A

A

REPORT ON

PRACTICAL TRAINING

TAKAN AT ASHOK LEYLAND

ON

WHEEL ALIGNMENT

From 13-05-2010 to 15-06-2010

Submitted to: Submitted by: Deptt. of` Mechanical Engg.

RAVI KR. AGARWAL

Govt. Engineering College, Ajmer B.TECH IV YEAR

R.N.:- 07ME58

CONTENTS

S. N.TITLEPAGE NO.

1Acknowledgement

3

2Declaration 4

3History of Ashok Leyland 5

4Introduction to Alwar plant 7

5Ashok Leyland departments 9

6Certificate and quality policies 15

7Energy power resources

18

8Ashok Leyland products

19

9Wheel Alignment 21

ACKNOWLEDGEMENT

I wish to acknowledge indebtedness to Mr. A.K. Chopra (GM, Ashok Leyland Alwar), Mr. Ramesh Kumar Yadav (Div. Manager HR, Ashok Leyland Alwar), Mr. Ashok Kumar (AGM, Production Department, Ashok Leyland Alwar), for giving me an opportunity to take my training in Ashok Leyland, alwar. For their support motivation and Guidance in throughout my training session.

I also pay thanks to Mr. Moulishankar sir and all the engineers, supervisors, and workers without whom this training would not have been a successful one.

Last but not the least-I thank to all the people who directly or indirectly

Supported in this endeavor.

DECLARATION

I RAVI KUMAR AGARWAL Student of Govt. Engg. College Ajmer Here by declare that all the information of in this report is based on my experience and study during training.

I further declare that all the information and facts furnished in this report are based on my intensive research and findings. They are original in nature.

Date: -

Ravi kr. Agarwal

Govt. Engg. College,

Ajmer

History of Ashok Leyland:

Ashok Leyland was urge for self reliance industry felt by Indias first Prime Minister Pt. Jawaharlal Lal Nehru, persuaded Mr. Raghunandan charan, an industrialist to enter automotive manufacture. In 1948,Ashok motors was set up but was then in Madras, for the assembly of Austin cars after that in 1955 companys name and luck changed by equity participation by British company Leyland and Ashok motors get a new brand ASHOK LEYLAND the manufacture of commercial vehicles. Since Ashok Leyland has been a foremost existence in Indias commercial vehicle industrial. With a convention of technological leadership achieved by tie ups and collaboration with international technology leading organization through enthusiastic in-house research and development it set up its existence in Indian and Foreign market.

Admittance to global technology and equipment enabled the company to set first with technology in full Air-brakes, Power-Steering, and Rear engine buses etc; Ashok Leyland pioneered all these concepts. Responding to the operating conditions and practice in the country, the company made its vehicle strong over engineering then with extra metallic Muscles

Ashok Leyland vehicles have built repute for reliability and austerity. The 5, 00,000 Vehicles put on the roads have considerably eased the additional pressure placed on road transportation in independent India.

Ashok Leyland buses are used by four for out of five most populated states as there state transportation corporation Vehicles.

Some of them like double decker and vestibule buses are unique models tram Ashok Leyland trailer made for high density routs. The companys products are inherent to Indian lives Ashok Leyland dominates in city passenger transportation with specialized high capacity buses such as the double decker and vestibule bus for which the company is the only Indian source.

Ashok Leyland supplies a host of modern special purpose to India defense sector. This includes stallion 4x4s forming the back bone of Indian armys logistics operations, now being assembled within the defense sector through a technology transfer agreement. The stallions left an indelible mark for reliability during the Kargil conflict. When India and Pakistan open there common gate at baga, Ashok Leyland buses was the choice for this prestigious cross border passenger service.

Ashok Leyland has maintained its technology even as it offers the most comprehensive range of model configurations in its class, offering the costumers the closest fit with his unique requirements. A pioneer in alternate fuels, Ashok Leyland made Indias first CNG powered buses in 1997. In 2002, India entered another frontier technology Ashok Leyland developed Indias first hybrid electric bus in a partnership with the Govt. sector.

