Rotary RWA5100HD User manual

© September 06, 2022 by Vehicle Service Group. All rights reserved. Co11904.2 2015-M358 rev. 02
COMPOSITION
66 pages (including cover pages)
63 numbered pages
• For any further information please contact your local dealer. Contact info are on the last page:
IMPORTANT Any damage caused by failure to follow the instructions in this manual or improper
machine use shall relieve the manufacturer of all liability.
RWA5100HD
INSTRUCTION MANUAL

SYMBOLS USED IN THE MANUAL
This symbol instructs the user to refer to this manual before using the
equipment or any parts of it.
This symbol indicates to the user that there are important operations to read
about and instructions that demand attention in the documentation that
accompanies the product.
This symbol indicates hazardous operations or conditions.
Carefully consult the text shown together with this symbol and follow the
instructions to avoid hazards.
WARNING
This symbol indicates that failure to follow the instructions could result in death
or serious injury.
ATTENTION
This symbol indicates that failure to follow the instructions could cause minor
personal injury or damage to the equipment.
This symbol indicates an operation that requires special attention because
there are sharp edges.
This symbol indicates an operation that requires special attention because
chemicals are present. Protect hands. Appropriate protective gloves must be
used to protect against corrosive substances.

1
TABLE OF CONTENTS
0WARNING..................................................................................................................................................................... 3
0.1 Preliminary safety information ............................................................................................................................ 3
1INTENDED USE............................................................................................................................................................ 5
2TRAINING OF DESIGNATED PERSONNEL............................................................................................................... 5
2.1 General prevention measures ............................................................................................................................. 5
3EQUIPMENT COMPONENTS ..................................................................................................................................... 7
3.1 RWA5100HD ........................................................................................................................................................... 7
3.2 TABLET.................................................................................................................................................................... 8
3.3 SENSORS ................................................................................................................................................................ 9
3.3.1 Measuring head keypads ................................................................................................................................................10
3.3.2 Automatic shutdown of detectors..................................................................................................................................10
3.3.3 Low battery warning.........................................................................................................................................................10
3.4 WHEEL CLAMPS STDA92E................................................................................................................................. 11
3.5 TURNPLATES STDA29L (available in option) .................................................................................................. 11
4EQUIPMENT CHARACTERISTICS ........................................................................................................................... 11
4.1 Safety devices...................................................................................................................................................... 11
4.2 Measuring ranges and precision...................................................................................................................... 12
4.3 Overall dimensions/weights............................................................................................................................... 12
5TRANSPORTATION AND INSTALLATION ............................................................................................................. 13
5.1 Transportation and unpacking .......................................................................................................................... 13
5.2 Installation ............................................................................................................................................................ 13
5.3 Electrical connection .......................................................................................................................................... 13
6APPLICATION SETTINGS......................................................................................................................................... 14
6.1 Program configuration........................................................................................................................................ 14
6.2 DATABASE configuration................................................................................................................................... 15
7VEHICLE DIAGNOSIS AND ADJUSTMENT ........................................................................................................... 16
7.1 Home page............................................................................................................................................................ 16
7.2 Vehicle make and model selection ................................................................................................................... 16
7.3 Viewing the technical data of the preselected vehicle................................................................................. 18
7.3.1 Display of ADDITIONAL MEASUREMENTS on RIDE HEIGHTS.................................................................................19
7.3.2 Display of VERIFICATION MEASUREMENTS on RIDE HEIGHTS ..............................................................................20
7.3.3 Viewing of ADJUSTMENT AID images .........................................................................................................................21
7.4 Preliminary operations........................................................................................................................................ 22
7.4.1 Preliminary vehicle check operations...........................................................................................................................22
7.4.2 Preparation for run-out ....................................................................................................................................................22
7.5 Run-out.................................................................................................................................................................. 23
7.5.1 Run-out with wheels raised ............................................................................................................................................23
7.5.2 Push run-out ......................................................................................................................................................................25
7.6 Preparation for measurements ......................................................................................................................... 27
7.7 Alignment and levelling / direct measurements ............................................................................................. 27
7.8 Steering procedure ............................................................................................................................................. 28
7.9 Vehicle diagnosis................................................................................................................................................. 29
7.10 Preparation for adjustment ................................................................................................................................ 29
7.11 Rear axle adjustment .......................................................................................................................................... 30
7.12 Front axle adjustment.......................................................................................................................................... 30
7.12.1 Adjustment of front toe with wheels steered...............................................................................................................32
7.12.2 “Jack-Hold” procedure ...................................................................................................................................................33
7.13 DIAGNOSIS and ADJUSTMENT data summary ............................................................................................. 34
7.13.1 Chassis diagnosis .............................................................................................................................................................34
7.13.2 “Test Drive” procedure....................................................................................................................................................35
7.14 Auxiliary functions menu.................................................................................................................................... 36
7.15 Measurements print-out..................................................................................................................................... 37

