHEEL BASE TABLE CAMERA VARIABLE HEIGHT FIXING DI...

Page 11: ...co planar at all heights it is relatively leveled for ease of push Pull Runout Check the Turn tables are free from binding and rotates freely The Platform level should be same diagonally between the L...

Page 12: ...PLATFORMS DIAGONALLY REAR WHEEL MAX WHEEL BASE REAR WHEEL MIN WHEEL BASE FRONT WHEEL MAX WHEEL BASE WHEEL BASE WB TO BE VARIED DUE TO LIFT RAMP DIMN LIFT CENTRE LINE WORKING AREA MINIMUM ROOF HEIGHT 1...

Page 13: ...N THE AVAILABILITY OF SPACE 7 A DISTANCE OF 1000mm SHOULD BE MAINTAINED BETWEEN CAMERA CENTRE LIFT PLATFORM 8 HORIZONTAL BEAM CAN BE POSITIONED BETWEEN 900 2400mm LEVEL THE FRONT REAR OF A SINGLE PLAT...

Page 14: ...Ref 3DWA SM Ver 1 8 11 SCISSOR LIFT DIMENSIONS Max Wheel base 4 6 metre For In Lift model FOR RIGHT HAND DRIVE VEHICLE DISPLAY VALUE DISPLAY VALUE Fig 8...

Page 15: ...Ref 3DWA SM Ver 1 8 12 SCISSOR LIFT DIMENSIONS Max Wheel base 4 6 metre For In Lift model FOR LEFT HAND DRIVE VEHICLE DISPLAY VALUE DISPLAY VALUE Fig 9...

Page 16: ...Ref 3DWA SM Ver 1 8 13 FOUR POST LIFT DIMENSIONS Max Wheel base 4 metre For VH model Fig 10...

Page 17: ...Y REAR WHEEL MAX WHEEL BASE REAR WHEEL MIN WHEEL BASE FRONT WHEEL MAX WHEEL BASE WHEEL BASE WB TO BE VARIED DUE TO LIFT RAMP DIMN ADJUSTABLE RUNWAY FIXED RUNWAY LIFT CENTRE LINE MIN WHEEL BASE MAX WHE...

Page 18: ...CAN BE POSITIONED BETWEEN 900 2400mm LEVEL THE FRONT REAR OF A SINGLE PLATFORM LEVEL THE TWO PLATFORMS LEVEL THE PLATFORMS DIAGONALLY REAR WHEEL MAX WHEEL BASE REAR WHEEL MIN WHEEL BASE FRONT WHEEL M...

Page 19: ...Ref 3DWA SM Ver 1 8 16 FOUR POST LIFT DIMENSIONS Max Wheel base 4metre For In Lift Fig 13...

Page 20: ...fuse 1 No 5A Dia 6 35mm x 31 8mm Slow blow type Glass fuse 1 No 2 4 Horizontal beam corrugated box Horizontal beam with Camera in EPE foam 1 No Target plate Front Left in EPE foam 1 No Target plate F...

Page 21: ...in cabinet 1 No Monitor column 1 No Wheel bracket holder Long 2 Nos Wheel bracket holder Short 2 Nos Brake pedal lock 1 No Steering lock 1 No Wheel stopper 2 Nos Printer 1 No Multimedia speaker 1 Pair...

Page 22: ...tray 1 No Printer tray 1 No Wheel bracket holder Long 2 Nos Wheel bracket holder Short 2 Nos Steering lock 1 No Brake pedal lock 1 No Wheel stopper 2 Nos Fuse 3A 5x20mm Slow blow type 1 No Windows8 Em...

Page 23: ...Target plate Rear Right in EPE foam 1 No PC Console box Desktop computer 1 No Monitor 1 No Printer 1 No Multimedia speaker 1 Pair Windows Embedded OS CD 1 No Align SW CD 1 No Calibration data CD 1 No...