In 1987, the overseas holding by land rover Leyland international holdings limited was taken over by a joint venture between the Hindu group, the known residential Indian transport group and IVECO. (Since July 2006, Hinduja group is 100% holder of LRLIH)

In the journey towards global standard of quality of Ashok Leyland reached a major milestone in 1993, when it becomes the first Indian history to win the ISO-9002 certification. The more comprehensive ISO-9001 certification came in 1994, QS-9000 in 1998 and ISO-14001 certification for all vehicles manufacturing units

In 2002.It has also become the first Indian auto company to receive the latest ISOTS-16949 corporate certification (in July 2006) which is specified to the auto industry.

INTRODUCTION OF ASHOK LEYLAND ALWAR PLANT

Ashok Leyland, Alwar plant is one of the production unit of Ashok Leyland Ltd. Alwar city situated in west north in Rajasthan and is very near to Delhi, The capital of India. Alwar comes in NCR (National capital region) also it is located at M.I.A (Matasya industrial area) Alwar.

This plant was established in 1982 and has completed his 25 years successfully. This plant is known for his high productivity. It is basically an assembly plant where the chassis is assembled.

Ashok Leyland, Alwar is worlds largest CNG vehicles producing plant. CNG (compressed natural gas) is used as an alternate fuel to diesel and is very less polluting. The pollution of CNG vehicles is less than even EURO-IV vehicles which is known for its lesser pollution value.

The total covered area of Alwar plant is 352 acres. And fencing is done around 161 acres of area. The plant comprises of 4 shops called shop-I, shop-II, shop-V and shop-VII. The plant has three gates; One main gate one for entering the goods carries and the third for the products going out of the plant for sale.

There is an administrative office, one P&A department block, department-offices, a medical centre, a canteen, a news paper reading room and library, a training centre and systems department, RSO yard and the construction is going on for new stores. The over view of alwar plant is

The plant is inaugurated on 22-08-1982.

The total land area is 352.09 acres.

Fenced area is 161.52 acres.

WORK SHOP: - In alwar plant the various workshops are SHOP-1 Chassis assembly takes place in the line by old assembly method and the PDI (pre delivery inspection) is carried. SHOP-2 Chassis assembly takes place on conveyor line which is newly installed in the plant. SHOP-5 Bus body manufacturing takes place on the conveyor line which is newly installed in the plant. SHOP-7 Pre inspection delivery of chassis takes place in this shop which is newly installed in the plant. LAYOUT: - The various parameter of the company are

SHOPS AREA AND DISCRIPTION

4 shops 140x100 14000 sq mt each Shop office area 274.5 sq meters in each shop.

Shop no 1 : Assembly activity

Shop no 2 : Chassis assembly shop

Shop no 5 : Bus body manufacturing shop

Shop no 7 : Pre delivery inspection (PDI)

TRAINING CENTRE

1350 sq meter being used by service promotion for training and display models.

MAIN ADMN. BLOCK

Main admin block Office space of 297 sq meters which include following sectors

Manufacturing managers office

Purchase department

Systems department

Reception and office service

Finance department

PERSONNEL AND ADMN. BLOCK

Total space allotted for the personnel department is- 428 sq meters this include following sector

Personnel department

Medical centre

ASHOK LEYLAND DEPARTMENTS

PRODUCTION DEPARTMENT:

This department handles all the plan work for production. This department is responsible for all the production and its process going at assembly line and also the PDI (pre delivery inspection)

They deal with all the workers to get the work output from them for production. They decide which model is to be assembled according to the availability of material and demand of production.

PERSONNEL ANDADMINISTRATION DEPARTMENT:

This department has to perform the no. of functions such as all kind of recruitments like executives, managers and workers. They conduct various types of tests and interviews for vacancy lying in the organization or at demand of managers.

They also take care of medical facility, canteen facility, library and security too. They are also responsible for the discipline in the plant. Mainly they deal with all the personal behaviors of employees. They arrange seminars and other motivating events for the employees. They also conduct cultural events and get together, in which they include the family members of the employees for giving a change from routine work.

They also record all individual working record in organization. They deal the relations with other organizations and institutes. This department is known as human resource department in other organization.

