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kwa-300 installation & parts manual
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1. Fig 4 2 Video Cameras and Posts Video Cameras There are four CCD video cameras included in KWA 300 3D wheel aligner They are used to capture the images of four targets installed on wheels respectively These video cameras are held between two post shells as shown in Fig 4 3 Users do not need to perform the video cameras calibrations during the use of 3D wheel aligner because precise video cameras calibrations have been done during the first installation Fig 4 3 Posts The two posts KWA 300 3D wheel aligner are used for containing and fastening the CCD cameras and their signal cables The two posts are respectively mounted on the ground by anchor bolts and the position relationship between the posts and the cabinet is shown in Fig 4 4 Note No matter during or after using ensure to prevent the posts from swaying otherwise the position of camera will be changed influencing the test result LAUNCH KWA 300 3D Installation and Parts Manual Components Structures Fig 4 4 Targets and Wheel Clamps KWA 300 3D wheel aligner totally has 4 target clamp assemblies which are key components for whole test system and are the objects monitored by cameras There are some bull eye signs for installing the wheel on the targets as shown in Fig 4 5 Fig 4 5 Whether the wh
2. 14 Main Unit Installation cree o or omes 14 Post InstalldtoEios ide uacua ptas tat ten hi Ep Ref 14 Checking and Adjusting According to S pot Inspection Item Table before Installation 14 Confirmation of Installation Location 14 POST ROUN antri t Sae 15 Video Camera Bracket Installation 15 Video Camera 1 5 15 Cable Wiring and 15 Main UnitAdjusting in Calibration 1 1 15 Precautions and Solutions nn 19 Common Problems and solutions in Installation 19 et rae 19 KWA 300 3D Installation and Parts Manual Spot Inspection Item Table before Installation 20 LAUNCH General Information Special caution All the operations in this manual Should be performed by the technical personnel trained by Launch for KWA 300 3D wheel aligner Brief Installation Introduction This installation manual is only suitable for the installation of KWA 300 3D wheel aligner post type manufactured by Launch this type of wheel aligner mainly includes two installation components cabinet and two posts For easy use and measurement following four factors should be taken into consideration during installation Working height of
3. ut NE End a e LE m P SLEIVS IPEIVIZEPPSCEPPSIIJBS IYIuee gue ee Y LEG IV c P utm Fig 2 3 The accessory box includes printer housing camera boxes monitor targets wheel clamps brake pedal holder and steering wheel holder LAUNCH KWA 300 3D Installation and Parts Manual Parts List Parts List and Main Component Structure Parts List o Oy KWASO03D wheel 1 KWA 300 3D wheel aligner instalation and pars manual 1 3 KWA 300iluminatonpostassembly 4 300 iluminationpostassembly 3 KWA300calbraton frame assembly Mowe QD P d 3 Keyboard Cwindows10T Acer ula thin pug lism 1 FA PHILIPS 17 inches LAUNCH KWA 300 3D Installation and Parts Manual Components Structures Structures of Main Components Camera Fig 3 1 Parts list of video camera ke Paam 3 leas 2 4 Lens sealing ring big _ Lens sealing ring small Cammbo Crossroundheadscew SSS o LAUNCH Target KWA 300 3D Installation and Parts Manual Fig 3 2 Target Parts List of target Part Name 4 Transparentgass 5 Webo 1 2 Components Struct
4. Fig 5 6 a Camera Calibration Fig 5 7 Select left front camera click CAMERA CALIBRATION to calibrate it Select left back camera click CAMERA CALIBRATION to calibrate it Select right front camera click CAMERA CALIBRATION to calibrate it Select right back camera click CAMERA CALIBRATION to calibrate it b Target Calibration 18 Fig 5 8 Select left front target press TARGET CALIBRATION pushbutton unscrew the lock handle lightly and rotate the left front target with even force to lean backward direction according to the prompt of the icon The screen displays the angle that the target has rotated in real time Reset the target until the screen arrow reminds to rotate backwards stop and lock the target tightly when the angle is less than 0 1 degree Select left back target press TARGET CALIBRATION pushbutton unscrew the lock handle lightly and rotate the left back target with even force to lean backward direction according to the prompt of the icon The screen displays the angle that the target has rotated in real time Reset the target until the screen arrow reminds to rotate backwards stop and lock the target tightly when the angle is less than 0 1 degree Select right front target press TARGET CALIBRATION pushbutton unscrew the lock handle lightly and rotate the right front target with even force to lean backward direction according to the prompt of the icon The screen displays th