Page 24: ...it Fix the Monitor supporting plate with Monitor clamp in Vertical column in case of VH model The Interface box will be fixed with Vertical column at factory itself Interface box will be fixed with M...

Page 25: ...Ref 3DWA SM Ver 1 8 22 VH model 12 3 7 8 9 4 5 2 1 10 11 11 13 14 Fig 15...

Page 26: ...Ref 3DWA SM Ver 1 8 23 AVH model 12 3 7 8 9 4 5 2 1 11 13 14 6 Fig 16...

Page 27: ...ation and setup Place the Horizontal beam over the seating plate Bracket in Vertical column Wall mount bracket and fix it using fasteners supplied Use Jack screws for adjustment if required In case of...

Page 28: ...ive Bracket holders 2 Fix the Monitor column at the rear side of Main cabinet using Allen screw Plain washer Spring washer 2 Nos each Fix the Monitor with Support plate in Monitor column 3 Fix the Cas...

Page 29: ...ment pit lift 2 Make a mark at 2mtr from the Left and Right Rotary plates centre Place the Vertical column centre on the centre line to the alignment pit Lift along the 2mtr line For DT model place th...

Page 30: ...orizontal beam assembly so that the pendulum matches with the 2 0 meter mark line Ensure the Vertical column centre matches with the centre line of the alignment pit lift 8 Using a Hammer drilling mac...

Page 31: ...22 1405 3700 2300 1700 1505 3500 2500 1800 1605 2 Now tilt the Beam mounting plate to match its locking hole with the respective hole punched with angle in bracket and lock the position by inserting...

Page 32: ...outing hole provided in the Top cover 7 In case of AVH remove the Distribution panel safety cover from the rear side of Main cabinet 8 Route the Camera USB cable to PC IR LED power cable to Interface...

Page 33: ...Ref 3DWA SM Ver 1 8 30 4 4 ROUTING Perform wiring connections per Routing diagram given below 4 4 1 PT VH MODELS For USB2 0 configurations Fig 27 For USB3 0 configurations Fig 28...

Page 34: ...Ref 3DWA SM Ver 1 8 31 4 4 2 AVH MODEL For USB2 0 configurations Fig 29 For AutoBoom V4 model USB2 0 configurations Fig 30...

Page 35: ...Ref 3DWA SM Ver 1 8 32 For AutoBoom V4 model W O Distribution panel USB2 0 configurations Fig 31 For AutoBoom V4 model USB3 0 configurations Fig 32...

Page 36: ...the concealed pipe 1 5 and connect with LED Driver Hub board in the Hub board box fixed in left side Vertical column as shown below Fig 34 Route the Camera USB cable and IR LED power cable from the H...

Page 37: ...tube and connect the IR LED power cable to LED Driver board and Camera USB cable FRC cable to Hub board in the Panel fixed in left side Camera column as shown below Fig 36 Route the assembled cable 5m...

Page 38: ...sed to acquire the image reflected from Target plate The Camera used in 3D Wheel aligner is a high resolution SI Scientific Imaging camera with USB port Left side Camera is mounted in such a way that...

Page 39: ...e Red LEDs whenever the alignment program requires The Input supply voltage is 12Volts from SMPS This board has two adjustable Regulators for IR LED board The Trimmer pot TR1 is to be adjusted to get...

Page 40: ...power to Desktop computer and peripherals The ON OFF switch provided in Panel can be used to switch OFF complete power to the system after shutdown of the PC EMI Filter board and 60Watts SMPS are fixe...

Page 41: ...mps AC OUTPUT FROM UPS CAUTION 1 5 6 9 230V AC 10 50 Hz CAUTION F2 5 Amps MONITOR POWER PC 2 2 3 4 7 8 Fig 41 Sl No Description Sl No Description 1 MCB 6 Fuse F1 For Interface box for PT DT VH In Lift...