QUALITY CONTROL DEPARTMENT:

This department is responsible for the quality of products and parts whatever they sell or purchase. The quality checking is done in three processes, which are given as follows:

1. Incoming material inspection

2. In process inspection

3. Final inspection

There is a GR & D (goods receipt and dispatch) section, which receives goods, and QC department inspect them and ensure the quality as per the recommended standards and then send them to store.

For in process inspection they use one chassis card in which the worker check whether all things has been done which he had to do and then do his signature in the card. This is known as self certification.

When the chassis become off track to the assembly line then the chassis goes for a road test. The defects and shortcomings in the chassis are noted such as noise, smoke, driving control etc. then an inspection of chassis takes place at PDI and then all the defects are noted and are rectified. After that the chassis is passed to sales department by QC department.

PPC DEPARTMEPPNT:

Production planning and control department is known as PPC department. This department control GR & D section and storerooms. They receive the goods coming from the factories. Then according to the vouchers, counting of parts is done. They prepare a daily report of goods receive and send it to finance department for further procedure.

They allot part number for the parts and parts are arranged according to the part number in the store room. They keep all the records of store room. Monthly counting of parts is also done.

PPC department does whole of the material planning for production. Also they make available all the material required for the production at the time of production at all the stages. Two bin system is being used here for the supply of material at all the stages. This is like there will be two bins at a stage and, as one becomes empty that will be replaced by a bin full of the material.

UNIT PLANNING DEPARTMENT:

This department basically does the planning work. They are given the project of some new units to be prepared in the plant for which they plan the appropriate place for installation of the new unit, the approximate duration of completion of project, cost estimation and benefits of the installation of new unit.

Presently they are taking care of new rear axle assembly conveyor line project being installed in shop-2, paint booth for body painting of foton bus in shop-5.

PRODUCTION SERVICES DEPARTMENT:

This department is also known as maintenance department. They are responsible to provide the services required for the production and also for the maintenance of all the equipments being used. They rectify the problem occurred in the equipment at the time of break down of some equipment. For example the equipments are bolt tightening machine, impact wrench, forklift, overhead crane, conveyor, compressor, generator and electricity, oil filling machine, greasing machine, pneumatic devices, lightning devices and fans etc.

They do regular checking and maintenance. A formal calling system is being used. Whenever the maintenance is required at assembly line or some break down occurs in machine, a person press the button and the maintenance department will be informed by the system. Then the person from maintenance section will come at the location and will solve the problem.

They also take care of horticulture in the plant. This makes the beauty of the plant and makes the plant environment friendly green plant.

They are responsible for those instrument and services provided by them to achieving the production.

PURCHASE DEPARTMENT:

Raw material is very important for the production. Purchase department purchases all the raw materials from various dealers and companies. They decide which material should be bought from which company.

They also look at the cost of material to be purchased and the transportation charges. It is better if the material is coming from a place nearer to the plant because the transportation cost will be reduced.

They also the firm to sell the scrap items of iron, wood etc. the tender will be given who ever will pay more.

They also hire the contractors from the market by tendering to manage many works in plant like material unloading, transportation, and construction.

FINANCE DEPARTMENT

This department takes care of all financial things of plant. They keep record of all the salaries and alliance of the employees, the money spent on purchasing the things for plant, the money earned by the sale of products and other financial activities. They prepare monthly and annual budget of the plant.

Also they monitor the attendance of employees by an electronic card punching attendance system. All the employees are provided with an electronic card, which is punched in the card-punching machine at the time of entering the plant and at the time of leaving the plant. The machine will note the time of punching and thus the department gets the data.

SALES AND MARKETING DEPARTMENT:

Products are made in the plant and they need to be sold for the customers. This department takes care of all the marketing activities. After the product is passed from QC department, sales and marketing department keeps all the products at R.S.O (regional sales office) with safety. The vehicle is kept in the RSO after fitting the heat guards, warning triangles, RUPD (rear under protection device) and canopy as per the government rule. Then at demand and requirement the products are sent to the dealers.

They look at the demand of product in the market and the customers feedback about the product. They also provide the training for servicing of the product.

They send their report that in what amount market has demand to production department so that they can decide the amount of production that they can.

