Bosch FWA 43 Series Technical specifications

FWA 43xx / FWA 44xx
en Maintenance instructions
Wheel alignment system

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2 | FWA 43xx / FWA 44xx |
1 690 326 006 2008-8-25 Robert Bosch GmbH
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Table of contents English
1. Symbols Used 4
2. Devices description 5
2.1 Functional description FWA 43xx / FWA 44xx 5
2.2 Scope of delivery 5
3. Technical data 6
3.1 Metering range and measuring accuracies 6
3.2 Frequency range 6
3.3 Weights and measurements 6
3.4 Temperature and working environment 6
3.5 Power supply 6
3.6 PC-Computer unit 6
4. PC-Computer unit 7
4.1 Connections 7
4.2 Dongle 8
4.2.1 Function 8
4.2.2 Connection 8
4.2.3 License number 8
4.2.4 Licensing 8
5. Functional diagram 9
5.1 Cable format 9
5.2 Radio format 10
6. Communication processor 11
6.1 Tasks 11
6.2 Function 11
6.3 Pin assignment 11
6.4 Functional diagram of cable splitter box 12
7. Splitter box (Cable) 13
7.1 Element 13
7.1.1 Tasks 13
7.1.2 Function 13
7.2 Splitter board 14
7.2.1 Connector pin assignment 14
7.2.2 Function 14
8. Measurement box (Radio) 14
8.1 Element 14
8.1.1 Tasks 14
8.1.2 Functional diagram of mess box 15
8.1.3 Function 16
8.1.4 Power supply board 16
8.2 Mess box in the device 17
8.3 Splitter box in the device 17
8.4 Fan mess box 17
8.5 Power supply board 17
8.6 Potentiometer- Setting 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 24
11.4.1 Tasks 24
11.4.2 Functional diagram MWA 25
11.4.3 DIP- switch 26
11.4.4 Board layout according to functionali–
ties 26
11.4.5 Flash- EPROM 26
11.4.6 Reading/ reflecting the adjustment
values 26
11.4.7 Change measuring processor 26
11.5 CCD camera 27
11.5.1 Functional diagram 27
11.5.2 Function 27
11.5.3 Measuring principle 27
11.5.4 Opening angle: 27
11.5.5 Technical data / features 28
11.5.6 Adjustment value 29
11.5.7 Reading/ reflecting the adjustment
values: 29
11.5.8 Change camera 29
11.5.9 Keyboard radio 30
11.5.10 Function 30
11.5.11 Keyboard function 30
11.5.12 Keyboard board cable 30
11.5.13 Function 30
11.5.14 Keyboard function 30
12. Operation of several axial cutter device (Radio)
31
12.1 General instructions 31
12.1.1 Radio frequency 31
12.1.2 Flash- EPROM 31
12.2 Change in transmission channel of measuring
element 31
12.2.1 Using key combination MWA 31
12.2.2 Using software program CCD server 31
12.3 Change in transmission channel of mess box 31

