CEMB DWA1100 User manual

Use and maintenance manual
DWA1100
CEMB S.p.A.
Via Risorgimento, 9
23826 Mandello del Lario (LC) ITALY
Telefono: + 39 706369 Fax: + 39 0341 700725
www.cemb.com [email protected]
The Manufacturer declines all liability for any damage to people or property caused by incorrect use of this product.
Subject to change without prior notice.

Istruzioni originali
Translation of the original instructions
Traduction de la notice originale
Übersetzung der Originalanweisungen
Traducción de las instrucciones originales
Tradução das instruções originais

I
CONTENTS
INSTRUCTIONS FOR USE
CAUTION! 3
GENERAL WARNINGS 3
PRECAUTIONS AND INSTRUCTIONS FOR SAFETY, USE AND MAINTENANCE 3
MACHINE DESCRIPTION 5
TECHNICAL DATA 5
COMPONENTS 5
1 - MACHINE USE 7
1.1 - BATTERY AND COMMUNICATION STATUS 7
1.2 - RECHARGING THE BATTERIES 8
2 - PROGRAM FLOW 9
2.1 - HOW TO INTERACT WITH THE PROGRAM 10
3 - PREPARING FOR MEASUREMENT 11
3.1 - HOME PAGE 11
3.2 - SETTINGS 13
3.3 - CUSTOMER DATABANK 16
4 - VEHICLE SELECTION 17
4.1 - SELECTING A VEHICLE 17
4.2 - CUSTOMER INFORMATIONS 17
5 - VEHICLE SPECIFICATIONS 19
5.1 - ADJUSTMENT HELP IMAGES 20
5.2 - RIDE HEIGHT 21
5.3 - LOADS 22
5.4 - VEHICLE CUSTOMISATION 22
5.5 - (TRUCK ONLY) AXLE CONFIGURATION 24
5.6 - FIT AND ALIGN THE BAR ON THE FIFTH WHEEL PIN 25
6 - RUNOUT 26
6.1 - HOW TO EXECUTE RUNOUT 28
6.2 - 180° OR 90° RUNOUT ON THE GROUND 29
6.3 - 180° RUNOUT LIFTED 31
6.4 - 3X90° RUNOUT LIFTED 32
7 - STEERING 33
7.1 - FAST STEERING 34
7.2 - 10° OR 20° STEERING 34
8 - DIAGNOSTICS 35
9 - ADJUSTMENT 36
9.1 - ADJUSTMENT PROCEDURES 37
9.2 - (CAR) ADJUSTING A REAR AXLE 37
9.3 - ADJUSTING A FRONT AXLE 38
9.4 - (TRUCK) ADJUSTING A REAR AXLE 41
9.5 - (TRUCK) ADJUST THE PARALLELISM BETWEEN THE TWO FRONT STEERING AXLES 42
9.6 - (CAR) ADJUSTING THE FRONT TOE-IN WITH THE VEHICLE RESTING ON A SUPPORT (TOE-IN
CURVE - VAS PROCEDURE)
43
9.7 - ADJUSTING WITH THE WHEELS RAISED OR STEERED (FREEZING) 44
9.8 - ADJUSTMENT IN CASE OF INTERRUPTION OF THE INFRARED RAYS 45
10 - SUMMARY 46
10.1 - VEHICLE DIMENSIONS 47
10.2 - MAXIMUM STEERING 47
11 - WHEEL ALIGNMENT AND MEASURING HEAD LEVELLING 48
12 - SPOILER 49
I 1093 - 03/18 - Ver. 01

13 - MAINTENANCE 51
13.1 - CLEANING 51
13.2 - HOW TO ACTIVATE THE DATABANK AND THE SOFTWARE 51
14 - TROUBLESHOOTING 53
14.1 - MALFUNCTIONS 53
14.2 - ALIGNMENT PROBLEMS 55
15 - STORING AND SCRAPPING 57
15.1 - STORING 57
15.2 - SCRAPPING 57
16 - TESTING THE MEASURING HEADS BY FITTING THEM ON THE VEHICLE 58
16.1 - MEASUREMENT I – TOE-IN AND CAMBER IN DRIVING DIRECTION 58
16.2 - MEASUREMENT II - TOE-IN AND CAMBER IN REVERSE DRIVING DIRECTION 58
16.3 - EVALUATION OF THE VALUES MEASURED DURING THE MEASURING HEAD TEST 58

3
►General warnings
▪The manual refers to the essential requirements set out in the directives, standards and provisions
pertaining to use of the machine summarising the most signicant points.
▪In addition to the service instructions, the general rules of law and the binding rules regarding the
prevention of accidents and protection of the environment must be observed.
▪For all the work to be carried out with or on the machine, the following provisions must be complied
with as well as the general safety regulations following the instructions.
▪The user must ensure that the machine is always and only used in perfect condition taking into
account the essential safety requirements and the applicable regulations.
▪The machine must immediately be put out of service if any defects or malfunctioning is found.
▪Only trustworthy persons may work with the machine; the user is responsible for ensuring that the
persons assigned to the job are suitably qualied and trained.
▪For any doubts about use and maintenance of the machine, consult this manual; if necessary,
contact the authorised technical service centres.
►Precautions and instructions for safety, use and maintenance
▪The data plate bearing the voltage and frequency data is axed on the rear of the machine.
NEVER CONNECT THE MACHINE TO A VOLTAGE OR FREQUENCY OTHER THAN THOSE INDICATED.
▪The machine is equipped with a 3-wire plug with incorporated earth to be inserted only in an
earthed socket. If it is not possible to t the plug in a socket of this kind, please consult an
electrician.
▪Do not modify or improperly use the plug.
▪This machine is not equipped with a manual power cutting device. To cut the power, pull out the
plug or turn o the main switch positioned upstream.
▪All the operations on live electrical parts must be performed after turning o the power switch on
the electric cabinet.
▪Do not remove or make unrecognizable the danger warning plates, adhesive labels and markings on
the machine and
▪make sure that they are always legible.
▪All the maintenance and inspection operations must exclusively be carried out by qualied persons.
▪Mechanical and electrical repairs as well as setting operations may only be carried out by qualied
persons.
▪Unauthorised persons must be prohibited from performing any work on the machines and equipment
of the system.
▪In the event of signicant faults that may compromise the safety and/or reliability of the machine,
it must be stopped and in any case not started before the faults have been corrected.
▪It is prohibited to transform or make modications to the electric system.
▪The user will be held responsible for any damages as a result of such modications. In case of doubt,
please contact the manufacturer before making any modications.
▪Exclusively use original fuses with the specied capacity in ampere! In the event of electrical power
supply faults, the machine must immediately be turned o.
▪Defective fuses may not be repaired or deactivated, but must be replaced with fuses of the same
type.
▪Comply with the environmental protection regulations when disposing of waste substances or
replaced parts.
The wheel aligner is a machine intended for measuring the characteristic angles of motor vehicles, in particu-
lar, the camber, toe-in and caster.
CAUTION!
13 - MAINTENANCE 51
13.1 - CLEANING 51
13.2 - HOW TO ACTIVATE THE DATABANK AND THE SOFTWARE 51
14 - TROUBLESHOOTING 53
14.1 - MALFUNCTIONS 53
14.2 - ALIGNMENT PROBLEMS 55
15 - STORING AND SCRAPPING 57
15.1 - STORING 57
15.2 - SCRAPPING 57
16 - TESTING THE MEASURING HEADS BY FITTING THEM ON THE VEHICLE 58
16.1 - MEASUREMENT I – TOE-IN AND CAMBER IN DRIVING DIRECTION 58
16.2 - MEASUREMENT II - TOE-IN AND CAMBER IN REVERSE DRIVING DIRECTION 58
16.3 - EVALUATION OF THE VALUES MEASURED DURING THE MEASURING HEAD TEST 58

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►Technical data
Power supply and consumption
Measuring cabinet
Power supply: 230 VAC single-phase 50/60 Hz
115 VAC single-phase on request
Max power absorbed: 0,46 kW
Max current absorbed: 2 A - 230V
4 A - 115V
Measuring heads
Internal power supply: 7.2 V rechargeable batteries (Li-Ion)
►Components
MACHINE DESCRIPTION
Measuring heads
The measuring heads are made up of CCD transducers to measure the horizontal angles and accelerometers
to measure the vertical angles. The power is supplied by rechargeable batteries; when the batteries are
at, measurements can still be made by connecting the battery charge cables - supplied as option and not
included in the standard equipment - to the measuring heads.
To turn on the measuring heads press any key on the keypad.
The measuring heads turn o automatically after about 15 minutes if no data is transmitted.
1. Keyboard
2. 3 LEDs for measuring head levelling
3. Connector for battery charge cable
4. Pin locking knob
1. Level indicator with red/green/red LED
Measuring head level
Measuring head o level
Measuring head o level
2. Power on/o
3. OK
4. Next page
5. Previous page

6
2
1
34
5
(option only for car) - Premium type turntables.
Turntables
Plate diameter: 310 mm Capacity: 1000 kg each.
Brake pedal lock
This device is used to lock the brake pedal while preparing to make a measurement.
1. Handle
2. O
3. Plate with non-slip disc
4. Goniometer
5. Reference dial
Steering lock
This device is used to hold the steering wheel in a xed position; it is positioned before carrying out the
vehicle adjustment operations.

7
The colour of the battery icons indicates the status of the battery charge:
• Light blue: battery recharging or almost fully charged
• Green: battery charged
• Yellow: battery low; estimated operating time 60 minutes
• Red: battery at estimated operating time 30 minutes
• Grey: no communication
• Black: rear measuring head not used in the 2 measuring heads mode
►1.1 - Battery and communication status
On some pages battery icons are displayed, which indicate the status of the batteries and the communication
between the computer and the measuring heads.
1 - MACHINE USE
FRONT RH
FRONT LH
REAR LH REAR RH

8
►1.2 - Recharging the batteries
To recharge the measuring head batteries:
1. Check that the battery power switch is set to (I)
Recharging is indicated on the screen by the blue battery icons and on the measuring head by the keypad
LEDs ashing in sequence and automatically ends after about 5 hours if the battery is completely at. It is not
necessary to wait for the batteries to go completely at before recharging them. The battery life in typical
operating conditions is 24 hours of operation, but could be less when the temperatures are low.
• If the measuring heads are not used for a long period of time (more than a week), it is advis
able to disconnect them from the power supply.
• Conditions of validity of the battery warranty
Recharge the batteries at least once every 6 months; a partial recharge (50%) is sucient.
• Operate in a temperature range between 0° and + 45°C.
Precautions for use of the batteries
▪Do not leave them near heat sources such as fire, heaters, direct sunlight
▪Do not disassemble or pierce them with sharp objects
▪Do not short-circuit them and do not invert the positive and negative poles
▪Keep them in a dry place and do not immerse them in water
▪Do not expose the battery to high external pressures, which may cause an internal short-
circuit or overheating. In case of impact or dropping, do not reuse the battery and properly
dispose of it.
In case of fire caused by a lithium battery:
▪Do not inhale the toxic vapours caused by lithium combustion
▪Extinguish the fire using a Class D or graphite powder-based (Lith-X) fire extinguisher
2. Connect the measuring heads to the power cables

9
Chapter 5
Chapter 6
Chapter 7
Paragraph 5.5
Chapter 8
Chapter 9
SKIP VEHICLE
SELECTION
EXECUTE STEERING
PREPARING FOR
MEASUREMENT
VEHICLE
SELECTION
VEHICLE
SPECIFICATIONS
RUNOUT
STEERING
2 - PROGRAM FLOW
AXLE SELECTION
Chapter 10 DIAGNOSTICS
Chapter 11 ADJUSTMENT
Chapter 12 SUMMARY
The following ow chart schematizes the typical program ow for a car or truck with only two axles. In case
of trucks with more axles certain operations must be repeated.

10







►2.1 - How to interact with the program
The operations indicated by the on-screen keys F1 ... F7 can be performed by clicking on or pressing ...
on the keyboard or pressing the arrow buttons of the measuring head keypad.
On the normal pages:
... : the function of these keys varies from page to page
or : goes back to the previous page
or : goes to the next page
: help
: goes back to the home page
In the menus:
... : select the desired function
: exits from the menu
• You can move between the pages using the measuring head keypad.
• To continue with the alignment procedure press or

11
12
a
bab
HYBRID HYBRID
►3.1 - Home page
The home page appears at the beginning of each alignment procedure.
From this page you can select:
▪the car and truck alignment procedure (if enabled)
▪the measuring mode with 2 or 4 measuring heads.
The measuring mode with 2 measuring heads allows measuring and adjusting only the toe-in and camber of
the front axle. The measuring mode with 4 measuring heads is faster because you do not have to t the rear
measuring heads.
It is recommended that only experts use the mode with 2 measuring heads as it is not guaranteed
that the steering wheel stays straight.
Generally, when the home page is displayed, the preliminary operations on the vehicle are performed.
To prepare for measurement:
1. Position the vehicle on the turnplates
2. Mount the wheel clamp and the measuring heads on the vehicle wheels
3. Turn on the computer
4. Turn on the measuring heads
If HYBRID mode is active:
3 - PREPARING FOR MEASUREMENT
Measuring heads positioning:
a. Sensor type CAR
b. Sensor type TRUCK

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: switch between the car or the truck procedure
: switch between the mode with 2 or 4 measuring heads
: menu
: settings page
: customer databank page
: test
: calibration
 : goes directly to measurement without selecting the vehicle
If the databank activation window appears on the home page the databank must be activated 13.2
Nevertheless, the databank can be used for a limited number of times without activating it. To do this, press
to close the activation window.

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78109
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20
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►3.2 - Settings
To access this page from the home page press and then .
The following parameters can be set:
1. Time of inactivity after which the measuring heads
go into standby to reduce battery consumption
(infrared LEDs o).
2. Language
3. Format of the fractions of an angle
• '/100 (dec) = hundredths of a degree (centesi-
mal degrees)
• °/60 (min) = sixtieth of a degree (sexagesimal
degrees)
4. Angle resolution shown on the display (the actual
resolution of the instrument does not change)
5. Toe-in format and resolution
• '/100 °/60 = degrees, resolution specied in box 6
• mm = millimetres, resolution specied in box 8
• inch (dec) = inches, resolution in tenths of an
inch
• inch (1/4) = inches, resolution in fourths of an
inch
• inch (1/64) = inches, resolution in sixty-fourths
of an inch
6. Toe-in resolution if expressed in millimetres or
inches
7. Distance unit of measure
8. Type of communication between the measuring
heads and the computer ('Cable' = via cable) 'BT'
= Bluetooth; 'BT2' = Second generation Bluetooth)
9. Type of runout permitted ('UP/DOWN' = both lifted
and on the ground; 'UP' = lifted only; 'Bypass' =
runout execution not required)
10.Enables checks on correct runout execution
11.Help texts:
• OFF: disabled
• ON: displays on the screen buttons their name
• ON+INF: displays the previous and pages titles
12.Settings page password ('ON' = password required
to access the Settings page)
13.Number of alignments executed
14.Car database active
15.Truck database active
16.COM port setting do not change (reserved for
technical service).
17.In IBRIDA or HYBRID mode (*): measurements made
with all the sensors (8 sensors) or disabling the rear
toe-in sensors (6 sensors). This second setting is
useful in order to be able to make a measurement
also if the rear toe-in radius is interrupted. *The
measurement execution mode requires the use of
2 CAR sensors and 2 TRUCK sensors.
18.() Level sensor tolerance. Select the 'Normal'
setting to optimise measurement accuracy. Use the
'Wide' setting only if you have diculty keeping
the measuring heads level, for example, when
measuring with the engine on
19. Option to disable caster measurement:
ON: steering required
OFF: steering not required
20.Automatic next page for the brake pedal lock and
steering lock positioning pages
AUTO ON: the next page is automatically displayed
after 15 seconds
AUTO OFF: you need to press F6 to go to the next
page

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1
5
3
4
2
6
: print settings see below
 : databank/software activation 13.2
: reset to factory settings
 : data export setting
 : saves the settings and exits
/// / ¨: allow selecting and setting the various parameters
►Print settings
1. Logo ON/OFF
2. Colour in which out-of-tolerance values are printed
: measurements before and after adjustment red
: measurements before and after adjustment black
: only measurements after adjustment (black)
3. Printer header
4. Print footer
5. Print mode
1. Tabular
2. Graphic
6. Values within tolerance green/black
/// / ¨: allow selecting and setting the various parameters
 : saves the settings and exits

15
►Data export setting
It is possible to save automatically and daily any single alignment anywhere in the network.
Any le contains the complete daily measurements before and after adjustment.
How to set it:
• Create a new folder where wished to save the data. Any accessible path in the network can be used.
• Enter the SET-UP page and select the DATA EXPORT icon ( )
• Click on ENABLE (LED must be on)
• Browse to the folder previously created
• Optional: insert the aligner serial number. It will be saved with the data.

16
SELECTED CUSTOMER /
VEHICLE
►3.3 - Customer databank
To access this page from the home page press then . From this page you can search for and display
the customer informations and the relative vehicles measurements stored previously. You can search the data
by customer name, vehicle license plate, date or work order. You can also backup or restore all the user data
(customer informations and relative vehicles measurements + customized vehicles).
: displays the list of customers/vehicles corresponding to what was entered in
the search box
: deletes the customer/vehicle selected
: backup see below
: restore see below
: selects the search box or the customer list
/ : select the desired customer
: displays the customer measurements of the selected customer
To backup the user data:
1. Plug a USB memory into a free USB port.
2. Press . The user data is copied to the USB memory
3. Copy the user data les from the USB memory to a safe location on another computer
To restore the user data:
1. Copy the user data les to a USB memory
2. Plug a USB memory into a free USB port
3. Press . The user data is copied to the computer
You can also use this method to transfer the user data from one alignment machine to another.
Restoring the user data deletes any user data already on the computer.

17
►4.1 - Selecting a vehicle
The Vehicle Selection page allows selecting a vehicle so that during adjustment you can compare the measu-
rements with the manufacturer's specications and display adjustment help images.
Select the vehicle rst by manufacturer and then by model and sub-model. For faster selection of the model
you can display only the models registered as of the year indicated.
You can also insert informations on a customer, which are saved in the customer databank together with the
summary of the measurements so that they can be viewed and printed later.
: to enter informations customer
A...Z, / : to select the desired make
/ : conrms the make of the vehicle selected
4 - VEHICLE SELECTION
: to insert customer informations
: decreases/increases the year of registration with which the models
are ltered
A...Z, / : model selection
: previous page (vehicle make selection) .
/ : conrms the model selected and goes to the database
: help

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: saves the informations and exits
►4.2 - Customer informations
Press to insert customer informations.