PDI (PRE DELIVERY INSPECTION):

It comes under the production department but it has its much utility that it has an important role in the production.

The vehicle coming from assembly line is not perfect in quality. It has many defects. So the chassis is inspected, faults are arrested in this section and all the defects and faults are noted. The chassis comes into PDI section after road testing.

Then all the defects and faults found in the chassis are rectified using necessary tools and items. Then the chassis is painted in paint booth and if there is any dent on the chassis FES then it is removed. And finally passed to sales department. The chassis passed from PDI is fault free

and prefect in quality.

Painting of the chassis is also done under this department.

GR&D (Goods Receive and Dispatch):

This department is providing for giving their services when the goods are received and dispatch in the plant as a material from out side and when it dispatch outside the plant.

This basically gives for their quality and amount assuring.

Certificates and quality policy of ashok Leyland In the journey towards global standard of quality of Ashok Leyland reached a major milestone in 1993, when it becomes the first Indian history to win the ISO-9002 certification.

The more comprehensive ISO-9001 certification came in 1994,

QS-9000 in 1998

ISO-14001 certification for all vehicles manufacturing units in 2002.

It has also become the first Indian auto company to receive the latest ISOTS-16949 corporate certification (in July 2006) which is specified to the auto industry.

QUALITY POLICIES

It is the objective of Ashok Leylands quality policy to achieve customer satisfaction by meeting the customer expectations in relation to the product and services offered by the company.

Towards this objective, the quality policy of Ashok Leyland is;

To make continuous improvements in the products manufactured by the company.

Give uninterrupted quality services offered to the customer

To enhance employee potential to contribute to quality by improving the knowledge and skills of the employee as appropriate to their functions.

To induce in vendors, commitment to continue improvement to meet quality standards.

To make good relation with the customer by providing regular service to vehicle by their service centre.

Get feedback from the customer to improve the quality of product and customer satisfaction.

Increasing the research and development centre to achieving quality standards and quality goal of the organization.

ENVIRONMENTAL POLICY:

Tech development

Industrialization

Population growth

More production

More automobiles

More food required

Any type of activity that is performed or any type of product that is manufactured has an effect on the surrounding or environment.

At Ashok Leyland are committed to preserving the environment through a comprehensive environmental policy and a proactive approach in planning and executing our manufacturing and service activities.

We are concerned about the earth our children will inherit. Thats why we make sure our vehicles consume less fuel and pollute less. This concern is reflected in the manufacturing systems, the various processes, energy conservation measure and conscious greening indicatives of the company.

A system is employed to control or minimize the adverse impact on the environment is environment management system (EMS).

Objective of Ashok Leyland environment policy are:

To adhere to all applicable environment legislations and regulations.

To adopt pollution preventive techniques in design & manufacturing of our products.

To conserve all such resources such as power, oil, gas, water, compressed air etc. and optimizes their uses through scientific methods.

To provide a clean working environment to our employees, contractors, and neighbors.

Commit to comply with all relevant legal and other requirements.

Continuously strive to minimize waste generation by all possible ways and to reuse and recycle same through a time bound action plan.

SAFETY AND HEALTH POLICY3

INTENTION AND COMMITMENT OF THE TOP MANAGEMENT

Ashok Leyland affirms that all its employees irrespective of the cadre or rank need to be safe guarded against any person injuries or damage to the properties during working period. That the management recognize the principle that accident prevention contributes in the long run to all process

and development of the organization.

Towards this objective, Ashok Leyland is committed to:

Implementing all practical safety measures like safe working and environmental condition.

Carrying out a systematic critical appraisal of all potential hazards involving personal, plant service and operating methods.

Following strictly safety rules and regulation incorporated in the factories act and rules.

Maintaining safe and health education program for employee with specific emphasis on creating safety and health awareness.

Welcoming useful and constructive suggestions and ideas in regard to safety and health.

ENERGY POWER RESOURSESThe power is being received from Jaipur Vidyut Vitran Nigam limited of 33KVA line which is stepped down to 11KVA at main receiving station. Each shop has got further step down transformer to bring down the voltage to 440 Volts.