2
7.16 Saving tests carried out with TEq-Link............................................................................................................. 42
7.16.1 TEq-Link function configuration .....................................................................................................................................42
8DIAGNOSIS AND ADJUSTMENT OF TRUCKS ...................................................................................................... 43
8.1 Adjustment of 3-axle tractor - 1 steering axle................................................................................................. 43
8.2 Adjustment of a 3-axle semi-trailer .................................................................................................................. 48
8.3 Adjustment of 3-axle tractor - 2 steering axles............................................................................................... 51
8.4 Adjustment of a full-trailer with drawbar......................................................................................................... 56
9ERROR NOTIFICATIONS ........................................................................................................................................... 60
10 PROBLEMS................................................................................................................................................................. 61
11 MAINTENANCE ......................................................................................................................................................... 61
12 STORAGE AND SCRAPPING.................................................................................................................................... 62
13 MACHINE IDENTIFICATION DATA/WARNING LABELS ..................................................................................... 63

3
0WARNING
Any damage deriving from failure to observe the instructions contained in this manual and from improper use
of the machine releases the manufacturer from any liability.
IMPORTANT SAFETY INSTRUCTIONS, READ AND SAVE THESE INSTRUCTIONS
When using your garage equipment, basic safety precautions should always be followed, including the
following:
-Read all instructions.
-Care must be taken as burns can occur from touching hot parts.
-Do not operate equipment with a damaged cord or if the equipment has been dropped or damaged –until it
has been examined by a qualified service person.
-Do not let a cord hang over the edge of the table, bench, or counter or come in contact with hot manifolds
or moving fan blades.
-If an extension cord is necessary, a cord with a current rating equal to or more than that of the equipment
should be used. Cords rated for less current than the equipment may overheat. Care should be taken to
arrange the cord so that it will not be tripped over or pulled.
-Always unplug equipment from electrical outlet when not in use. Never use the cord to pull the plug from
the outlet. Grasp plug and pull to disconnect.
-Let equipment cool completely before putting away. Loop cord loosely around equipment when storing.
-To reduce the risk of fire, do not operate equipment in the vicinity of open containers of flammable liquids
(gasoline).
-Adequate ventilation should be provided when working on operating internal combustion engines.
-Keep hair, loose clothing, fingers, and all parts of body away from moving parts.
-To reduce the risk of electric shock, do not use on wet surfaces or expose to rain.
-Use only as described in this manual. Use only manufacturer’s recommended attachments.
-ALWAYS WEAR SAFETY GLASSES. Everyday eyeglasses only have impact resistant lenses, they are not
safety glasses.
-To reduce the risk of injury, close supervision is necessary when this product will be used around children.
(Pertains to cabinets only.)
0.1 Preliminary safety information
Before turning on the equipment:
•Read the instructions and the entire manual before using or working on the wheel aligner. This manual is
an integral part of the product and is intended to provide the user with instructions on the use of the
RWA5100HD wheel aligner. Therefore, keep it, for the entire operating life of the machine, in a known and
easily accessible place and consult it whenever uncertainties arise. All product operators must be able to
read the manual.
•Check that the power supply complies with the specifications shown on the plate. The plate with the voltage
and frequency data is located on the back of the equipment. Please note the information on the plate.
NEVER connect the appliance to a voltage or frequency other than those indicated.
•Properly arrange the power cable of the wheel aligner. This product has a built-in 3-wire earthing plug. It
only fits into a socket that is also earthed. If it is not possible to insert the plug into a socket of this type,
please consult an electrician. Do not modify or misuse the plug

4
In emergency conditions and before any maintenance work:
•Isolate the machine from the energy sources, with the appropriate main switch of the machine and remove
the plug from the power socket.
•Do not try to perform maintenance this unit arbitrarily, as removing the panels could expose you to
dangerous voltages; maintenance to this machine must only be carried out and exclusively by authorized
service personnel.
Work environment and cleaning of equipment:
•Work environment must be kept clean, dry, not exposed to outside elements and sufficiently lit. Do not
locate the equipment in places where there are oils or corrosive substances.
•Avoid cleaning the equipment with jets of water and compressed air.
To clean plastic panels or shelves, use a damp cloth (avoid liquids containing solvents).
Rotary may at any time make changes to the vehicles described in this manual for technical or commercial
reasons.
The trademark is owned by Rotary. All the remaining trademarks mentioned, the reproduced
logos and the images belong to the legitimate owners who fully hold the relevant rights.