5. less than 1mm Keep level meter close to target surface and make the horizontal bubble in the middle by adjusting target At last hold target Fig 5 5 by turning the lock handle of target lightly and keep the whole calibration instrument stand still The installation 4 Video Camera Holding calibration sketch map is shown as Fig3 3 Aube zin mnm GREC mou Se GERi EE LAUNCH In the end use two M6 10 socket head screws to lock horizontal adjustment Tighten the lock handle and use two M6 10 socket head screws to lock vertical adjustment Run 3D wheel aligner software and click pushbutton Cover the post housing from the top hold it by M4X6 round TARGET WATCH in alignment testing surface The screen head screw and seal with guarantee Use M3 5 screw to displays images observed by each camera Adjust visual seal side board and seal with guarantee Later pay attention angle and make every target image in the center of every to prevent post and camera from strong bump to shift visual field Adjust focus distance to fine adjust aperture and make gray level value in each visual field between 5 System Calibration 130 150 Hold the focus and aperture of lens by glue Click pushbutton SYSTEM CALIBRATION in alignment 3 Video Camera Adjustment 17 LAUNCH KWA 300 3D Installation and Parts Manual Installation and Adjustment testing interface When the screen reminds to input password provided by LAUNCH then do it and press OK
6. LAUNCH Table of Contents General Information 1 Brief Installation 1 Precautions before Installation 1 Installation cce 1 Power Supply 1 UNPACKING 2 2 2 ACCES SOIN 4 Parts and Structures of Main Equipments ix ME Parts List of Main 5 Structures of Main Parts ix MBE Bici ERREUR 6 LAOS 7 Wheel breites 8 Steering Wheel 9 Brake Pedal 10 ra niii cori eoi ae IR Deis 1 Overall SUC WI Gs oen otf ftf hs 1 ne ene 1 Video Cameras and 5 5 11 Vaco 11 POSIS taa 11 Targets and Wheel 12 Communication 12 IB terete bade 12 Steering Wheel 12 Brake Pedal 13 Installation and Adjustment
7. ace the posts on the anchor bolts vertically 2 Ring the bolts with plain washers spring washers in turn and then screw the nuts on the bolts and tighten them with wrench Install the Video Camera Bracket Connect video camera to the top of the post by four screws then tighten them with wrench Install the Video Cameras Install two video cameras respectively on the left and right video camera bracket Install left rear and left front camera boxes on the upper and lower positions of the left post video camera bracket Thread the video camera shaft through the hole of the video camera bracket and tighten it by locking handle In the same way install right rear and right front camera boxes on the upper and lower positions of the right post video camera bracket Cable Wiring and Others 1 Place monitor printer keyboard and mouse on the proper positions of the cabinet and connect the corresponding cables Put the cabinet on suitable place between left and right post 2 Thread left front video camera cable and illumination cable as well as the left rear respectively through the left post and then use cable locking clamp on the top post to hold cables Thread the other ends through the wiring hole on the bottom of the cabinet and connect them to the corresponding sockets on the computer rear panel Hold cables by cable locking clamps on the line out position of the post and line in position of the cabinet Connect and hold the cabl
8. and accessory box Cabinet Box For unpacking of the cabinet box please take Fig 2 1 as reference There are two turntables placed on the bottom of the cabinet box and the communication cables and the main unit are inside the box 2 T 0 a Fig 2 1 Post Box Two posts and a set of calibration frame are packed in one package box as shown in Fig 2 2 Unpacking LAUNCH KWA 300 3D Installation and Parts Manual Unpacking e CE T o Bracket Post Bracket Shaft Tie Rod Fig 2 2 LAUNCH KWA 300 3D Installation and Parts Manual Unpacking Accessory Box Please see Fig 2 3 Foot Screw PAL M v Turntable V oo i Protection Cover Level gt SCA Meter Box X QAO ORS LISI AS 205 ee ee ee ee ee 1 ee ee ee JLUEPUGLUNFRGLCURP a r r Printer Camera Box J LI d ror uer curia ear Eid Eran Uribe POR ar Pour Ir r Per Per rur a PS SP RD nar E LI Bottom Wheel Clamp Brake Pedal Holder Steering Wheel Holder ma E i a a aaa at Ba et ot Set
9. cessary To install 3D wheel aligner together with lift mark out the spot according to the Spot Inspection Item Table before Installation install and adjust the lift first and then install 3D wheel aligner KWA 300 3D Installation and Parts Manual General Information Installation Tools Tools needed in 3D wheel aligner installation are bmtapeline accuracy 1mm hammer gt 2kg cable drilling tool 8 and 18 drilling bits monkey wrench medium size 20cm wiring tube 4m lineation chalk hexagon ring spanner M3 M 22 cross screw driver medium size 20cm and 10cm installation sets including calibration frame installation bolts etc level meter accuracy 0 02 degree Power Supply Requirement 3D wheel aligner is a precise computer system that needs 220 10 v 50Hz power supply Good earthing helps to protect the equipments and persons If power supply cable needs to be lengthened its load must not be less than 6A 220V So in order to protect electronic products such as 3D wheel aligner it is suggested to use AC power supply voltage stabilizer Note Installation engineer must confirm that power supply satisfies the requirements above mentioned before switching 3D wheel aligner on LAUNCH KWA 300 3D Installation and Parts Manual Unpacking The transportation package of 3D wheel aligner consists of three separated package boxes quadrate post box Square cabinet box