Page 42: ...2 2 SMPS The 60W SMPS generates 12VDC with 5ampere output It is a wide operating voltage SMPS ranging from 90V to 270VAC 47Hz 63Hz input The 12V is then distributed to Cooling fan IR LED board and LED...

Page 43: ...Description 1 Base frame 2 Base plate with bearing housing 3 Bottom nylon bush housing 4 Screw rod 5 Guide shafts 6 Top plate 7 Top cover 8 Micro switches 9 Micro switch actuator Bottom 10 Micro swit...

Page 44: ...te fixing Allen screw 7 Bottom plate Screw rod pulley fixing Allen screw 8 Bottom plate bearing 9 Micro switch 10 Micro switch fixing Slot head screw 11 Screw rod pulley 12 Screw rod pulley fixing spe...

Page 45: ...g hex nut 18 Guard fixing plate Top 18 Roller guide assy fixing plain washer 5 5 DESKTOP COMPUTER AMD Processor is not recommended for 3D alignment system Anti virus software should not be loaded in t...

Page 46: ...icle data Brazilian vehicle data Indian vehicles data User vehicle data c wheel aligner data vehicledata usdata mdb Vehicledata mdb brazildata mdb indian mdb userdata mdb NOTE The indicated files will...

Page 47: ...nsert Windows8 CD in the CD Drive d Right Click Microsoft NET Framework 3 5 Offline Installer and select Run as administrator option to execute the program as shown below Fig 48 e Select the CD drive...

Page 48: ...Paste the Enterprise Product key in PC console use it for activation NOTE PLEASE TREAT THIS PRODUCT KEY AS CONFIDENTIAL AND NOTE THAT THIS RUNTIME PRODUCT KEY WILL ACTIVATE MANY INSTANCES OF YOUR IMA...

Page 49: ...Fig 57 Fig 58 h Ensure the Network cable is connected to access internet Install the PC hardware drivers by downloading the required drivers from Dell Website by entering the Service Tag available for...

Page 50: ...n Control panel and select Add a language as shown below Fig 59 l Select the required language and press ADD button Fig 60 m Click the Options link on the right side of the language just installed Fig...

Page 51: ...lug the USB cable from the Horizontal beam Vertical column to the PC during OS installation iii Make sure the Printer is installed and set as default Printer iv The PC should have d partition with a m...

Page 52: ...the software is installed following screen will appear Fig 67 6 Restart the system Notification Settings 1 Select User Accounts from Control panel as shown below Fig 68 2 Click Change User account Co...

Page 53: ...70 Wheel Aligner 3D Setup installation 1 Double click WA32Axxx exe file in the Software CD last xxx denotes the SW version No Following setup wizard screen will be displayed Fig 71 2 Press Next button...

Page 54: ...s shown below Fig 74 5 Adobe reader will be installed as shown below Fig 75 6 Crystal reports Basic Runtime will be configured as shown below Fig 76 7 USB driver will be configured as shown below Fig...

Page 55: ...Press Next button and tchen follow the On screen instructions provided to proceed with installation of Camera driver as shown below Fig 80 2 Following screen will be displayed to indicate the completi...

Page 56: ...Fig 83 2 Following screen will be displayed to indicate the completion of Alignment software installation Fig 84 3 Select Yes restart the computer now and then press Finish button 4 Plug the USB cable...

Page 57: ...ect the CD ROM in the screen If the user prefer to copy the calibration files from other locations select From specified location and click BROWSE button to choose the source folder 8 Following error...

Page 58: ...ect the DESKTOP from above option to go to Windows desktop 4 Double click the Software update executable file provided by Manufacturer to update the PC software and then press Next button Fig 89 5 Onc...

Page 59: ...ed in system 1 Double click Autodata_XXXX_PhaseXX 3D exe file in the CD Following setup wizard screen will be displayed Fig 91 2 Press Next button then follow On screen instructions provided to procee...

Page 60: ...for all vehicles are error prone then it is advisable to check calibration Calibration is to check the raw data transmitted by sensing devices The procedure for checking the calibration is as follows...

Page 61: ...mtr away from Front target plates as shown in screen Fig 97 Press NEXT SCREEN button to proceed further Try to make Front Left and Right distance equal Same way make both Rear Left Right distances equ...

Page 62: ...n Demo mode only Select SENSOR CALIBRATION from Calibration menu The following screen will appear Fig 101 Press SAVE button to save the zero offset values of the Dual axis sensor Fix the 6 block Big o...

Page 63: ...tion shaft with the Connecting tube end blocks properly as shown below Fig 105 3 Lock the Calibration shaft with the Connecting tube end blocks using C clamp and fasten it using M8x25mm Allen screw as...

Page 64: ...Stepped pins into the front rear side LH shaft mounting blocks ie diagonally as shown below and then locate the Cross pipe assembly with the diagonally placed Stepped pins Fig 109 Fig 110 Fig 111 8 Us...

Page 65: ...ront shaft and another pendulum in mid of rear shaft Make equal distance of pendulum line by positioning the Calibration kit in such a way that front pendulum rear pendulum are at equal distances from...

Page 66: ...el For Right hand steering drive vehicles 865 865 Fig 114 NOTE Gap between the two platforms of Scissor lift should be 860 886 2mm Depending upon the Lift models Indicated dimensions should be made eq...

Page 67: ...Left hand steering drive vehicles 865 865 Fig 115 NOTE Gap between the two platforms of Scissor lift should be 860 886 2mm Depending upon the Lift models Indicated dimensions should be made equal Tol...

Page 68: ...on press NEXT SCREEN button to proceed The Machine will search for the target plates and then displays a STOP indication as shown below Fig 117 DO NOT disturb move the Calibration kit while identifyin...

Page 69: ...Ref 3DWA SM Ver 1 8 66 For Drive Through model Fig 118...

Page 70: ...Ref 3DWA SM Ver 1 8 67 Fig 119...

Page 71: ...s towards left or right directions to make FLXD equal to RLXD 175mm For left side Vertical column FRXD equal to RRXD 175mm For right side Vertical column Turn the left Camera column towards left side...

Page 72: ...Ref 3DWA SM Ver 1 8 69 For Drive Through model Fig 121...

Page 73: ...Ref 3DWA SM Ver 1 8 70 For In Lift model 865 865 Fig 122...

Page 74: ...CTRL F9 keys Ensure the XD settings are equal for FL RL FR RR by adjusting the Vertical column Set both Left Right VVA angle as per Factory setting Tol 0 2 Calibration saved message will be displayed...

Page 75: ...ation shaft using End cap In case of VH model raise the Lift platform to required height by ensuring the Target plate images are visible in the screen For AVH model during Calibration rest both the Ho...

Page 76: ...w blinking by the system on the screen The readings will become green after achieving the all the readings are within 1mm Try to achieve the difference values zero for the Distance ZD and Horizontal X...

Page 77: ...Left Right side Once the distance is achieved move the Calibration stand in horizontal direction either Left of Right side as guided by the system on the screen The readings will become green after a...

Page 78: ...system on the screen to get equal distance RLZD RRZD between the Camera to the Rear Target plates for left right side Once the distance is achieved move the Calibration stand in horizontal direction e...

Page 79: ...e spirit level Remove the rear image plates Mount the front target plates in the respective locations i e left image plate on Left side and right image plate on Right side of the calibration kit and l...

Page 80: ...e the spirit level again Fig 140 Move the calibration kit as per the blinking arrows in the screen Fig 141 Fig 142 Click SAVE button to save the Front zero offset values After saving the zero offset v...

Page 81: ...plate calibration should be done the data files provided along with new Target plates should be updated into the system This option facilitates replacement of any one of the Target plate also The res...

Page 82: ...k and ensure the calibration data of the Equipment Target plates Camera carried out so far Fig 147 7 6 CALIBRATION CERTIFICATE This feature should be used only by authorised Service personnel Hence Us...

Page 83: ...Screen and by providing the Password Fig 149 The following Menu will be displayed Vehicle specifications Ref chapter 7 7 1 of Operating manual Measurement units Ref chapter 7 7 2 of Operating manual...

Page 84: ...intensity as 25 for ISH series Gain 115 Intensity 25 for the respective Left Right Camera as shown above 8 2 CAMERA CONFIGURATION Only for spare replacement This feature should be used only by author...

Page 85: ...the Camera calibration procedure 8 4 LEFT RIGHT STEERING WHEEL SETTING This feature should be used only by authorised Service personnel Hence User should not enter into this module This screen provide...

Page 86: ...available in the CD USB2 0 USB3 0 Calib_3D mdb Camdata_L dat Calib_3D_L mdb Camdata_L dat e If Right camera needs to be replaced ensure following files are available in the CD USB2 0 USB3 0 Calib_3D...

Page 87: ...e System will display Restore the camera files screen Select CD USB stick click on the arrow at the right bottom of screen Camera files will automatically get updated system comes to Welcome screen 8...

Page 88: ...program and go to Settings option Provide the required password mas space algn and select Camera testing 6 Ensure the Camera gain intensity as explained in Chapter 8 1 Also ensure the Target plates a...

Page 89: ...d properly 7 Re fix the Hub board cover Front facia 8 Ensure the equipment functions without any errors In case of replacing the Hub board alone 1 Remove the Hub board from the LED Driver board 2 Repl...

Page 90: ...ard SMPS safety cover 3 Replace the defective SMPS with new SMPS and re fix it Restore all the connections 4 Power up the system Check ensure Input 230VAC Output voltage 12VDC at respective sections o...

Page 91: ...ghtness of belt 9 4 TARGET PLATE 1 Fix the New Target plate with Calibration kit 2 Run the alignment program and go to Settings option Provide the required password mas space algn and select Camera te...

Page 92: ...Ref 3DWA SM Ver 1 8 89 10 DIAGRAMS 10 1 BLOCK DIAGRAM Fig 154...

Page 93: ...Ref 3DWA SM Ver 1 8 90 10 2 WIRING DIAGRAM 10 2 1 PT VH MODEL Fig 155...

Page 94: ...Ref 3DWA SM Ver 1 8 91 Fig 156...

Page 95: ...Ref 3DWA SM Ver 1 8 92 10 2 2 AVH MODEL Fig 157...

Page 96: ...Ref 3DWA SM Ver 1 8 93 Fig 158...

Page 97: ...Ref 3DWA SM Ver 1 8 94 10 2 3 IN LIFT MODEL Fig 159...

Page 98: ...Ref 3DWA SM Ver 1 8 95 Fig 160...

Page 99: ...up Ensure the free movement of Rotary plate by lubricating it Improper calibration Re do the calibration with high accuracy Un even level between Front Rear floor platform Level the Floor Platform 2 C...

Page 100: ...he external parameters have been checked But the display problem remains as it is ON OFF Switch or Power supply board may be faulty Get the problem solved through Service Engineer 2 When equipment is...

Page 101: ...ving belts loose Tighten the driving belt 2 Abnormal noise during operation Insufficient lubrication Check apply lubricants as required 3 Abnormal noise in Belt Slackness in belt Ensure the tightness...

Page 102: ...D board is 9VDC Target plate not clean Clean the Target plate Direct Sun light falls on Camera or Target Plate Avoid direct sunlight falling on Target plate Target plate physical damage Replace the re...

Page 103: ...red If Toe is adjusted correctly and Rear axle alignment is within specifications check that the Steering wheel has not been remounted off centre Remove the wheel and centre it 4 Other symptoms Tyre w...

Page 104: ...acturer All information illustrations and specifications contained in this Manual are based on the latest information available at the time of publication Manufacturer reserves the right to make chang...

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