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13. Cable overview 32
13.1 PC – splitter box 32
13.2 Power supply cable +8 V 32
13.3 Cable power supply of fan 32
13.4 Serial cable PC – KP 32
13.5 Line filter – power supply board 32
13.6 Communication processor (KP) –splitter
board 32
13.7 Radio module splitter board 32
13.8 Splitter board – fitting socket 33
13.9 Measuring processor – fitting socket 33
13.10 Splitter board – charging socket +8.00 V DC 33
13.11 Fitting socket – Splitter board / storage 33
13.12 Splitter board +8.00 V DC 33
13.13 Key measuring processor board 33
13.14 Measuring processor – Fitting socket (Turn-tilt
board) 33
13.15 Charging electronic –Measuring processor 33
13.16 Measuring processor – fitting sockets 34
13.17 Measuring element 6.5 m 34
13.18 Measuring element 4.5 m 34
13.19 Measuring processor CCD camera 34
13.20 Charging cable measuring element 34
13.21 Cabling diagram 34
14. Operating System-Software 35
14.1 Windows XP Professional - Multi-Language 35
14.2 Recovery – DVD 35
14.3 Installation of Software-Packages 35
14.4 Uninstalling Software 36
14.5 Maintenance function in the main program 37
14.5.1 Version report 37
14.5.2 Equipment status 37
14.5.3 Direct angle measurement 38
14.6 Adjustment program (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 check in case of Flashwriter 41
14.8.6 Update of the communication
processor 41
14.8.7 Update of the measuring processors 41
14.8.8 Special handling of individual
measuring processors 42
14.8.9 Updating the cameras 42
14.8.10 Settings/FlashWriter 42
14.8.11 Special instructions and error
messages 42
14.8.12 Additional Information 43
14.8.13 Instructions for individual case
handling 43
14.9 System monitor 43
14.9.1 Function 43
14.9.2 Control panel 44
14.9.3 Register card "Type and version info" 44
14.9.4 Functions called via "Actions" 45
14.9.5 Significance of the fields in the display
blocks 45
14.9.6 "Graph" tab 46
14.9.7 Further executable functions via
"Actions" 46
14.10 Camera Recovery Tool 47
14.10.1 Function 47
14.10.2 Backup 47
14.10.3 Recovery 47
14.11 User software 48
14.11.1 Description of the User software 48
14.11.2 Main program/user interface 48
14.11.3 CCD server 49
14.11.4 Demo server 53
14.11.5 License server 54
14.11.6 ILSV server 56
14.11.7 TargetDataEditor 57
14.11.8 RemoteControlEx 57
15. Instruction report 58

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4 | FWA 43xx / FWA 44xx | Symbols Used
1 690 326 006 2008-8-25 Robert Bosch GmbH
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Symbols Used1.
Pictograms linked with the key words Danger, Warning
and Caution are warnings and always indicate an imme-
diate or potential hazard to the user.
Danger!
Immediate danger that could cause serious
personal injury or death.
Warning!
Potentially dangerous situation that could
cause serious personal injury or death.
Caution!
Potentially 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– In addition to these warnings, the following
symbols are also used.
Single-step procedure
¶– instructions for a procedure
that can be completed in just one step.
Intermediate result?– an intermediate r esult is
displayed during a procedure.
Final result
!– the final result is displayed at the end
of the procedure.

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Devices description | FWA 43xx / FWA 44xx | 5
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Devices description2.
Functional description FWA 43xx /2.1
FWA 44xx
FWA 43xx / FWA44xx is a conventional chassis
measuring system for automobiles and light commercial
vehicles.
Besides, the devices are suited for the measurement of
vehicles with a wheel base of 6.50 meter (Transporter).
Front view SPtv with accessoriesFig. 1:
1 Monitor
2 Mouse
3 Keyboard
4 PC-Computer unit
5 Printer
6 Reading recorder (MWA) for charging points 2)
7 Slide-on receptacle for cable set 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 SPtvFig. 2:
1 Steering wheel clamps
2 Break lock
3 Multiple socket
4 Cable socket
5 Splitter box (Cable) or Messbox (Wireless)
Scope of delivery2.2
The scope of delivery depends on the orderedi
design.
Carriages,
R
Computer unit,R
TFT- Monitor and colour inject printer,R
Measuring element,R
Connection cable,R
Universal quick holder,R
a set of mechanical wheel bases,R
Steering wheel clamp,R
Brake lockR
Standard software packet with target data.R