10. e angle that the target has rotated in real time Reset the target until the screen arrow reminds to rotate backwards stop and lock the target tightly when the angle is less than 0 1 degree Select right back target press TARGET CALIBRATION pushbutton unscrew the lock handle lightly and rotate the right back target with even force to lean backward direction according to the prompt of the icon The screen displays the angle that the target has rotated in real time Reset the target until the screen arrow reminds to rotate backwards stop and lock the target tightly when the angle is less than 0 1 degree LAUNCH KWA 300 3D Installation and Parts Manual Precautions and Solutions Precautions and Solutions Common Problems and solutions in Installation Can KWA 300 work with 110v working power supply Yes it can Set the switch on the back of the computer to 110v Notice if the monitor and printer bought by user satisfles the power How to do when run the software and display the prompt of Illegal user At first examine if the watch dog is installed properly or in poor contact Then check if the serial number and user s password provided are correct If necessary contact with technical service section of our company for verification How to do when run the software and display the prompt of Hardware does not exist Run Equipment Management software in Win2000 program at first and check if there are two domino alpha eq
11. e in and camber etc Mark at the corresponding shift positions of the lift as the alignment height when users operate on it each time Measure the height between ground and turntable center and fil it in the corresponding column of Spot Inspection Item Table before Installation Confirm the post installation central line Obtain two center points by measuring front and rear widths between two lift runway rails Connect these two points to confirm the central line of the lift lengthen the line in the direction of posts Confirm the post base line B Confirm line B according to the positions of two turntables Make sure that this base line is parallel to turntable central line and vertical to lift central line The distance between line B and the turntable central line is 2500mm Confirm installation positions C and D of left and right post as shown in Fig 5 1 both point C and point D are the points of line B their symmetry center line is the central line of the lift The distance from C to D is 2000 2500mm Place two posts on the ground vertically and make the sides with wiring wholes below left and right post face to face drill on the ground by cable drilling tool according to the installation holes on the post pedestals LAUNCH and then install the anchor bolts During installation make sure that the posts are vertical to the ground and their sides with LAUNCH labels are towards the lift Fix the Posts 1 Pl
12. eel clamps are fastened correctly or not has the great relations with the test result Turn the adjusting knob to adjust the span between wheel claws until it 5 proper and then attach the clamp to the wheel rim Adjust the knob to make the wheel clamp fixed on wheel rim tightly Use the wheel clamp tie to bind the wheel clamp and the wheel rim together The installation of wheel clamp is crucial to the test result The claws should be in even contact with the wheel rim without touching the lead weight Avoid hitting during operation Otherwise distortion may be caused and the test result may be influenced Communication Cables There are 4 signal cables and 2 power supply cables for infrared light between the main unit and the cameras of KWA 300 3D wheel aligner which should be fixed on the ground at first installation and should be protected with the bushing Ensure to prevent the liquid from entering the inside of the cable bushing or to avoid putting the heavy on it in order to prevent the bushing from being damaged Turntables and Transition Bridges KWA 300 3D wheel aligner has two mechanical turntables standard configuration see F ig 4 6 Fig 4 6 The turntables are placed at the front wheel positions of the vehicle on the lift Use the lock pin to lock the turntable before driving the vehicle on Pull out the lock pin after the vehicle is stopped and the front wheels are at the centers of the turntables While
13. es of the right post in the same way KWA 300 3D Installation and Parts Manual Installation and Debugging It L i LL II a Fig 5 2 Debugging of the Main Unit Debug the main unit before operating the wheel aligner Connect the main power cable to the power socket 220V press down the indicator switch on the left in the middle of the cabinet to power the main unit Take out the key in the packing box of computer and open the computer press down the power supply Switch to start the computer Enter the WINDOWS 2000 operation system Press down the power supply switch of the printer P rint the test page to see if itis normal debugging of main unit is successful if all the above steps are normal Exit WINDOWS2000 and shutdown the computer Calibration for Installation Note In normal using please do not perform the calibrating operations The left front left rear right front right rear
14. istance from ground to turntable Post standard distance horizontal AB 2000 2540mm distance from turntable center to post installation base Distance between left and right CD 2000 2500mm post Height difference between front 2mm or 0 1degree and back of aligning platform Power supply Requirement AC220 or 110v 5A Eo J 20
15. lift when aligning Horizontal distance from the center of the turntable on the lift to the post Installation height of camera Distance between left and right camera Only the qualified technician can operate the Wheel Aligner operator must have knowledge of computer application and basic theory of wheel alignment The post height of 3D wheel aligner is 2000mm and the working height of the lift is between 600 1200mm which Can Satisfies the use requirements Correct installation 15 very important to the alignment performance and the types of the vehicle that can be aligned please do read this manual carefully Precautions before Installation Spot Inspection Item Table before Installation must be provided by business personnel before installation It is convenient for installation engineer to learn beforehand if the spot satisfies the use requirements of 3D wheel aligner and then select suitable installation bracket Working flow there is no Spot Inspection Item Table before Installation please fill out another kind of the table Every measurement must be marked correctly very important and confirmed by technical service personnel Solve the problems met in the process of filling out the table first and then perform the installation During installation please abide by the advices and requirements of this manual strictly Please contact the technical support engineers for help if ne
16. mentioned in this manual refers to the orientation when the driver faces to the cameras in Installation and Debu KWA 300 3D Installation and Parts Manual LAUNCH Fig 5 3 Installation calibration sketch map 16 LAUNCH KWA 300 3D Installation and Parts Manual Installation and Adjustment Sure all the support legs of the calibration bar are placed 1 Calibration Frame Assembling steady and in the same surface Finish the other calibration Hold calibration support leg on calibration bar by Mg Par Installation In the same way hexagon ring spanner Attention keep the support leg end face close to calibration bar end face and tighten them When holding the other calibration support leg please make Calibration Shaft Lock Screw Adjusting Screw Bracket 2 Calibration Frame Installation Adjust alignment platform to common height that used for vehicle alignment Install calibration frame symmetrically on alignment central line and make front wheel calibration bar on turntable In both sides of front and back calibration bar connect two isometric tie rods and make them close to the end face of support legs According to the signs on the target on both sides of calibration bar install targets left front left back right front and right back Adjust the position of calibration bar measure the measurement terminals on the top of support legs and make the difference between two diagonals of calibration rectangle
17. on the top of the cabinet Lead the cable to the computer inside the upper compartment of the cabinet through the hole on the back of the cabinet Unpack the packing box of the monitor place the related materials well and install the monitor Lead the cable to the computer through the hole on the back of the cabinet Plug the power plug into the connection board on the lower compartment inside the cabinet the packing box of printer place the related materials well and install the printer Lead the printer communication cable to the computer through the hole on the back of the cabinet Install the ink cartridge Plug the power plug of the printer power cable into the connection board on the lower layer inside the cabinet Lock the four doors of the cabinet at last The installation of main unit is complete Install the Posts Checking and Adjusting According to Spot Inspection Item Table before Installation Confirm the Installation Position The position relationship of posts and lift is shown in Fig 5 1 KWA 300 3D Installation and Parts Manual Installation and Debugging 2000 2500m 2500mm Central Line A ste Y Lift F ig 5 1 Confirm the lift height For the lift with multi level height please select suitable working height from 0 6m to 1 2m for operators to push and pull vehicles conveniently as well as adjust to
18. testing try your best to keep the vehicle front wheels at the centers of the turntables Each turntable is equipped with a transition bridge which is placed between the turntable and lift ensuring the wheel on the turntable move reposefully Steering Wheel Holder KWA 300 3D has a steering wheel holder as shown in Fig 4 7 Use the steering wheel holder to lock the steering wheel according to the tips on the screen LAUNCH KWA 300 3D Installation and Parts Manual Components Structures Fig 4 7 Brake Pedal Holder KWA 300 3D has a brake pedal holder shown in Fig 4 8 Itis used to hold the vehicle brake pedal down to ensure the vehicle will not move forward and backward during testing procedure Fig 4 8 LAUNCH Installation and Debugging Professional technical personnel are responsible for the installation and calibration of KWA 300 3D wheel aligner Users need not to do these but to provide installation conditions as follows KWA 300 3D wheel aligner is a type of three dimensions infrared image wheel aligner and it should be used indoors without strong infrared light irradiating directly So it is best to be installed indoors Install the Main Unit Place the cabinet to a suitable place and leave enough places for installation Open the door on the lower part of the cabinet and undraw the drawer And you can see the User s Manual Parts Manual Packing List etc Please keep them well Place the mouse
19. tructures Overall Structure Overall Structure The KWA 300 3D wheel aligner mainly consists of main unit video cameras Fig 4 3 and their posts Fig 2 2 targets wheel clamps communication cables turntables Steering wheel holder and brake pedal holder as shown In Fig 4 1 Fig 4 1 Overall Structure 1 target 2 main unit 3 wheel clamp 4 steering wheel holder 5 brake pedal holder 6 mechanical turntable 7 wheel clamp tie belt Main Unit The main unit which is a control and operating platform consists of cabinet computer main unit interface power supply etc as shown in Fig 4 2 The computer assembly includes industry computer monitor keyboard mouse printer image acquisition power supply switchboard and so on The monitor mouse and printer therein are placed on the upper desk of the cabinet The industry computer is set in the upper compartment of the cabinet The image acquisition and power supply switchboard are installed inside the industry computer The keyboard is on the keyboard drawer The power supply assembly includes power supply leads power supply socket fuse and power supply switch The power supply socket is set below the cabinet 11 The fuse is connected to power supply socket The power supply switch is on the left side panel of cabinet
20. uipments included in Eurecard Then examine if the image acquisition card is loose With the help of changing the acquisition card s position in PCI slot judge itis the fault of PCI or the acquisition card and replace it How to do when run the software and select Target Monitoring but with no images display First check cables of video camera and illumination if the connection is right and the illuminating lamp is lightened Secondly check the light path Sway target near the camera lens and observe if there is image appears At last check if the camera aperture is C and if it is adjust the camera to suitable position according to the video camera adjusting requirements in the chapter of calibration for installation Precautions y Calibration for installation is the base of 3D wheel aligner so every step of operations must be very careful Otherwise test precision and equipments usage will be affected y After calibration for installation posts and cameras are not permitted to move and adjust y Keeptarget clean y filter on camera box is a special optical material so it must be kept clean and cleaned with soft lens tissue when dirty Avoid crushing the filter and moving the camera 19 LAUNCH KWA 300 3D Installation and Parts Manual Appendix Spot Inspection Table before Installation Inspection Item Installation Requirement Actual Measurement Height of aligning platform vertical AH 600 1200mm d
21. ures LAUNCH KWA 300 3D Installation and Parts Manual Components Structures Wheel Clamp Fig 3 3 Wheel Clamp Structure Parts list of wheel clamp Part Name Arm right screw thread Right thread bar King pin Pin Left thread bar Arm left screw thread Claw A ae Quantity 6 8 Boi Knob Gasket Gasket Bolt M6 X 12 Guiding plate Nut M20 Claw B O ring rubber LAUNCH KWA 300 3D Installation and Parts Manual Components Structures Steering Wheel Holder 20 Parts list of steering wheel holder 2 Sm E 3 E 4 5 1 e N rmn 6 1 7 Rightsupportbar 0 0 0 0 0 00 1 8 Supportblock 0 000 9 JN 0 0 00 0 0 00 0 0 0 00 0 0 1 10 Adjustingsleeve 0 0 0 0 0 0 0 1 amp n jmM8 1 W D Supportseat 5 0 0 0 0 1 amp e I m ee LAUNCH KWA 300 3D Installation and Parts Manual Components Structures Brake Pedal Holder 0 Fig 3 5 Parts list of brake pedal holder Part name 4 QR berhande 1 6 jSlotedpanheadsetscew o 6 8 Supotbok 1 Nt 8 31 LAUNCH KWA 300 3D Installation and Parts Manual Components S
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