5
1INTENDED USE
The RWA5100HD system is equipment intended for total detection of the characteristic angles of light vehicles
and trucks.
The angle detection is carried out by four sensors with microprocessor technology and infrared measuring and
data transmission system (without using cable connections between the sensors).
Data transmission from the measuring heads takes place VIA RADIO via Bluetooth-compatible modules.
Use the equipment (CAT II) in the following operating range:
•Internal use
•Temperature from 32°F (0°C) to 104°F (40°C)
•Relative humidity from 30% to 70%
•Maximum altitude 9842Ft (3000M) above sea level (asl)
2TRAINING OF DESIGNATED PERSONNEL
Only specially trained and authorized personnel may use the equipment. In order to ensure machine
management are optimal and for measurements to be carried out efficiently, the designated personnel must be
properly trained to learn the necessary information in order to achieve an operating mode that is in line with
the instructions provided by the manufacturer. For any uncertainty relating to the use and maintenance of the
machine, consult the instruction manual; if unsure, do not interpret but instead consult the authorized service
centres or the technical assistance directly.
2.1 General prevention measures
ATTENTION
•During the operation and maintenance of this machine it is absolutely essential to comply with all the
safety and accident-prevention regulations in force and with the European Directives 89/686/ EEC, UNI
EN ISO 20345, UNI EN ISO 13688: 2013, EN 388 and EN 420.
•The equipment must only be used by authorized and adequately trained personnel.
•It is not permitted to attach very heavy objects (weighing more than 33lb (15kg) on the console (e.g.:
rotary plates).
•Do not use the equipment in places where a lot of dust is present (pollution degree equal to or greater
than 3).
•Do not install or store the device in outdoor areas or in areas exposed to climatic conditions such as
direct sunlight, wind, rain or temperatures below freezing.
•When operating the device outside the specified conditions, there is a risk that its safety and operation
could be compromised.
•Always insure that the equipment is positioned in such a way that the electrical outlet is accessible.
•The equipment must always be on a flat and horizontal surface.
•If the power cord is damaged, it must be replaced by the manufacturer, an authorized dealer or
qualified personnel to avoid danger.
•It is important to keep this manual for future use. It is an integral part of the equipment. For this reason,
it should always be with the equipment.

6
WARNING
•For safety reasons, plug the cord into a grounded AC outlet.
•Risk of Fire and explosion! To mitigate this risk the machine must only operate in places where there is no
danger of explosion or fire. This product shall only be installed and used within the ordinary location of a
minor repair garage as defined by the National Electrical Code.
•Risk of electric shock! Never open the system. For continued protection against electric shock the cabinet
must be connected to a reliable ground connection. Do not remove the ground connection. If the receptacle
in the building installation does not contain a ground pin connection, do not modify the attachment plug.
•This equipment must only be used for the purpose for which it is expressly designed. ROTARY declines all
responsibility for damage to persons, animals and property caused by improper use of the machine.
•The installation of accessories and spare parts must be performed by authorized ROTARY personnel and
original accessories and spare parts must be used. It is also not permitted, in any way, to replace batteries
using non-original batteries. It is necessary to use only the manufacturer's original batteries on the
measuring heads.
•The removal or modification of safety devices or of warning signs placed on the machine can cause serious
danger and constitutes a violation of the OSHA safety standards.
•Before carrying out any maintenance on the system, it is necessary to disconnect the power supply. If in
doubt, do not guess, contact the ROTARY technical assistance in advance in order to receive information to
be able to perform operations in conditions of maximum safety.
•The operator must wear safety footwear to avoid damage to their feet, caused by the accidental falling of
clamps or measuring heads. Use footwear with certified protection according to the EN ISO 20345 standard.
•The operator must wear protective gloves when handling the clamps. Use gloves according to the EN 388
standard.
•Prevent unauthorized personnel from approaching the wheel aligner during use.
•Use only the supplied cables. In the event of breakage or a fault, consult qualified service personnel.
•Never try to use the equipment if it is damaged, if it works incorrectly, if it has been partially disassembled
and if any components, including cable and plug, are missing or damaged.

7
3EQUIPMENT COMPONENTS
3.1 RWA5100HD
Figure 1
ATTENTION
The equipment is equipped with two protection fuses, one on the neutral. The fuses are inside the side-mounted
power socket.
Use only T 6,3A L - 115V AC.
THE STEERING LOCK is a tool used to hold the steering at
a fixed position. It is used before the adjustment
procedure as shown in the instructions that appear
during the program.
THE PUSH PEDAL is a tool used to lock the
brake pedal during the preparation operations
for measurements. It is to be used as shown
in the instructions that appear during the
program.
PC Tablet” with features
suitable to manage the App
RWA5100HD - See para. 3.2
MAIN POWER SUPPLY SOCKET
Power supply: 1/N/PE 115V AC,
maximum current 6,3A (approx.
693W) 50/60 Hz
Battery charger circuit protection
fuse T 0.5A L- 110-120V AC
Main switch
Measuring heads
see para. 3.3
Tablet support - Metal plate for
tablet housing
Sensor housed on
charging stands

8
3.2 TABLET
The equipment includes a "Rugged” tablet PC. The Device is supplied with adequate requirements (see
minimum characteristics below) to manage the APP RWA5100HD
The table shows the minimum characteristics for operation of the APP
Processor 2,4Ghz;
RAM 8 Gb;
1 USB 3.0 Type C, 1 USB 3.0 Type A
Bluetooth 4.0
WiFi 802.11ac/b/g/n
Operating system Windows 10 in English
Hard Disk ≥180 Gb
The device is equipped with three magnets fixed on the back, to be able to secure it on the vehicle lift or on the
vehicle chassis, for example during adjustment operations.
Figure 2
At the first launch of the application you will need to enter the codes for the
activation of the license, which are shown in a document supplied with it.
Subsequently, it will be necessary to enter some data relating to the user, to
start the start of the manufacturer's warranty. Keep the document with the
codes because if the application is uninstalled and reinstalled these are
requested again.
Figure 3
MAGNETS