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6 | FWA 43xx / FWA 44xx | Technical data
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Technical data3.
Metering range and measuring3.1
accuracies
Measuring options Metering range Measuring accuracy
Total toe (VA + HA) ±2° ±3'
Single toe (VA + HA) ±2° ±2'
Camber ±3° ±2'
Wheel offset
(front axle)
±2° ±2'
Rear axle angle ±2° ±2'
Caster ±18° ±4'
Steering axle
inclination
±18° ±4'
Toe-out on
turn angle
20° ±4'
Caster adjustment
range
±7° ±4'
Wheel offset 1) ±2° ±2'
Wheel patch
distance
difference 1)
±2° ±3'
Lateral offset,
left / right
±2° ±2'
Track width
difference
±2° ±3
Axle offset
(rear axle)
±2° ±3'
1) not in case of FWA 43xx
Frequency range3.2
The frequency range of the radio system, depending on
the design of measuring element comprises of 433 MHz
or 2.4 GHz.
Weights and measurements3.3
Function Specification
Measurement H x B x T : 1,600 x 900 x 800 mm
Weight Approx. 105 kg
Temperature and working3.4
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
-200 m - 12,000 m
Power supply3.5
Function Specification
Input voltage 110 V AC / 240 V AC reversible
Input frequency 50 - 60 Hz
Performance 0.5 kW
PC-Computer unit3.6
At present the computer BX-7 is installed in the series
FWA4xxxx:
Description Technical data
Body ATX- Minitower
MSI- Motherboard MSI PM8M3
CPU 2.533 GHz Intel Celeron
RAM 512 MB-DDR
Hard disc 80 GB
drive Floppy 3.5“
DVD/CD-RW drive Combo BTC 48x
Graphic card On Board
Sound card On Board
Network interface card On Board
6 x USB 2.0 2 x front, 4 x behind

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PC-Computer unit4.
Connections4.1
Connector pin assignment of back side of the PCFig. 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 - DVDFig. 4:

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8 | FWA 43xx / FWA 44xx | PC-Computer unit
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Dongle4.2
Front and rear viewFig. 5:
Function4.2.1
The hardware license number of the axial cutter
R
computer is stored in the dongle.
Without the dongle (or faulty dongle ) just a demo
R
operation is possible, measurement operation with
actual measurements is not possible, and the target
database is closed!
During the initial installation and every further
R
update, this hardware license is read from the
memory of the dongle and compared with the
enclosed software license of installation.
Installation is continued further and successfully
R
completed only if both the licenses match.
After that during every run of the axial cutter
R
computer, the license of the dongle hardware is
compared with one of the software license installed
on the hard disc.
Same is applicable for each operation of C button
R
in the axial cutter program. Measurement is not
possible if the licenses do not match.
Connection4.2.2
The dongle is fixed on the parallel interface LPT 1 at
R
the back side of the computer.
For other dongles of other program or a connected
R
printer is permeable and they do not affect further
Hardware.
License number4.2.3
The license number is a part of the serial number. It
consists of alpha numerical product code LA or LB
follows a seven digit number.
LA – device with radio transmission
R
LB – device with cable transmissionR
Example of a serial number
License number – LA 0000123
R
License number – LB 0000123R
Licensing4.2.4
Licensing = programming the serial number in the
R
memory of dongle and can be carried out exclusively
in Bosch plant.
Each license number is assigned only once. In case
R
of loss or theft, the dongle is replaced, which is
marked with "98" in place of the first two letters (for
example 98 0000123).
For special purpose (Service technician, seller) in
R
stead on the first two letters, "00" is used as a mark
(for example 00 0000123).

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Robert Bosch GmbH 1 690 326 006 2008-8-25
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Functional diagram5.
Cable format5.1

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10 | FWA 43xx / FWA 44xx | Functional diagram
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Radio format5.2
PS2
RS 232
230V AC 3,15A
VGA
D2
USB
L,N,PE
D1
COM2
A1
D4
RS 232
video
COM1
keyboard
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

