JOSAM AM34 A User manual

Manual
JOSAM laser AM
Measuring system
®
©
ALIGNMENT OF
WHEELS AND AXLES

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Measuring system
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Introduction
The following things should be checked
before wheel and axle measurements are
taken:
• Tire pressure
• Tires (are the correct tires mounted or are
different types of tires mounted on the same
axle).
• Bearing 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 bushings with JOSAM play detector AM 900:K

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Measuring system
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Title Page
Introduction.................................................................................... 2
MEASURING EQUIPMENT............................................................ 4-9
PREPARATIONS BEFORE MEASURING..................................... 10-25
Checking of frame gauge................................................................ 10-11
Wheel adapter and laser projector, description and calibration....... 12-15
Wheel alignment gauge AM301, description and calibration........... 16-17
Hanging the frame gauges.............................................................. 18-19
Toe-in/toe-out - calculations in mm/m............................................. 20
Toe-in/toe-out - calculations in degrees/minutes.............................. 21
Toe-in/toe-out - calculations in mm/bead of rim............................... 22
The Test 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
Toe-in/toe-out with measuring scale and sliding scale.................... 40-43
Measurement of out of square front axle.......................................... 44
Measurement of camber ................................................................. 45
Measurement of caster.................................................................... 46-49
Measurement of KPI........................................................................ 50-53
Measurement of toe-out on turn (TOOT)......................................... 54
Measurement of maximum turn....................................................... 55
INDEX

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Measuring system
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Measuring equipment
Frame gauge with hangers as well as gauge
extensions with sight pins.
NOTE! The hangers are to be 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.

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Measuring system
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Measuring equipment
Trailer tow bar adapter AM48 A.
Attaches in the towing 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.

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Measuring system
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Measuring equipment
Wheel adapter AM10 and AM8.
AM10 for 16” – 24” wheel.
AM8 for 13” – 19” wheel.
Diode laser AM20-D1.
Battery-driven rechargeable 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

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Measuring system
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Measuring equipment
Turn angle gauge AM135.
Together with the laser projector measures maxi-
mum wheel turn, toe-out on turn, as well as posi-
tion for KPI and caster.
Turn plate AM585.
Designed to measure maximum turn, toe-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 as a complement to measurement test
report AM39.

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Measuring system
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Turn angle gauge AM135
Description
Turn angle gauge AM135 is, together with the laser
projector, designed to measure the maximum 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.

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Measuring system
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Turn angle gauge AM135
Hang frame gauge, gauge extensions and
measuring scales.
Jack up the axle.
Attach wheel adapters and laser projector.
Run-out of the wheel can be compensated with the
adjustment knobs on the adapter
Place the turn angle gauges on the floor for both
the left and right sides, with a centered scale and
in the middle 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) of the
measuring scale.
Move measuring scale until laser dot hits the
intersectional point of the 0-line (2).
Align the laser dot on the degree scale and read
the value.

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Measuring system
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Frame gauge
Checking the frame gauge
Mount hangers at both ends.
Both hangers should be placed with the 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.

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Measuring system
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Frame gauges
Hangers
Right angle
Sight pins
Frame gauge
Checking the frame gauge
The self-centering frame gauges must be checked
while they are hanging in the storage trolley.
Hang the frame gauges on the support rack in the
storage trolley.
At least three frame gauges are required.
Make sure that the 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.
Turn a frame gauge 180°and check the sight pins
again. If the deviation exceeds the tolerance level,
then one or more of the hangers are bent.

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Measuring system
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Wheel adapter AM10 - AM8
AM8
AM10
Wheel adapter AM10
Intended for rims between 16” – 24”.
The adapter is equipped with reversible grip hooks.
Wheel adapter AM8
Intended for rims between 13” – 19”.
The adapter is equipped with reversible grip hooks.
Attachment of the wheel adapter
Attachment is done with the knob (1) on the short
side of the adapter.
On rims with corners, the wheel adapter is
attached according to figures Aand Band
tightened outwards.
On the rims shown in figure Cor 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 Aand B) or gripping in between the tire
and the rim (figures Cand D).
Press the adapter against the rim during the
clamping with the knob (1).
(1) Knob for clamping
(2) Grip hooks
(3) Adjustment arm

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Measuring system
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Hang frame gauges, gauge extensions, and
measuring scales. Jack up the axle so that you can
spin the wheel. Attach the wheel adapter on the
wheel (wheels). Attach the laser projector on the
axle of the wheel adapter. The guide pin should
run in the groove. Turn the knob so that rotating
the laser projector meets with some resistance.
The measuring scales are to be placed 2–4 meters
from the laser projector. The measuring scales can
be placed on the floor if the distance is less than 2
meters or more than 4 meters. When the distance
is too short or too long between the measuring
scales and the laser projector, the measurements
are not as exact.
APlace the laser projector 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.
BRotate 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 Aand Bat C. The value is
75 in this example.
CRotate the wheel a quarter turn (90°). Adjust with
the “black” knob (2) until the laser dot hits the
earlier value C75. Rotate the wheel and check
to make sure the laser dot has not “wandered” to
the side. Repeat the adjustment if the laser dot
“wanders”.
If value Ais less than value Bcarry out the
adjustment according to the same principle.
Compensate for run-out of the wheel rim
Adj. arm
Axle
Parallelism
Parallelism
Measuring
scale
Parallelism
Parallelism
Floor
A
B
C
Measuring
scale

