OPERATION INSTRUCTIONS Form 4925T, 02-06 Supersedes Form 4925T, 09-03 DSP500 Series Wheel Alignment Sensors ©Copyright 2003 - 2006 Hunter Engineering Company
Contents 1. Getting Started ..................................................................................................... 1 1.1 About This Manual............................................................................................................... 1 1.2 For Your Safety ................................................................................................................... 1 Hazard Definitions ........................................................................................
ii • Contents DSP500 Series Wheel Alignment Sensors
1. GETTING STARTED 1.1 About This Manual This manual contains important operation, maintenance, and safety information for the DSP506, DSP506XF, DSP508, and DSP508XF sensors. It is supplemented by the alignment system console operation manual. Read and become familiar with the contents of these publications. A calibrated set of DSP506, or DSP508, Series Sensors can be used with any Hunter aligner using WinAlign® software version 7.1 or higher.
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 near open containers of flammable liquids (gasoline).
1.4 XF Pod (DSP506XF and DSP508XF Sensors Only) The DSP506XF and DSP508XF sensors communicate with the aligner console using Extra High Frequency (XF). Radio waves are transmitted and received from the sensors and the XF Pod. Occasionally the XF Pod may receive interference from electronic devices in the neighborhood (microwaves). The DSP506XF and DSP508XF sensors and XF Pod may be configured to use different radio frequencies to minimize interference.
1.5 Charging Sensor Batteries (XF Sensors Only) Each sensor contains a 12VDC sealed lead acid rechargeable battery. To get the maximum life out of the batteries in the sensors, follow these three rules: 1. If the sensors are not in use, charge them. 2. Switch sensors “OFF” during charging if you are using cables. 3. Charge for eleven to thirteen hours, and/or provide an extended charge time (24 hours or longer) at least once a week.
The charge indicator light turning from red to yellow is an indication that the charging mode has switched from a fast charge mode into a “trickle” charge mode. It does not mean that the battery is 100% charged. A fully discharged battery should be allowed to “trickle” charge a minimum of five hours to ensure a full charge. The charge indicator light turns green after approximately 6-8 hours of trickle, indicating the charger has entered “float” mode, which maintains the battery at full charge indefinitely.
Additional information: Any sensor that is powered up after being off for a while will initially indicate 100% capacity on the aligner screen. This is not an accurate indication of the charge state of the battery. The battery has a “surface charge” which dissipates quickly. Within 5 minutes of operation the on-screen battery level indicator will settle at its true value. The individual wheels on the screen indicate the actual battery condition and are color-coded.
1.6 Vehicle Preparation Drive the vehicle onto the alignment lift/rack until the front wheels are centered on the turnplates. Install wheel chocks to prevent the vehicle from rolling. Raise the front and rear axles off the lift/rack. If your lift/rack does not have front and rear axle jacks, raise the axle on which you will be performing the alignment. Lower the lift/rack leveling legs if your lift/rack is so equipped, and then lower the lift/rack onto the legs.
REAR SENSORS FRONT SENSORS DSP506/506-XF SENSORS REAR SENSORS FRONT SENSORS DSP508/508-XF SENSORS 8 • 1.
2. MOUNTING SENSORS 2.1 Mounting Sensors Onto Wheel Adaptors Sensors may be mounted on the wheel adaptors before mounting the wheel adaptors on the vehicle. In some cases, it may be easier to mount the wheel adaptor first and then mount the sensor onto the adaptor. Either method may be used. Center the wheel adaptor center casting between the upper and lower castings. When the center casting is properly centered, a plunger ball will fall into the detent position on the adaptor rod.
Wheel Adaptor 175-285-1 ADAPTOR LEVER UNLOCKED POSITION Rotate the adaptor locking lever clockwise to the locked position. ADAPTOR LEVER LOCKED POSITION CAUTION: When mounting sensors to the wheel adaptors, the sensor shaft must be fully seated. Make certain that there is no play or looseness between the sensor shaft and the wheel adaptor. Rotate the wheel while holding the sensor. Listen and feel for movement between the sensor and wheel adaptor.
Wheel Adaptor 175-321-1 with Ratchet Adaptor Locking Lever Rotate locking lever clockwise to tighten. If upper casting prevents rotation of lever, either expand adaptor to move upper casting or re-position the lever by lifting lever up to disengage, rotating counter-clockwise, and lowering to re-engage. Proceed until the shaft is locked tight to adaptor.
CAUTION: Failure to follow tightening and loosening procedures may result in damage to lever. Upper casting can damage lever if contact occurs when going for a large to small diameter rim. Refer to figure below. LOWERING THE UPPER CASTING CAN DAMAGE THE LEVER WHEN LOCATED IN THE WRONG POSITION 12 • 2.
2.2 Mounting Wheel Adaptors Onto Wheels Wheels With No Rim Lip (Attaching To Outer Rim Lip) Position the wheel adaptor with the two upper external rim studs on the outside of the wheel rim. Align the two lower external rim studs on the outside of the wheel rim and check that all four rim studs will engage the outside of the wheel rim. Turn the adaptor adjustment knob to firmly attach the adaptor to the wheel.
Wheels With Rim Lip (Attaching To Inner Rim Lip) Position the wheel adaptor with the two lower rim studs engaging the lower wheel rim lip. Align the two upper rim studs with the upper wheel rim lip and check that all four studs will engage the inner portion of the rim lip. Turn the adaptor adjustment knob to firmly attach the adaptor to the wheel. ADAPTOR ADJUSTMENT KNOB WHEEL RIM RIM STUD Test the security of the installation by tugging on the wheel adaptor.