The plant has SKL Diesel generator of 1100KVA kept in generator house. Total diesel storing capacity of the generator house is 133KL. The generator output Voltage is 11KV.

LEYLAND PRODUCTS

From 18 seated mini buses used by schools and corporate to 82 seated to double Decker buses from 7.5 ton to 49 ton in haulage vehicles, from numerous special vehicle applications to diesel engines for industrial, marine and genset applications.

Ashok Leyland offers a wide range of products. Though timely innovations the company has created new products and application segments, there by expanding the market. From eggs to steel, from flowers to carswhat doesnt moves Ashok Leyland vehicles?

Ashok Leyland have made and sold product like roadways buses, CNG buses, Defense trucks Vestibule buses, luxury buses, Rear engine buses, School buses, Tripper and Dumper, Vehicles for fire brigade.

The bus run on Delhi-Lahore route is also made by Ashok Leyland.

Apart from these Ashok Leyland makes the engines which are being used for Generators, marine and industrial applications. Ashok Leyland makes three kinds of engines-Al engines, Iveco engine; Mostly hino engines are being used.

3516 TRUCK 4018 TRUCK 1611 TRUCK

3116 TRUCK CHEETAH BUS VIKING BUS

SLF CNG

BUS ULE A/C & NON A/C BUS

DYNAMIC SPACE TECHNOLOGY

ALADIN 3 ALIGNER

Specifications:

Designed for the alignment of trucks-buses. 4 Measuring Heads, 6 CCD Sensors

Main Features: Designed for the alignment of trucks-buses.4 Measuring Heads, 6 CCD SensorBluetooth System data transmissionWindows XP, Different Languages,15 Monitor, Pentium PC, Ink-Jet Printer,0.01 degree data displaySteering angles measured automatically and directly by the sensors, no need for electronic turntables

Measurement:A camera unit (sometimes called a "head") is attached to a specially designed clamp which holds on to a wheel. There are usually four camera units in a wheel alignment system (a camera unit for each wheel). The camera units communicate their physical positioning with respect to other camera units to a central computer which calculates and displays how much the camber, toe and caster are misaligned.

Often with alignment equipment, these "heads" can be a large precision reflector. In this case, the alignment "tower" contains the cameras as well as arrays of LEDs. This system flashes one array of LEDs for each reflector whilst a camera centrally located in the LED array "looks for" an image of the reflectors patterned face. These cameras perform the same function as the other style of alignment equipment, yet alleviate numerous issues prone to relocating a heavy precision camera assembly on each vehicle serviced.

Necessity:

Wheel alignment is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the vehicle maker's specification. The purpose of these adjustments is to reduce tire wear, and to ensure that vehicle travel is straight and true (without "pulling" to one side). Alignment angles can also be altered beyond the maker's specifications to obtain a specific handling characteristic.

EXPERIMENTAL DATA

STUDY OF WHEEL ALIGNMENT

Wheel Alignment should be checked whenever new tires are installed, suspension components installed, when the vehicle has encountered a major road hazard or curb and any time unusual tire wear patterns appear.

Wheel Alignment is the Measurement of complex suspension angles and the adjustment of a variety of suspension components. Itis a suspension-tuning tool which greatly influences the vehicle's handling andtire wear.

Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tire life and ensures straight and true tracking along a straight and level road.

The primary static suspension angles that need to be measured and adjusted are caster, camber, toe and thrust angle. The following are definitions Conditions and Possible Causes of each angle and its influence on a vehicle and its tires.

Wheel Alignment: Abstract of These Fundamental Elements

CASTER:

Caster is the angle between an imaginary line drawn

through the upper and lower steering pivots and a line

perpendicular to the road surface (viewed from side of

vehicle).

If the top of the line tilts rearward, the vehicle

is said to have POSITIVE caster. If the top of the line

tilts forward, the vehicle is said to have NEGATIVE caster.

Positive caster can also be defined as when the

spindle is tipped so that the pivot support centerline

intersects the road surface at a point in front of the

Initial tire contact. Negative caster would then be the

center line intersection to the road surface behind the

initial tire contact.

Purpose:

The King Pin is usually set so that tire contact

point with the ground is behind the intersection

point between the steering axis and the ground

This forces the tire to always go ahead.