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Measuring system
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DIRECTION OF
LASER BEAM
Laser projector AM20-D 1
AM22-D 1
R14 Ni-Cd
AM20-D 1 5
SP LA 91:106
KLASS 2
TYPE: AM20-D 1 MADE IN SWEDEN
SERIAL NO
MANUFACTURED
Description
The laser is powered by 6 rechargeable R 14 Ni-
Cad batteries.
Charging takes place with a power operated trans-
former AM22-D 1 connected to the contact (5) on
the rear end.
The normal charging time is 14 hours.
Operation time is approx. 50 hours.
Change of batteries
- Remove the front end, 3 screws.
- Replace the batteries.
- NOTE! Place the batteries according to the
diagram in the housing.
- Replace the front end on.
Respect the text on the warning labels.
The manufacturer will not be held responsible
if the laser projector is used for 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 reduced light intensity,
press on the bottom part of the circuit breaker.
(4) The shutter.
The opening for the laser beam can be closed
by turning the knob a half turn.
Adjustment
The angle of the laser beam in relation to the
wheel with the wheel adapter is adjusted by turning
an adjustment screw (6), located on the side of the
housing, with a 2 mm Allen wrench.
Laser radiation
do not stare into beam
Diode laser
Output less than 1mW
Class ll laser product
CAUTION
LASER RADIATION
DO NOT STARE INTO BEAM
DIODE LASER CLASS 2
WARNING

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Measuring system
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Laser projector AM20-D 1
Calibration of laser projector
Hang the frame gauges front and back, with measuring
scales AM34 A and sliding scales AM84 A.
Attach the wheel adapter and laser projector.
Aim the laser dot at the front measuring scale (A).
Move the sliding scale so that the laser dot hits the
O-line.
Rotate the laser projector on the axle with the
wheel adapter.
Align the laser dot on the rear measuring scale (B).
Move the sliding scale so that the laser dot hits the
O-line.
Detach the laser projector and turn it around 180°
on the axle of the wheel adapter.
Align the laser dot on the O-line of 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 (after
you have turned the laser upside down) adjust the
laser dot.
With a 2 mm Allen wrench, adjust the adjusting
screw on the laser housing located according to (6)
on page 14, to a value 1.5 on the same distance
line (the value halfway between 0 and 3).
Check again that the same value is maintained
front and rear by putting the sliding scales on 0 and
turning the laser projector 180°on the axle of the
wheel adapter.
Rear scale B
A
180°

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Measuring system
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Measuring
level
Measuring
Scale
Indicator
Upper level
Lock
Wheel alignment gauge AM301
AM301 for measurement of camber/caster AM301 for KPI measurements
Measuring instrument for camber, caster and
KPI.
Description
The wheel alignment gauge AM301 has a rotating
scale and an adjustable measuring spirit level.
The scale is divided into degrees and 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 instrument towards the bottom and lock
with the upper knob.
Attachment hole for measuring of camber and
caster.
Move the instrument towards the locking pin and
lock with the bottom knob.

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Measuring system
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Calibration
Mount the wheel adapter and compensate for run-out of
the wheel with the adjustment knobs on the adapter.
(1) Mount the AM301 to the wheel adapter by
inserting the adapter spindle into the hole for
camber and caster measuring. Move the instru-
ment towards the locking pin.
(2) Check the top bubble, and lock with the lower knob.
(3) Turn the measuring scale until the measuring
bubble shows the horizontal position.
(4) Read the camber from the outer numbers on
the scale. Record the values.
NOTE! Do not forget to write down if it is a (+)
or a (–) number.
Example: +0°50´
(5) Take AM301 off the wheel 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 adjusted.
Example:
Reading in the first case = +0°50´ camber.
Reading in the second case = -0°20´ camber.
The second reading should have been -0°50´.
Adjust the measuring scale to -0°35’ camber,
which is halfway between -0°50´ and -0°20´.
(8) Adjust the measuring bubble with one of the
screws until the measuring bubble shows it is
horizontal.
Check the numbers by repeating the first
measurement.
Wheel alignment gauge AM301
7
6
8
5
1
3
2
4

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Measuring system
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Hanging the frame gauges
Hanging the frame gauges on a truck
Hang the frame gauges with hangers and gauge
extensions as far forward and as far back as
possible on the frame.
Adjust the height on the hangers so that the frame
gauge and hangers are at the same height as the
center of the wheel.
Place the measuring scales on the gauge exten-
sion sight pins.
Adjust the frame gauge with stepless adjustable
mounting for the hangers and gauge extension
with bubble to horizontal position.
NOTE! Make sure during the installation of the
frame gauge that the attachment on the truck
frame flange is the same 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 the adapter.
Check that the frame gauge and the gauge
extensions are at a right angle to the frame by:
Aiming the laser dot at the measuring scale.
Turn the frame gauge, gauge extensions and
adapters on the kingpin and observe the laser dot
on the measuring scale.
When the laser dot shows the HIGHEST value,
the frame gauge and gauge extensions are at a
right angle to the frame.
Hang the rear frame gauge as far back as
possible.
King-Pin

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Measuring system
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Hanging the frame gauges
Hanging frame gauges on a trailer with a trailer
hitch
Front axle(s) on “dolly”
Attach trailer tow bar adapter AM48 in the towing
eyelet.
Attach the gauge extensions to the trailer tow bar
adapter and place the measuring scales on the
sight pins.
Check that the gauge extensions are at a right
angle to the tow bar by:
Aligning the laser dot on the measuring scale.
Turn the front gauge extensions connected by the
AM48 and observe the laser dot on 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
mounting.
Hanging frame gauges on a bus with steerable
rear axle
Requires 3 frame gauges. Hang two frame gauges
on the front section of the bus- one all the way
forward and one all the way back. Hang a frame
gauge on the back section of the bus at the
extreme rear.
Frame gauges and measuring scales
AM48 A

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Measuring system
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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