2.3 Connecting Sensor Cables Connecting Sensor Cables With Optional Rack Wiring Kit Connect each sensor to a rack wiring box with short sensor cables (either connector may be used). Connect a front rack wiring box to the console with a long sensor cable (any available connector may be used).
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3. COMPENSATING SENSORS 3.1 General Compensation The sensors must be compensated to eliminate errors in angle measurements caused by runout of the wheel, wheel adaptor, and sensor shaft. The default setting for the alignment console can be set for either 2 or 3-point compensation. However, the operator still has the option to override the default setting by pressing the “2-Point” or “3-Point” Compensation softkey on the “Compensation Control” screen on the aligner console.
RED LED COMPENSATE INDICATOR COMPENSATION BUTTON GREEN LED POSITION INDICATOR Hand-tighten the sensor lock knob. Rotate the wheel until the sensor is level (as indicated by the spirit level on top of the sensor). Press the compensate button. Do not disturb the sensor until one red LED begins to blink and the green LED turns off, indicating that the measurements have been stored. Loosen the sensor lock knob and rotate the wheel 120°, left or right, until the green LED turns on.
3.3 2-Point Compensation NOTE: To compensate the sensors, both the front and rear sensor on that side of the vehicle must be mounted, and the longitudinal toe beam must not be obstructed. Do not rotate one wheel while the measurements are being saved at the other. The preferred method is to compensate the sensors separately. Raise either the front or rear wheels of vehicle. WARNING: Chock wheels on axle that is not being raised during compensation to prevent vehicle rolling.
3.4 Rolling Compensation NOTE: CAUTION: This procedure can be performed using the 3-point or 2-point compensation method. This procedure should be performed only on a pit-installed rack, and should not be performed on a lift or above-ground rack. The vehicle could roll off the lift/rack, causing severe personal injury and damage to the vehicle, or rack. From the “Control Compensation” popup screen, press “Use Rolling Compensation.” The “Rolling Compensation” popup screen will appear.
Press and release the compensate switch on any ONE sensor. When the sensors are all stable, the measurements will be saved. The screen instructs you to roll the vehicle forward so the wheels rotate another 120°. Vertical bar graphs show when this is correct. Unlock the sensors and roll the vehicle forward until the arrows are in the null position. Level and lock the sensors. The green LED must be on at each sensor. Press and release the compensate switch on any ONE sensor.
Procedure Limitations CAUTION: This procedure must be performed carefully, or inaccurate alignment measurements will result. The axles must always “point” exactly the same direction as the vehicle rolls during the procedure. A change in the pointing direction of an axle during the procedure will be interpreted by the system as runout. 1. Do not allow the front wheels to change their “steering” direction as the vehicle is rolled. 2. Do not perform the procedure on a bumpy or uneven surface. 3.
4. OPERATION INFORMATION 4.1 Adjusting Wheel Adaptor 175-285-1 Lock Lever The wheel adaptor lock lever should not contact the wheel adaptor center casting before the sensor shaft is tightly secured. An adjustment can be made to the lock lever assembly to restore its full tightening capability. Turn the adjusting thumbscrew to adjust the lock lever adjustment screw as illustrated below (do not remove the assembly).
4.2 Sensor Level Check Procedure To achieve an accurate alignment, it is important that the sensors hang level when the sensor lock knob is loosened. A sensor must be balanced correctly to hang level. To check the balance of a sensor: Mount the sensor on a wheel adaptor. Mount the wheel adaptor onto a wheel without connecting the sensor cable. With the sensor lock knob loosened, wait until the sensor does not rock on the wheel adaptor. Observe the level in the sensor.
4.3 Ride Height Measurement (Optional) When equipped with the ride height option, the DSP500 Series Sensors will take accurate ride height (RH) measurements using a ride height tool and compare them to the stored specifications. The CRT must be displaying the "Ride Height" screen to measure ride height. The ride height procedure can be accessed from the primary screen labeled “Make Additional Adjustments.” From the “Additional Measurements Procedures” screen, select “Ride Height” and press “OK.
NOTE: Failure to fully seat the ride height tool shoulder on the sensor will cause inaccurate RH measurements. Raise the RH tool until the horizontal arm touches the underside of the wheel arch above the center of the wheel. Hold the RH tool in that position until the console indicates a reading has been taken. Remove the RH tool and repeat this procedure with the other sensors. 26 • 4.
5. MAINTENANCE 5.1 DSP506XF and DSP508XF Battery Replacement Instructions This procedure provides instructions for replacing the lead acid battery in DSP506XF and DSP508XF wireless sensors. Remove the battery as follows: 1. Depress the upper and lower release buttons on the battery cover and remove. 2. Tilt sensor back and remove battery. Replace the battery as follows: 1. Insert the battery with the positive terminal on top. 2. Replace the battery cover.
5.2 DSP506XF and DSP508XF Hot Swap Battery Replacement Instructions This procedure provides instructions for hot swapping the lead acid battery in DSP506XF and DSP508XF wireless sensors during an alignment procedure. Hot swapping the battery will recall/retain the information in the sensor if the alignment procedure is still in progress.
DSP500 Series Wheel Alignment Sensors 5.
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DSP500 Series Wheel Alignment Sensors 5.