This improves Straight-Ahead Drivability,

and improves Handling/Steering Return.

Characteristics:

Larger Caster Angle -

Merit: -

Better Straight-Ahead Drivability Tire contact point Caster Trail Intersection point Better Steering Wheel Return

with the ground between steering

Demerit: - Heavier Steering

Camber Angle

The camber angle will affect the wear on the inner

or outer edge of the tire. Camber is the inclination

of the centerline of the wheel from the vertical as

viewed from the front of the vehicle. Camber angle

is measured in positive or negative degrees.

Positive camber is the outward tilt of the top of the

tire. Negative camber is the inward tilt of the tire at

the top. If a tire was absolutely vertical, the degree

of camber would be zero. Unlike the caster angle,

camber will change with vehicle load and ride height.

With the weight of the driver in the vehicle

Purpose:

1. Improve Steering Control Performance

(Which is related with King Pin Offset?)

2. Improve Cornering Performance.

Characteristics:

Larger Positive Angle (King Pin Offset is smaller)

Merit:-

Better Handling Control

Better Handling/Steering Return

Demerit:-Reduced Cornering Capacity *

Larger Negative Angle (King Pin Offset is larger)

Merit: - Better Initial Handling Response

Better Cornering Capacity

Demerit: - Reduced Handling Control

(Cornering Capacity Safety on Cornering Speed or Radius)

Thrust Angle

Thrust angle is the direction that the rear wheels are pointing in relation to the centerline of the vehicle. The vehicle will "dog track" if the thrust angle is not zero and the steering wheel will not be centered. The best solution is to first adjust the rear toe to the centerline and then adjust the front toe. This is done during all wheel alignment if the rear toe is adjustable. If the rear is not adjustable, then the front toe must be set to compensate for the thrust angle, allowing the steering to be centered.If the thrust angle is not correct on a vehicle with a solid rear axle, it often requires a frame straightening shop to correctly reposition the rear axle.Vehicles with independent rear suspension, the toe must be adjusted individually until it has reached the appropriate setting for its side of the vehicle; incorrect thrust angle is often caused by an out-of-position suspension or incorrect toe settings. So in addition to the handling problems that are the result of incorrect toe settings, thrust angles can also cause the vehicle to handle differently when turning left vs. right.

Toe-In and Toe-Out

Toe is the difference between the leading edge (or

front) and trailing edge (or rear) of the tires. Toe-in is

the measurement in fractions of an inch, millimeters or

decimal of degrees that the tires are closer together in

the front than they are in the back. Toe-out is the same A < B = Toe-In

A > B = Toe-outmeasurement, except the tires are further apart in the

front than in the rear.

Some manufacturers measure the angular change from straight-ahead in degrees. Slight toe-in is preferred

to toe-out on most vehicles because steering is

aligned while the vehicle is stationary, is moving, linkage

components flex causing a change in

alignment angles. The usual tendency is for the tires to turn outward

while the vehicle is in motion, so most vehicles are

designed with a static toe-in setting.

Purpose:-

By setting the most appropriate Toe condition

with the correct Camber condition, driving

performance is well arranged to:

1. Improve Straight Drivability.

2. Improve Handling Response.

The Case:

According to the Camber condition, the Toe-In or Toe-Out settings are adapted as follows to:

avoid irregular wear, and

balance side forces by Camber and by Toe for high speed driving performance.

Scrub Radius

Scrub Radius is the distance between the extended centerline

of the steering axis and the centerline of the tire where the

tread contacts the road. This distance must be exactly the

same from side to side or the vehicle will pull strongly.

If the steering centerline is inboard of the tire centerline, the

scrub radius is positive. If the steering centerline is outboard

of the tire centerline, the scrub radius is negative. Rear-wheel drive cars and trucks generally have a positive scrub

radius while FWD cars usually have zero or a negative scrub radius

because they have a higher Steering Axis Inclination (SAI), angle. Using different wheels other than stock can alter the scrub radius.

TOOLS USING IN WHEEL ALIGNMENT FOR 3116 MODEL TRUCK

Space Aladin 3 Aligner (Bluetooth) Running plot Numetic gun Torque ranch Jack Wooden block Sockets Pressure gauge Other toolsWheel Aligning Process

Remove cover from the equipment

Switch on the UPS, CPU and monitor

Fix the running plot with the base by studs Bring the assembled chassis on running plot Inflate all 12 tires to 40 psi Remove the running plot stud Enter the chassis number, vehicle type, etc. in the log book.

Axle 1:

Mount the sensor bracket on the 1st front axle and the rear axle 2

Mount the front sensor on the 1st front axle and rear sensor on the rear axle 2

Raise the 1st front axle and 2nd rear axle using jack.

Rotate the wheel and keep the knob on the bottom direction and tighten the knob

Press centre button in the sensor and loosen the knob

Rotate the wheel and keep the knob on the up direction and tighten the knob

Press centre button in the sensor.

See the monitor it shows stop and the wheel direction shows up.

Lower the jack and remove the jack. Follow the steps 1 to 6 on four wheels The monitor shows all four wheels in up direction

Press F4 to show next step

Level all four sensor and the monitor shows level position of each sensor

After leveling the sensors the monitor shows stop and goes to next step

Steer the steering and place the steering box in green column as shown in the monitor

And make steering position in centre as shown in the monitor

The monitor shows thrust angle reading.

Correction of Thrust Angle

Loosen all the 2nd axle U bolt nut

Place wooden piece (3"x18") in the 1st and 2nd rear axle.

Place the jack in between the wooden piece.

Rise the jack up to the reading shows 0 00' in the monitor.

Tighten all the U bolts in 2nd rear axle.

Remove the jack and wooden box

See the readings in the monitor it should show in the range -0 05' to +0 05'

Torque all U bolt nuts to 375lbft

Press F4 to go to next step.

The monitor shows the 1st front axle toe reading

Correction of Toe The toe reading shows in the monitor

Loosen the pinch bolt in the track rod

Adjust the track rod by rotating it should in the range of 0.00mm to +2.00mm.

Tighten the pinch bolt using gun.

Press F4 to go to next step.Axle 2:

The monitor shows the second position in the screen

Retain the 1st axle sensor position

Remove the sensor with bracket from 2nd rear axle

Mount the sensor with bracket in the 1st rear axle

Follow the steps from 1 to 6 on two wheels in the 1st rear axle

Press F4 to go to next step.

The monitor shows Scrub angle reading.

Correction of Scrub Angle

Loosen all the 1st front axle U bolt nut

Place wooden box in the 1st and 2nd rear axle.

Place the jack in between the wooden box.

Rise the jack up to the reading shows 0 00' in the monitor.

Tighten all the U bolts in 2nd rear axle.

Remove the jack and wooden box

See the readings in the monitor it should show in the range -0 02' to +0 02'

Torque all U bolt nuts to 375lbft.

Press F4 to go to next step.

Axle 3:

The monitor shows the third position in the screen

Retain the 1st rear axle sensor position

Remove the sensor with bracket from 1st front axle

Mount the sensor with bracket in the 2nd front axle

Follow the steps from 1 to 6 on two wheels in the 1st rear axle.

Press F4 to go to next step.

The monitor shows the 2nd front axle toe position

Axle 4: The monitor shows the fourth position in the screen

Retain the 1st rear axle sensor position

Remove the sensor with bracket from 2nd front axle

Mount the sensor with bracket in the 1st front axle

Follow the steps from 1 to 6 on two wheels in the 1st rear axle.

Press F4 to go to next step.

Steer the steering and place the steering box in green column as shown in the monitor

And make steering position in centre as shown in the monitor

NOTE

Run-out: Rotate the any one side wheel in any direction to 180 and push the center button of camera. rotate once again wheel to 180 and push button.

Keep steering always in centre position Always level first front axle cameras

Use locking device as steering, brakes when needed.

Always lock running plot in the starting of wheel alignment

Apply torque wrench (345 lbft) after tightening U-bolts.

Use hand brake when lifting rear axles.

There should not be present any objects between sensor heads.CASTER

CAMBER

TOE

THRUST ANGLE

WHEEL ALIGNMENT