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Communication processor | FWA 43xx / FWA 44xx | 11
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Communication processor6.
Tasks6.1
Communication controlR
Data transfer on PC (serial)R
Saving the channel number (max. 6 transmissionR
channel)
Function6.2
The communication processor (KP) is a central
manager for the measuring functions.
The installation location is different depending on the
type of device (radio or cable).
The connection between communication processor
R
(KP) and PC interface COM 2 is done using a 9 pin
serial cable.
The connection between communication processor
R
(KP) and 4 measuring elements (MWA) is made
using a splitter box or mess box.
Radio devices have KP built in the mess box. The
R
mess box also serves for loading the batteries.
In emergency cable operation (Breakdown radio),
i
the measuring element can be connected to the
mess box.
KP is installed in PC in case of cable equipments.
R
A splitter box manages the connection possibilities
of the measuring element.
The KP, in case of radio or cable devices, serves for
i
data transfer of measuring elements (MWA) sensors.
Pin assignment6.3
Pin assignmentFig. 6:
1 Power supply 12 V through PC-mains adapter
2 Serial connection COM 2 from PC
3 DIP- Switch (not used)l
4 Not assigned (for ex-works programming)
5 Not assigned
6 Outlet to splitter box
7 Not assigned
Fig. 7:
1 Serial connection COM 2 from PC
2 DIP- Switch (not used)
3 Not assigned (for ex-works programming)
4 Connection to Splitter board
.

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12 | FWA 43xx / FWA 44xx | Communication processor
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Functional diagram of cable splitter box6.4

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Splitter box (Cable) | FWA 43xx / FWA 44xx | 13
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Splitter box (Cable)7.
Element7.1
Tasks7.1.1
Serial data transfer from / to PC
R
Y-Partitioning of data and power supply in 2 outletsR
Fuse protection 1,6 AT for connecting cableR
Looping of 8 VR
Looping of measuring dataR
Function7.1.2
The splitter box divides the serial connection of
measuring data coming from the KP and the 8 V power
supply in 2 Neutrik connecting 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 supplyR
The device protection with 2 x 3.15 AT is found inR
the splitter box.
A looping of 240 V AC is made for switch-able
R
multiple sockets.
Configuration of front sideFig. 8:
Delay fuse for 8 V DC 1.6 A
Configuration on back sideFig. 9:
1 Input multiple socket with fuse carrier 2 x 3,15 AT
2 Outlet multiple socket
Configuration of left sideFig. 10:
Connection of input splitter box
from PC/ Communication processor (KP)
Configuration of right sideFig. 11:
Two connection of outlet splitter box

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14 | FWA 43xx / FWA 44xx | Measurement box (Radio)
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Splitter board7.2
Connector pin assignment7.2.1
Connector pin assignmentFig. 12:
1 Fitting socket – connecting cable
2 Fitting socket – connecting cable
3 Loading socket 1)
4 Loading socket 1)
5 Power supply 1)
6 Communication processor (KP)
7 Radio module 1)
1) only be used in the Measurement box
Function7.2.2
The splitter board divides the necessary data cables
and voltages.
Looping of data:
i
Rn radio operation (Measurement box)
in cable operation
R(splitter box/emergency cable
mess box)
Looping of voltages
+ 8 VDC for Battery charging
R
+ 8 VDC for cable operationR
+ 5 VDC for radio moduleR
There are only conductor paths and clips on thei
board, no electronic components.
Measurement box (Radio)8.
Element8.1
Measurement boxFig. 13: (Radio version)
Tasks8.1.1
Data transfer to MWA over radio or emergency cable
R
Serial data transfer on PCR
Looping supply voltage for PCR
Mains protection 3.15 ATR
Conversion 110 V / 230 VR
Fuse protection the 8 VDC with 2,0 ATR

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Measurement box (Radio) | FWA 43xx / FWA 44xx | 15
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Functional diagram of mess box8.1.2

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16 | FWA 43xx / FWA 44xx | Measurement box (Radio)
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Function8.1.3
The mess box provides the necessary low-voltages of
12 VDC and 8 VDC.
8 VDC = for cable operation, charging of batteries,
R
supply of communication processor
12 VDC = for Fan
R
Power supply board8.1.4
The conductor board power supply generates two
necessary voltages from 8 VDC and 12 VDC for the fan.
Fan:
R
The fan starts when required, depending on the
temperature.
Communication processor
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
measuring processors in the measuring elements.
Splitter board
R
see 7.2.2
Configuration of front side of mess boxFig. 14:
1 Delay fuse for 8 VDC 2 AT.
Pin assignment of right side mess boxFig. 15:
1 + 2 socket for connecting cable
Pin assignment at back side of the mess boxFig. 16:
1 Converter 110 V /230 V
2 Socket for 2 PC (Null modem cable)
3 Power supply socket / line filter
4 Socket for multiple sockets

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Measurement box (Radio) | FWA 43xx / FWA 44xx | 17
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Mess box in the device8.2
Splitter box in the device8.3
Fan mess box8.4
Power supply
The fan required power supply of approx. 12 VDC.
The supply is taken from the power supply board.
Switch-on / switch-off time
The switch-on time of the fan is controlled by the power
supply board depending on the temperature. It runs
only when required.
The setting of switch-on time is carried out on the
power supply board with potentiometer R 16 Tadj. See
also potentiometer - setting power supply board.
Power supply board8.5
Connector pin assignmentFig. 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 converts
this to direct current. From that 8 VDC for
the supply voltage of communication processor (KP)
R
charging the batteryR
the supply voltage of measuring element (MWA) inR
emergency cable.
Besides, the power supply board provides approx.
12 VDC for the supply of temperature controlled fan.

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18 | FWA 43xx / FWA 44xx | Measurement box (Radio)
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Potentiometer- Setting8.6
Fig. 18:
1 Breaking point 3
2 Breaking point 2
3 T adjust potentiometer R16 for fan
4 V adjust potentiometer R8 for 8.00 V DC
5 I adjust potentiometer R11 for 23 m V
6 Breaking point 4
7 Breaking point 1= measure
8 Breaking point 5
9 Breaking point 6
Setting
The settings must be made necessarily in the speci-
i
fied sequence after visual inspection. After success-
ful adjustment, the spindle potentiometer must be
sealed.
1. Vadj (R8)
= setting the supply voltage for communication
processor (KP), the battery, cable connection.
Setting location:
RR8 (Spindle potentiometer 200 Ω)
Setting condition: Temperature between
R
20°C...30°C, no load.
Breaking point: MP2 on C6 Pin 1 (+) to GND (MP1)
R
Vadj = + 8.00 V + 0.04 V (0.25%) - 0.00 Vi
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 location: R11 (Spindle potentiometer 200 Ω)
R
Setting condition: Temperature betweenR
20°C...30°C, no load
Breaking point: Voltage of MP4 (Pin 5) after MP3
R
(Pin 6) on OP U2
In case of Ilast= 0
i
∆UOp- inputs = +23m V +/- 0.5m V3.
3. Tadj (R16)
= Setting of the switch-on time of the fan operating
depending on the temperature.
Setting location: R16 (Spindle potentiometer 200 Ω)
R
Setting condition: No load, fan off!R
Breaking point: Voltage of MP5 (Pin 2 ) after MP6R
(Pin 3) on OP U2,T is the heat sink temperature.

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Setting is carried out according to the following table:
T/°C U/m
V
0 300,0
1 291,5
2 283,1
3 274,8
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

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20 | FWA 43xx / FWA 44xx | Charging equipment MWA
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Charging equipment MWA9.
Overview sensor9.1
Overview of different receptacle for the MWA seei
spare parts list.
Mount receptacle MWA longFig. 19:
+ (breadth, length) in direction of front side of the vehicle
Mount receptacle MWA short on left sideFig. 20:
+ (breadth, length) in direction of front side of the vehicle
Mount receptacle MWA short on right sideFig. 21:
+ (breadth, length) in direction of front side of the vehicle
Connector pin assignment9.2
Connector pin assignmentFig. 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 thei
radio version.
During mounting, the plus pole must always be
!
mounted in the direction front side of the vehicle.
Test after mounting. Wrong wiring leads to short
circuit.
Mount receptacle on the vehicleFig. 23: