User Manual PDF

JOSAM cam-aligner
User Guide
JOSAM
cam-aligner
T 163 1 1508
1
Table of Contents
JOSAM cam-aligner user guide................................................................................................... 7
System description ................................................................................................................. 8
Agreed functionality ................................................................................................................... 8
Technical data ............................................................................................................................ 9
Measurement specifications .................................................................................................. 9
Other specifications ............................................................................................................... 9
System Requirements ............................................................................................................ 9
Recommended ................................................................................................................... 9
Minimum ............................................................................................................................ 9
Required operating system .............................................................................................. 10
Component description............................................................................................................ 11
Camera sensor CA1010 .................................................................................................... 11
Inclinometer unit CA1007, inclinometer kit CA ANGLE K ................................................ 12
Reflective targets.............................................................................................................. 12
Wireless Server CA1009 ................................................................................................... 13
Wheel adapter .................................................................................................................. 13
Frame gauges ................................................................................................................... 13
Low friction plates ............................................................................................................ 14
Reference blocks .............................................................................................................. 14
Measurement reference definition.......................................................................................... 15
Chassis centre line reference ........................................................................................... 15
Rear axle reference .......................................................................................................... 15
Installation guide .................................................................................................................. 16
Introduction.............................................................................................................................. 16
Install wireless server (Windows 7 and 8.1)............................................................................. 17
Installing the server device driver manually ........................................................................ 17
Step 1 (Windows 7) .......................................................................................................... 17
Step 1 (Windows 8.1) ....................................................................................................... 18
Step 2 (Windows 7 and 8.1) ............................................................................................. 19
JOSAM cam-aligner installation ............................................................................................... 24
Software settings...................................................................................................................... 29
General: ................................................................................................................................ 30
System standby: ............................................................................................................... 30
Working mode: ................................................................................................................. 30
Reference: ........................................................................................................................ 30
Toe unit: ........................................................................................................................... 30
Steerbox measurement type:........................................................................................... 30
Language: ......................................................................................................................... 31
Communication: ................................................................................................................... 31
Pairing ............................................................................................................................... 32
Report: .................................................................................................................................. 35
Report style: ..................................................................................................................... 35
Report header and preview: ............................................................................................ 35
Graphics:............................................................................................................................... 36
Registration: ......................................................................................................................... 37
Wheel alignment ...................................................................................................................... 39
Measurement preparations ..................................................................................................... 41
Mount frame gauges ............................................................................................................ 41
Mounting frame gauges when measuring the axle(s) on a ‘dolly’....................................... 42
Mount wheel adapters ......................................................................................................... 43
Mount reference blocks on wheel adapters ........................................................................ 43
Mount inclinometer unit ...................................................................................................... 44
Create work order .................................................................................................................... 45
Vehicle identification number (VIN)................................................................................. 45
Mileage ............................................................................................................................. 45
Make & Model .................................................................................................................. 45
Employee .......................................................................................................................... 45
Date .................................................................................................................................. 46
Measure............................................................................................................................ 46
Comments ........................................................................................................................ 46
Select vehicle type .................................................................................................................... 47
Select vehicle type ............................................................................................................ 47
Select axle configuration .................................................................................................. 47
Select vehicle specification .............................................................................................. 48
Steering gear side ............................................................................................................. 48
Configure a new axle configuration ................................................................................. 49
Configure a vehicle specification...................................................................................... 51
All values window - select measurement functions ................................................................ 53
All values vehicle: ............................................................................................................. 53
All values vehicle: ............................................................................................................. 54
Align vehicle ............................................................................................................................. 56
Select reference axle ........................................................................................................ 56
Using the driven axle of the tractor as the reference ...................................................... 57
Using the rigid axle on the trailer as the reference ........................................................ 61
Measurement ....................................................................................................................... 65
Run-out ..................................................................................................................................... 65
Step 1:............................................................................................................................... 65
Step 2:............................................................................................................................... 66
Step 3:............................................................................................................................... 66
Step 4:............................................................................................................................... 67
Step 5:............................................................................................................................... 67
Step 6:............................................................................................................................... 68
Step 7:............................................................................................................................... 68
Toe & Camber after run-out..................................................................................................... 70
Procedure when measuring after run-out: .......................................................................... 70
Toe & Camber - rolling 1 axle ................................................................................................... 73
Procedure when measuring by rolling: ................................................................................ 73
Toe & Camber - multi axle roll ................................................................................................. 77
Floor reference ......................................................................................................................... 82
Using the inclinometer unit in combination with caster / KPI measurements................ 82
Caster / KPI / maximum turn.................................................................................................... 85
Using the inclinometer unit in combination with Caster / KPI measurements ............... 85
Adjust maximum turn............................................................................................................... 90
Adjustment ........................................................................................................................... 93
Adjustment ............................................................................................................................... 93
Absolute / relative .................................................................................................................... 95
Adjust total toe ......................................................................................................................... 96
Adjust individual toe ................................................................................................................ 97
Adjust out of square ................................................................................................................. 99
Adjust camber ........................................................................................................................ 101
Adjust double steering left/right............................................................................................ 103
Adjust caster ........................................................................................................................... 106
Steering box position.............................................................................................................. 108
Equipment calibration ............................................................................................................ 111
Calibrate camera .................................................................................................................... 111
Calibrate inclinometer ............................................................................................................ 116
System maintenance .............................................................................................................. 119
Cameras and inclinometer unit ...................................................................................... 119
Reflective targets............................................................................................................ 119
Other equipment ............................................................................................................ 119
Measurement documentation ............................................................................................... 121
Order management ................................................................................................................ 121
Reports ................................................................................................................................... 124
JOSAM cam-aligner
JOSAM cam-aligner user guide
7
JOSAM cam-aligner
System description
Agreed functionality
• The JOSAM cam-aligner system is designed for wheel alignment and frame check of
all commercial vehicles.
• The JOSAM cam-aligner system provides measurement of total toe, individual toe,
axle offset, out of square, camber, caster, KPI, toe out on turn, max turn angles and
steering gear middle position.
• The JOSAM cam-aligner system enables dynamic toe and camber measurement while
in driving position. No lifting of the axles with run-out compensation is required
during this measurement.
• The JOSAM cam-aligner system enables performing of run-out compensation of rims
and wheel adapters, which is necessary for caster, KPI and turn angle measurements.
• The JOSAM cam-aligner system enables measurements to be performed fast and
reliable on all types of commercial vehicles.
• The JOSAM cam-aligner system uses wireless communication technology for
transmission of information between camera sensors and computer.
CAR-O-LINER AB may not be held responsible for any losses, damages or other effects,
economical, human or otherwise, derived from using this equipment in ways not explicitly
specified within this document.
Updated 2015-01-12
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Technical data
Measurement specifications
Feature Accuracy Measurement range
Total Toe <0,4 mm/m ± 40 mm/m
Individual Toe <0,2 mm/m ± 40 mm/m
Camber <3’ ± 6°
Feature Measurement range

Caster ± 20°
KPI ± 20°
Maximum turn 65°
Other specifications
Operating time with fully charged >16h
batteries
Charging unit operating voltage 100-240V, 50-60Hz
Operating temperature -5° to +40° Celsius
Wireless communication 2,4GHz Spread Spectrum Wireless Industrial
Transceiver with frequency range 2401 - 2495 MHz
System Requirements
Recommended
Central Processing Unit (CPU) Intel i5 2,3GHz or higher
Memory (RAM) 4GB
Available hard disk space 80GB
Graphics Super SVGA (1024 x 768) or higher-resolution video
adapter and monitor
Media CD-ROM or DVD drive
Ports 1xUSB2.0
Minimum
Central Processing Unit (CPU) Intel i3 1,6 GHz
Memory (RAM) 4GB
Available hard disk space 40GB
Graphics Super SVGA (1024 x 768) or higher-resolution video
adapter and monitor
Ports 1xUSB2.0
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Required operating system

Microsoft Windows 7 64-bit
Microsoft Windows 8.1 64-bit
Additional system requirements might apply to get the above mentioned operating systems
fully functional, please check with your operating system supplier.
Updated 2015-01-12
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JOSAM cam-aligner
Component description
Camera sensor CA1010
The camera sensor is a rugged, high precision sensor specially
designed to measure angles and distance relative to a reflective
target. It has a strong housing with rubber protection at both ends.
The camera lens and built-in flasher is protected by a hardened front
glass.
The camera is equipped with an infra-red (IR) flasher, sending out

short flashes of IR light a few times per second. When this light hits a
reflective target, the light will reflect back to the camera lens. The
lens is equipped with an IR-filter, only permitting IR light to pass
through. The result is a picture having a reflective target depicted
against a black background. Thus the camera can operate in
complete darkness or in sunshine, since it only uses the light from
the IR flasher.
The picture is analyzed by a microprocessor within the camera sensor itself, and information
is sent to the computer by wireless communication. The computer finishes the calculations,
giving the three angles α (alfa), β (beta) and camber as well as the distance to the target as a
result. These parameters are then used by the computer software to calculate the wheel
angles.
The camera is equipped with three electronic inclinometers as well as a gyroscope. The
signals from these sensors are combined with the data from the camera to produce a very
powerful tool to be used for wheel alignment. The gyroscope is used to extend the angle
range to handle max turn angles for steerable axles. The electronic inclinometers are used to
calculate camber, castor and KPI directly on the wheel itself.
The camera sensor is powered by a built-in battery pack, and the batteries are recharged
every time the camera is placed in the charging cradle. The operating time of the batteries is
>16 hours, depending on the way of use of the system. The camera has a standby mode
where it consumes only 15% of the power. In standby mode the wireless connection is still
active while the camera part itself is switched off. The software in the computer
automatically switches the camera from standby mode to operation mode as needed.
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Inclinometer unit CA1007, inclinometer kit CA ANGLE K
The inclinometer unit is used to compensate influences from floor inclination, difference in
tire size or tire pressure while measuring. The inclinometer monitors not only the horizontal
position of the axle, but also monitors the angle of inclination of the axle while lifting the
front axle. This enables the operator to measure correct caster and KPI values in lifted
position without levelling the vehicle or the axle beam. By using the inclinometer unit during
rolling measurement, the inclinometer monitors the horizontal position of the axle while
moving the vehicle half a wheel turn. In this way high accuracy camber values can be
achieved even on an uneven floor.
Reflective targets
The reflective targets are markers
that the camera sensor uses to
determine angles and distances.
These markers need to be kept
clean, to maintain high
measurement accuracy and long
life time of the system. For
cleaning recommendations, please
see chapter "System
maintenance".
Note! To keep the marker clean, make sure to always avoid touching the reflective
surfaces on each side of the target when handling them.
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Wireless Server CA1009
The wireless server is connected to a PC and powered via a USB

cable. It permits the camera to communicate with the PC
software.
Wheel adapter
The wheel adapter is used to mount the cameras

to the wheels of the vehicle. The wheel adapter is
designed according to a tripod principle, to enable
the best accuracy possible when measuring and fits
aluminium as well as steel rims in sizes 12” – 24”.
Frame gauges
The frame gauges work
according to a self-centering
principle. When mounted to a
vehicle they determine the
chassis centre line, which is the
standard reference in a camera
wheel alignment system. The
reflective targets are placed at
the end of each frame gauge.
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Low friction plates
The low friction plates are used to eliminate friction

between floor and tire when adjusting toe. The plates can
hold a weight of up to six tons each.
Reference blocks
The reference blocks are used to correctly position the cameras when doing a
multi-roll measurement.
Updated 2015-06-18
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JOSAM cam-aligner
Measurement reference definition

Definitions of the measurement references mentioned in this user manual
Chassis centre line reference
This is the standard measurement reference for the JOSAM

cam-aligner system. The chassis centre line is determined by
the self centering frame gauges hung in the front and rear of
the frame or body.
Rear axle reference
The measurement reference line in this case is a line

perpendicular to the rear axle of the vehicle, e.g. all front axle
values are calculated in relation to the out of square value of
the rear axle. The out of square of the rear axle is measured
with chassis centre line reference as described above.
Updated 2015-03-02
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JOSAM cam-aligner
Installation guide
Introduction
JOSAM cam-aligner is the measurement data container for all JOSAM camera applications:
• Wheel alignment
• Radar alignment (ACC / AICC)
• Frame check
Please take the time to read the instruction thoroughly before you start the installation.
Note! Make sure you have administrator rights during installation and usage.
Note! Make sure to install the wireless driver before the software is installed.
Note! Make sure that the wireless server can communicate freely, do not place it
inside a cabinet, always outside.
Updated 2015-01-09
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JOSAM cam-aligner
Install wireless server (Windows 7 and 8.1)

Start your computer and insert the JOSAM cam-aligner software USB stick.
Plug the wireless server into a USB port, and Windows will find the server. If your computer
is connected to the Internet, Windows Update will automatically install the device driver.
Otherwise Windows will tell you that the device driver was not installed correctly. In that
case, please follow the steps described below.
Installing the server device driver manually

Step 1 (Windows 7)
Open the Start menu, and click [Computer] in the list to the right to open the Computer
window (image below).
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Click [System Properties], and then [Device Manager]. Go to step 2.
Step 1 (Windows 8.1)

Right click on the Start menu button, and click [Device manager].
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Step 2 (Windows 7 and 8.1)
In the Device Manager you will see the TruckCam Wireless unit displaying a question mark
warning. Right-click on “TruckCam Wireless” and choose [Update driver software].
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Choose to browse your computer for the device driver software.
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Specify a location by browsing to the driver folder on the USB stick. Click [Next].
Click [Install this driver software anyway]. The device driver for the wireless server is
perfectly Windows compatible and can be installed without risks, although this warning
might occur during installation.
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Click [Close] when the device driver has been completely installed.
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The TruckCam Wireless unit will now show up properly in the list of USB controllers.
Updated 2015-06-30
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JOSAM cam-aligner
JOSAM cam-aligner installation

Insert the JOSAM cam-aligner software USB stick, and choose the folder for the applicable
language.
Double click on the ‘Setup’ icon.
The software installation process will start up.
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Choose to install the cam-aligner program in a different folder by clicking [Browse] or

continue the installation by clicking [Next].
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Click "I accept the license agreement" and then click [Next].
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Click [Next].
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Click [Finish] when installation is complete. If the above "Restart" warning dialog shows,
please click [Restart] to restart the computer before starting to use your cam-aligner system,
in order for the software to work properly.
Updated 2015-06-30
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JOSAM cam-aligner
Software settings
Double click on the JOSAM cam-aligner program icon to start the alignment software. Start
up the cameras and, when applicable, the inclinometer unit by pressing the ON/OFF button
on the units respectively.
Click [Setup ] to enter the program setup. Before using the system for the first time, it is
required to enter the setup area to configure the program settings. These settings will then
be stored in the program when you click [Save ] in the setup window.
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General:
System standby:
This is where you set the time of system inactivity before the system enters standby mode.
A 0 [zero] value indicates that the standby mode is de-activated.
Working mode:
Sets the system working mode to Standard or Advanced.
Reference:
One chooses whether to use Midpoint axle reference (here referred to as “Center line”) or
Rear axle reference (“Rear axle”). The choice made will only apply when the reference switch
in Define Vehicle is put to "Rear axle”, see chapter "Measurement reference definition".
Toe unit:
Choose whether to measure toe angles in mm/m or degrees and minutes.
Steerbox measurement type:

Choose whether the system should measure steering box middle position based on a single
sided measurement (using the individual toe value of the wheel on the steering side of the
vehicle) or a double sided measurement (based on the split toe value of the front axle).
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JOSAM cam-aligner
Language:
Select system language from the drop-down list. The new language will be active after
restart of the software.
Communication:
It is vital to the functionality of the system that you enter the correct radio numbers of the
cameras – and, when applicable, the inclinometer unit – here in order for the wireless
connections to work properly.
When using the inclinometer unit, please click the [Active] square box to activate the unit
during measurements.
The first time the system is used the wireless communication has to be configured before
the system is fully functional. This is done by entering the serial numbers of the units in your
system into the software and pairing the units to the wireless server.
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JOSAM cam-aligner
Pairing
Enter the Pairing function of the JOSAM cam-aligner system by clicking [Pairing ] in the
“Setup” window. Follow the steps presented by the help texts in the grey square on the
computer screen. When experiencing problems with wireless communication or if adding an
inclinometer unit to a system already in use, you might need to ‘Pair’ the system units.
Press and hold both OK buttons on each camera and, when applicable, the OK button on the
inclinometer unit for 7 seconds to activate the service channel of the units. This is indicated
by the blue LEDs on the units, which start to blink once the unit has entered pairing mode.
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Wait until the red squares on the screen have turned green for all available units.
Click [Pair ] to automatically change the wireless channel to a randomly selected

channel number. Or click [Advanced] to set the wireless channel to a manually selected
number between 1 and 29.
The squares on the screen will change from green to red and back to green again as the
changing of communication channels is performed on all units. Please wait during this
procedure.
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The system will tell you when the pairing of the units is done by a message in the grey help
text square. Now the units should communicate with each other.
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Report:
Report style:
Choose whether you want a separate report sheet for the ‘before’ and ‘after’ values
respectively, or if you want them presented on the same report sheet. You can also choose
whether or not to show the offset value of axles on the report sheet.
Report header and preview:

Enter company details to be printed on each measurement report sheet. Also specify the
path to the logo you want to use on each measuring report. In case you would prefer to use
the JOSAM logo, this logo can be found in the Support subfolder of the JOSAM cam-aligner
folder. Please note that a logo needs to be specified in order for the system to print a
measurement report.
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JOSAM cam-aligner
Graphics:
This is where you specify at which measured values the graphics move on screen and on the
final measurement report. These values will of course adapt automatically to a change in toe
measurement unit on the Main setup page. To go back to the default values, click [Set
Default].
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Registration:
Note! You can run the software unregistered for 30 days, after that the measurement
functions are unavailable. Register the software and its different plug-ins as soon as
possible after installation to prevent any problems later on.
Select the plug-in that needs to be registered from the list, and select [Register ], a
window will now pop-up.
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JOSAM cam-aligner
Enter the CD-key you received in the upper field, and press this link
.
Create a user ID and fill in the required data on the website, when finished you receive a
lock-up code. Enter this lockup code in the lower field and press [Lockup ].
When successful you have now registered the software.
Note! Save the CD-keys you have received together with the user information from
our website for support reasons.
Updated 2015-01-12
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JOSAM cam-aligner
Wheel alignment
For all measurement sequences described below, start the software by double clicking on
the program icon.
Follow the necessary steps for preparation as described in "Measurement preparation" and
"Calibration of equipment".
In the “All Values” measurement window, select the axle you want to measure by clicking on
the axle, or select [All values axle ]. The selected axle is now indicated with a light
blue square, and the measurements possible are shown in the top menu.
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Measurement preparations
Before you start measuring the vehicle, please complete the below mentioned steps:
• Check that all vital parts, like bolt joints and bushings, are free of any excessive play.
Note! Play will have influence on wheel positions and measurements.
• Check tire pressure, tire size and inflate the tires to the specified pressure.
• Check if the floor or other surface that you’re measuring on is reasonably flat or use
the inclinometer unit to compensate such influences.
Mount frame gauges

Place the frame gauge hangers
symmetrically on the frame gauge.
Note! The symmetrical

positioning is absolutely necessary
in order to get accurate
measurement values.
Mount the self centering frame

gauges as square as possible (within
eyesight accuracy) to the frame of
the vehicle, one in the front, the
other in the rear.
Make sure the frame gauges are levelled, by checking the built-in spirit level and adjusting
the frame gauges if necessary.
There are several different adapters available to make it easier to mount the frame gauges
to the vehicle, such as bumper adapters and chassis extenders, please check out the
accessories list in the product sheet or contact your local distributor for further information.
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Place the reflective targets on the frame gauges. The best way to ensure that the reflective
targets are positioned correctly is to trust the indicators on the reflective targets and lay the
targets out according to the indicators on the targets. Once laid out correctly, fit them to the
frame gauges.
Note! To keep the markers clean, make

sure to always avoid touching the reflective
surfaces on each side of the targets when
handling them.
Make sure the targets are positioned correctly by:
• checking the placement symbols on the target plates
and
• checking that the positioning

screws on the frame gauges are
placed in the same positioning
hole for all four frame gauge
beams (frame gauge CA1004)
or
• checking that the positioning screws of the frame

gauge are placed in the same positioning hole for all
four targets (frame gauge JT120 A).
Mounting frame gauges when measuring the axle(s) on a

‘dolly’
Place the hangers symmetrically on the frame gauge, as described above.
Mount the tow bar adapter to the towing eyelet. Mount the front frame gauge by placing
the frame gauge hangers in the correct position on the tow bar adapter bar.
Mount a frame gauge in the rear end of the axle frame (the ‘dolly’).
Place the four reflective targets in their correct positions, as described above.
Check that the front frame gauge is perpendicular to the tow bar by eye sight.
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JOSAM cam-aligner
Mount wheel adapters

The wheel adapters are made to fit both aluminium and steel rims in sizes 14” to 24”.
They are mounted by fitting the hooks at the end of the wheel adapter legs either on the
inside of the rim or between rim and tire, depending on rim make, and rotating the knob on
the side of the wheel adapter to secure it. For light commercial vehicles like vans,
transporters etc, use the smaller leg with the van hook on the wheel adapter and place it
between rim and tire.
Mount reference blocks on wheel adapters

Use a 4mm Allen key to loosen the tightening
screws on the TC-416 reference block.
Insert the reference block on the wheel

adapter axle, as far inwards as possible.
Make sure the reference block fits over the
wheel adapter nut (as seen in the picture).
Tighten the screws on the reference block

until the block fits tight to the wheel adapter
axle and is not movable.
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JOSAM cam-aligner
Mount inclinometer unit
Take the inclinometer out of the TC-395 Charging Cradle. Mount the CA1007 Inclinometer
Unit into the CA1065 Inclinometer Bar by inserting the unit into the slot of the bar and by
tightening the screws in order to clamp the unit to the bar.
Note! Before use with the measurement software, the mounted inclinometer unit and
bar must be calibrated using the built-in inclinometer calibration function in the
software. See chapter "Calibrate inclinometer".
Updated 2015-06-25
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JOSAM cam-aligner
Create work order

When entering the new order menu by pressing the new order menu button , you
will get the choice to enter all information associated with the order you are about to create
as well as save information about the vehicle for further use ahead.
Vehicle identification number (VIN)

All vehicles you enter into JOSAM cam-aligner need to have a unique identification number.
This number can be any number the workshop desires to use (for example registration or
chassis number).
Mileage
Enter the mileage of the vehicle.
Make & Model

Enter the vehicle make and model.
Employee
Enter the name of the person performing the measurement.
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Date
The date of measurement is filled in automatically when starting a new measurement.
Measure
Choose type of measurement (Wheel alignment or Frame check).
Comments
Add any comments, they will be printed on the report sheet.
When ready continue by pressing the continue button .
Updated 2015-06-25
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Select vehicle type

When the order is created, continue by selecting a vehicle type (truck, bus or trailer) and its
axle configuration. You can also create new axle configurations and specifications
(tolerances).
Select vehicle type

The supported vehicle types are truck, bus and trailer.
Select axle configuration

The selected configuration in the middle section of the screen is marked as a green vehicle
and is shown on the right side.
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Select vehicle specification

Vehicle specifications define the values and tolerances for most measured values during the
measurement process from a drop-down list.
Steering gear side

Check the position of the steering gear (default = left).
When ready continue by pressing the save and continue button and you will be
forwarded to the all values vehicle window.
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Configure a new axle configuration

To create a new axle configuration, select a vehicle type (truck, bus or trailer) and press
and the following window will open.
Click to add a new configuration, or to delete a configuration.
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After clicking to add a new axle configuration the following window will open. On the
left side a list of available axle types are shown. A configuration is built from the front and
works backwards. Click on an axle type in the list on the left and it will be added to the
configuration on the right. When a wrong axle is selected, you can click on it in the right list
and it will be removed.
When ready just add a name of the created axle configuration and click to save it.
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Configure a vehicle specification

To create a new vehicle definition, select a vehicle type (truck, bus or trailer) and press
and the following window will open.
Select an axle configuration and click to add a new definition, or to delete a

definition.
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After clicking to add a new vehicle definition the following window will open. The axle
list is shown on the left side, on the right side you can add tolerances for wheel angles. NaN
means not a number which equals no tolerance value.
When ready just add a name of the created vehicle specification and click to save it.
Updated 2015-03-02
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All values window - select measurement

functions
There are 2 all values windows in the software:
All values vehicle:
Menu options available in all values vehicle are:

Return to the start window, Home
Proceed to all values axle
Align articulated vehicle
Multi axle roll (note: this option is not available in the basic software)
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All values vehicle:
Select an axle in the left axle list, the selected axle is marked with a blue square. When the
axle has been measured before the measurement results are shown on the right.
Menu options available in all values vehicle are:

Return to the start window, Home
Proceed to all values vehicle
Measure toe and camber after run-out
Measure toe and camber by rolling (one axle per roll)
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Perform run-out
Measure floor reference used during measurement of caster, KPI, toe out on turns
and maximum turn
Measure caster, KPI, toe out on turns and maximum turn
Adjust
Updated 2015-03-02
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Align vehicle
This function is designed as a help function, used to line up the two parts of an articulated
vehicle before continuing with regular measurements and adjustments.
Note! The articulated vehicles for which this function is meant are vehicles with at
least one steerable axle in the rear, e g behind the articulation point, that is actively
steered from the front part of the vehicle. One example is a tractor/trailer
combination where the semitrailer has one or more steerable axle(s) connected to the
fifth wheel (sometimes called a “city trailer”). Regular tractor-trailer combinations as
well as articulated buses with only stiff axles in the rear should always be measured as
two separate vehicles, a tractor unit and a trailer unit.
Select reference axle

Start by selecting a reference axle:
• Drive axle of the tractor unit, or

• Rigid axle on a trailer.
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JOSAM cam-aligner
Using the driven axle of the tractor as the reference
Mount the frame gauges on the tractor unit, and place a wheel adapter with camera on the
main driven axle of the tractor unit. Perform a "run-out compensation" of the wheel
adapter.
Follow the instructions given by the help text in the gray square and animations.
1. Aim the camera reasonably horizontal at the front marker and press the OK button on the
camera.
2. Aim the camera reasonably horizontal at the rear marker and press the OK button on the
camera.
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3. Move the rear frame gauge to the end of the trailer, as shown in above illustration.
4. Make sure the camera is still aiming at the rear marker, then press the OK button on the
camera.
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5. While making sure the camera continues to aim at the rear marker at all times, move the
tractor unit forward until the parallelism bar graph on the computer screen shows zero.
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6. Press the OK button on the camera.
Measurement is done, and tractor unit and trailer unit are now parallel.
Click [Back] to return to the “All Values” measurement window.
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Using the rigid axle on the trailer as the reference
Mount the frame gauges on the trailer unit, and place a wheel adapter with camera on the
main driven axle of the tractor unit. Perform a "run-out compensation" of the wheel
adapter.
camera.
camera.
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3. Move the front frame gauge to the front of the tractor unit as shown in above illustration.
4. Make sure the camera is still aiming at the front marker, then press the OK button on the
camera.
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5. While making sure the camera continues to aim at the rear marker at all times, move the
tractor unit forward until the parallelism bar graph on the computer screen shows zero.
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6. Press the OK button on the camera.
Measurement is done, and tractor unit and trailer unit are now parallel.
Click [Back] to return to the “All Values” measurement window.
Updated 2015-03-03
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Measurement
Run-out
To compensate the wheel adapter for skewness in rims and/or the wheel adapter itself, the
software enables you to perform a run-out compensation. This function guides the operator
to adjust the two knobs on the wheel adapter to compensate for above mentioned
skewness. Please note that one of the knobs is marked with a white spot to help identify one
knob from the other.
In the top menu, click [Run-out ]
Follow the steps presented by the help texts in the white square on the computer screen.
Step 1:
• Lift the axle so that the wheels are free from the ground in order to rotate them
• Turn the wheel so that the white knob is pointing straight up.
• Mount and lock the camera pointing straight upwards.
• Rotate the wheel so that the camera aims towards the far marker.
• Press OK when the green LED lights up.
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Step 2:
• Turn the wheel so that the white knob points straight up again.
• Turn the camera so that it points straight down.
Step 3:
• Adjust to zero using the white knob.
• Confirm by pressing OK.
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Step 4:
• Turn the wheel so that the black knob is pointing straight up.
• Turn the camera so that it points straight up.
Step 5:
• Adjust to zero using the black knob.
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Step 6:
• Turn so that the camera points straight up.
Step 7:
Run-out complete!
Press OK on the camera to perform a run-out on the next wheel, or press [Back] in the top
menu to start measuring.
(Instruction continues on next page.)
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• When the run-out is within tolerance you will get a green check mark like in the
picture above with the deviation between black and white knob.
• When the run-out is outside tolerance you will get a red cross like the picture below
and the run-out procedure should be done again on this wheel.
The wheel adapter is now compensated for any skewness in rim and/or the wheel adapter
itself, and the spindle of the wheel adapter is now, figuratively speaking, an extension of the
axle.
Updated 2015-08-06
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Toe & Camber after run-out

The camera wheel alignment system allows you to measure toe and camber using one of
two different methods. Either by lifting the vehicle and compensating the wheel adapter for
skewness in rims and the wheel adapter itself, called ‘run-out’, or by rolling the vehicle half a
wheel turn forward. When measuring using the rolling method the software compensates
the skewness of the rims and wheel adapters automatically and measures wheel angles like
toe, camber, out of square and parallelism in one single procedure, for one or more axles at
the same time.
Procedure when measuring after run-out:
Click [Toe Camber After Run-Out ] in the “All values axle” window.
When measuring a front axle, the software will ask you to put the steering gear in middle
position when selected to do so in the program setup.
Click the check button on the right lower part of the screen to confirm that you have
put the steering gear mechanically in the middle position.
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On both sides of the vehicle, starting on steering gear side:
1. Aim the camera reasonably horizontal at the nearest marker and press the OK button on
the camera.
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2. Aim the same camera reasonably horizontal at the far marker. Press the OK button on the
camera.
3. Repeat the same procedure on the opposite side to complete the measurement.
The measured toe and camber values, and in applicable cases the axle offset and steering
gear middle position, are displayed on the computer screen. Here you can select to store the
values before or after adjustment. When using a specification the software will indicate if
the measured values are within or outside specification.
before adjustment
after adjustment
The program will then return to the “All values axle” measurement window. All measured
values will be displayed on the measured axle.
Updated 2015-06-25
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Toe & Camber - rolling 1 axle

The camera wheel alignment system allows you to measure toe and camber using one of
two different methods. Either by lifting the vehicle and compensating the wheel adapter for
skewness in rims and the wheel adapter itself, called ‘run-out’, or by rolling the vehicle half a
wheel turn forward. When measuring using the rolling method the software compensates
the skewness of the rims and wheel adapters automatically and
measures wheel angles like toe, camber, out of square and parallelism in one single
procedure, for one or more axles at the same time.
Procedure when measuring by rolling:
Click [Toe Camber After Run-Out ] in the “All values axle” window.
When measuring a front axle, the software will ask you to put the steering gear in middle
position when selected to do so in the program setup.
Click the check button on the right lower part of the screen to confirm that you have
put the steering gear mechanically in the middle position.
On both sides of the vehicle, starting on steering gear side:
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1. Aim the camera reasonably horizontal at the far marker and press the OK button on
the camera.
2. Aim the same camera reasonably horizontal at the near marker. Press the OK button
on the camera.
3. Repeat the same procedure on the opposite side.
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4. Slowly roll the vehicle half a wheel turn in the driving direction, until the measured
wheel angle values appear on the screen, to complete the measurement.
(Instruction continues on next page.)
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The measured toe and camber values, and in applicable cases the axle offset and steering
gear middle position, are displayed on the computer screen. Here you can select to store the
values before or after adjustment. When using a specification the software will indicate if
the measured values are within or outside specification.
before adjustment
after adjustment
Updated 2015-06-25
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Toe & Camber - multi axle roll

Note! For this measurement you will need at least four wheel adapters, all equipped
with TC-416 reference blocks. For information on how to mount the reference blocks
on the wheel adapters, please see chapter "Measurement preparations".
Note! Check that the cameras and reference blocks are fitted with arrow stickers and
reference stickers from the 16776 arrow sticker kit.
Click [Multi-roll ] in the “All values vehicle” window.
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Choose which axles to roll simultaneously by clicking on the axles on the screen. We
recommend to equip all wheels with wheel adapters and measure the complete vehicle in
one roll.
If you have selected to measure the steering gear middle position in the setup you have to
put the steering gear in the middle position before the measurement.
Note! Make sure the steering gear is in the correct middle position mechanically.
Start the measurement on the opposite side of the steering box position on the first axle
with the following 3 steps:
1. Aim the camera to the front marker, click OK.

2. Aim the camera to the rear marker, click OK.
3. Place the camera so that the reference surface hits the surface of the reference
block.
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Perform the same procedure on all wheels by walking around the vehicle ending up at the
front wheel on the driver position.
Note! Leave the camera in the last position since it is the reference for rolling 180°.
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Slowly roll the vehicle half a wheel turn in the driving direction, until the background of the
roll value turns green.
Then repeat the measuring procedure in the opposite direction, starting at the steering box
position on the first axle with the following 3 steps:
1. Aim the camera to the front marker, click OK.
Note! Move the camera back into the slot before performing a measurement!
2. Aim the camera to the rear marker, click OK.
3. Place the camera so that the reference surface hits the surface of the reference
block.
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The measured values are displayed on the computer screen. Select to store the values
before or after adjustment. When using a specification the software will indicate if the
measured values are within or outside specification.
before adjustment
after adjustment
The program will then return to the “All values vehicle” measurement window. All measured
values will be displayed on the measured vehicle.
Updated 2015-06-25
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JOSAM cam-aligner
Floor reference
Using the inclinometer unit in combination with caster / KPI measurements
Caster, KPI can be measured in two ways, either in lifted position or with the vehicle placed
on floating plates.
Normally in order to have realistic values of castor and KPI in ride height, in both cases the
rear of the vehicle should be compensated with the same height lifted or the height of the
floating plates. By using the inclinometer unit with a floor reference measurement, this
compensation at the rear can be eliminated as the inclinometer measures the angle change
from ride height to lifted position or position on floating plates.
Normally in order to get correct KPI values when measuring in a lifted position, the axle
beam must be horizontally levelled. By using the inclinometer unit this manual levelling is
not necessary as the inclinometer unit is monitoring the angle changes of the axle beam and
compensates the measurement by these angle changes.
It is necessary to use the inclinometer unit when measuring on floating plates in order to get
correct and accurate caster values. The reason is that while turning the vehicle will tilt left to
right which changes the angle of the axle beam. The inclinometer unit is monitoring these
changes in order to get accurate caster and KPI values.
In the top menu, click [Floor reference ]
Mount or hang the inclinometer on the axle you want to measure using the hanger adapters.
Note! The LEDs and OK button on the inclinometer unit should always face forward in
the driving direction!
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Click [Take Value] or press the OK button on the inclinometer unit. The software saves the
angle of the axle in the driving position.
When the floor reference value is saved, click [End] to return to the “All Values”
measurement window.
Lift the front axle to make a run out compensation on both sides. This compensation is
required to get accurate caster and KPI values.
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Perform a caster / KPI measurement, by taking the first picture of the first camera on the
front target the inclinometer registers the angle of the axle in lifted position or on floating
plates. The software compares the lifted value with the value taken in the ride position and
will compensate the difference to the caster value. In this way accurate and realistic
measurement values are ensured.
Updated 2015-03-02
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Caster / KPI / maximum turn

Using the inclinometer unit in combination with Caster / KPI measurements
Caster, KPI can be measured in two ways, either in lifted position or with the vehicle placed
on floating plates.
Normally in order to have realistic values of castor and KPI in ride height, in both cases the
rear of the vehicle should be compensated with the same height lifted or the height of the
floating plates. By using the inclinometer unit with a floor reference measurement, this
compensation at the rear can be eliminated as the inclinometer measures the angle change
from ride height to lifted position or position on floating plates.
Normally in order to get correct KPI values when measuring in a lifted position, the axle
beam must be horizontally levelled. By using the inclinometer unit this manual levelling is
not necessary as the inclinometer unit is monitoring the angle changes of the axle beam and
compensates the measurement by these angle changes.
It is necessary to use the inclinometer unit when measuring on floating plates in order to get
correct and accurate KPI values. The reason is that while turning the vehicle will tilt left to
right which changes the angle of the axle beam. The inclinometer unit is monitoring these
changes in order to get accurate caster and KPI values.
Important! To have correct measurement results, please perform a floor reference

measurement followed by a run-out compensation of wheel clamps before proceeding with
this measurement; please see chapter "Floor reference" and chapter "Run-out".
Click [Maximum turn / caster / KPI ] in the “All values axle” window.
On both sides of the vehicle, starting on opposite side of the steering gear:
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camera.
camera.
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3. Repeat the same procedure on the opposite side to complete the measurement.
4. Note! Brake the wheels!
5. Turn smoothly to maximum left and wait until green light appears in the black square
above the wheel on the computer screen.
6. Turn smoothly to maximum right and wait until green light appears in the black square
above the wheel on the computer screen.
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7. Turn back to straight ahead position until values are shown on the computer screen.
The measured values are displayed on the computer screen.
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To avoid taking new reference measurements against front and rear markers:
click [Restart ] if you need to re-measure the turn angles, or
click [Adjust turn angles ] to adjust the toe out on turn and max turn angles.
You can also select to store the values before or after adjustment. When using a
specification the software will indicate if the measured values are without or outside
specification.
before adjustment
after adjustment
Updated 2015-03-02
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Adjust maximum turn
The screen will show live values during adjustment for a time frame of 15 seconds, after
which you will have to return to +-10° of the straight ahead position to update angle
calibration data. After returning close enough to the straight ahead position for the cameras
to see the markers, you are able to turn the wheels out again to continue adjustments.
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When having 5 seconds left to turn the wheels the clock will turn yellow. After that the 15
second time frame is up by the ‘time out’ indicator turning red and the live values disappear
from the screen.
When the adjustments are done, click [Back] and repeat the measurement sequence as
described in "Caster / KPI / maximum turn", to check the aligned axle.
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Click [restart ] if you want to start the complete measuring process again.
Updated 2015-03-02
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Adjustment
Adjustment
When diagnostic measurements show that an adjustment is needed, you can choose to
adjust any of the parameters individual and total toe, out of square, camber, maximum turn
as well as double steered vehicles, using the “Adjust” function of the software.
In the “All values axle” window, select the axle you want to align by clicking on the axle in
the left axle list. The selected axle is marked with a light blue square around it.
Click [Adjust ].
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Choose the desired function by clicking the appropriate button on the computer screen.
Back to all values axle menu
Adjust total toe
Adjust individual toe
Adjust out of square
Adjust camber
Adjust twinsteer left
Adjust twinsteer right
Adjust caster
Adjust steering box position>
Updated 2015-03-03
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Absolute / relative
The ‘Absolute’ method presents the actual measurement value at all times, based on
continuous measurements. When doing the alignment, the user has to consider
influences of lifting, tilting etc on measurement values. This method is only possible
to use when measuring after run-out. When using the ‘Absolute’ alignment method,
the measurement can be performed independently of when the adjustment is made
by clicking [Absolute].
The ‘Relative’ alignment method recalls the previously measured values independent
of lifting, tilting etc. This method provides the possibility to adjust directly to a
desired value.
Note! When using the ‘Relative’ alignment method, it is of vital importance that you
don’t start the alignment process, i.e. there is no change to wheel or axle angles,
before clicking [Relative] to start the measurement.
Updated 2015-03-02
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Adjust total toe
1. Aim the cameras at the far markers.
2. Choose whether you want to align using the ‘Absolute’ or the ‘Relative’ method by clicking
either [Absolute ] or [Relative ].
Note! Measurements taken by rolling are always ‘Relative’ measurements, which

means the only choice possible in that case will be [Relative].
Adjust to the desired value by turning the tie-rod. The background color is grey when no
tolerance is set for the value to adjust, or red/green when a tolerance is set like on the
example above.
Click [Back ], or click [Save after adjustment ] to store the measurement results.
Updated 2015-03-02
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Adjust individual toe

This function enables monitoring of individual toe as well as total toe of an axle while
adjusting.

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Adjust to the desired value. The background color is grey when no tolerance is set for the
value to adjust, or red/green when a tolerance is set like on the example above.
Updated 2015-03-02
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Adjust out of square
either [Absolute ] or [Relative

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Updated 2015-03-02
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Adjust camber
Camber angles on front and rear axles can be adjusted in various ways. On vehicles with
certain adjustment possibilities, for instance vehicles with independent suspension,
adjustment can be easily monitored using the system.

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Updated 2015-03-02
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Adjust double steering left/right

Choose this function to adjust double steered axles with their steering system, choose left or
right depending on the position of the steering gear.
Specify on which axles the cameras are mounted. Click [Continue ] to proceed.
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1. Aim the camera on the first axle at the front marker.
2. Aim the camera on the second axle at the rear marker.


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The screen displays the values of the two steered axles.
The straight ahead is the total position of the first axle calculated over the total toe value,
this means that the left wheel and the right wheel are running perfectly straight and parallel
to the centre line of the vehicle. Parallelism is also calculated over the total toe value of the
axles. Note: This is not a one-sided but a double-sided measurement, as all previously made
toe measurements from both sides of the vehicle are taken into account during the
calculations.
Adjust the drag link or track rod until the axles are parallel to each other. The background
color is grey when no tolerance is set for the value to adjust, or red/green when a tolerance
is set like on the example above.
Note! Make sure to have the first axle in straight ahead position while adjusting.
Updated 2015-03-02
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Adjust caster
2. Choose [Relative ] to start adjusting.
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Updated 2015-03-03
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Steering box position

Choose this function to adjust the steering gear middle position.
Note! Make sure the steering gear is in the correct middle position mechanically.

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Adjust the drag link in the direction applicable, to come to your desired value. The
background color is grey when no tolerance is set for the value to adjust, or red/green when
a tolerance is set like on the example above.
Updated 2015-03-02
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Equipment calibration
Calibrate camera
The software has a built-in functionality for checking and calibrating the cameras. This
calibration is carried out on the vehicle to be measured, using the standard measurement
equipment.
If necessary, start up the unit itself by pressing the ON/OFF button on the back of the
camera.
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Start the program and select [Calibration].
Select [Camera ]
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Follow the steps presented by the help texts in the grey square on the computer screen:
Aim the camera slightly upwards and press the OK button.
Aim the camera slightly downwards and press the OK button.
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Aim the camera horizontally and press the OK button.
End turn the camera by taking it off of the wheel adapter spindle, turning it upside down and
putting it back on the wheel adapter spindle again. Aim the camera at the same marker and
press the OK button.
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The screen will display the calibrated values.
Click [Back ] to continue.
Updated 2015-01-12
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Calibrate inclinometer
The software has a built-in functionality for calibrating the inclinometer. This calibration is
carried out on a stable stand, using the standard measurement equipment.
If necessary, start up the unit itself by pressing the ON/OFF button on the back of the
camera.
Start the program and select [Calibration].
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Select [Inclinometer ]
Follow the steps presented by the help texts in the gray square on the computer screen:
Mount the inclinometer unit in the inclinometer bar, as described in chapter "Measurement
preparations", section "Mount inclinometer unit".
Place or hang the inclinometer and its bar in a stable position. Click [Take value] to take a
first measurement.
End turn the inclinometer and its bar, put it back in the same stable position as in step 2, and
click [Take value] to take a second measurement.
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The software has now saved the measurement values and calculated the calibration factor.
The inclinometer is calibrated and ready to use.
Note! After mounting or dismounting the inclinometer unit to the bar a calibration is
always necessary to ensure high measurement accuracy.
Click [Back] to return to the “Calibration menu”.
Updated 2015-01-12
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System maintenance
Well kept and well maintained system parts will greatly increase and secure the reliability
and life time of the system.
Cameras and inclinometer unit

In order to maintain the measurement system, make sure the cameras and inclinometer unit
are kept in order and store them in the charging cradle when not in use to avoid damage.
The protective front glass of the cameras may be cleaned using a dry, soft cloth if necessary.
If a camera or inclinometer unit is dropped on the floor, please do a calibration of the unit. If
that calibration fails, please send the unit for repair accompanied by necessary fault
descriptions.
Reflective targets
The reflective targets should be kept clean at all times. Clean them when necessary, or at
least once every third month, using a mixture of 50% alcohol and 50% water and dry them
with a soft cloth.
Please be aware that dirt, such as for example grease or oil, on the reflective wave will affect
the functionality of the system and might influence measurement results and/or the working
speed of the cameras. Therefore, be sure never to touch the reflective surfaces when
handling the targets.
Other equipment
Please check the functionality of all other hardware, like wheel adapters and frame gauges,
on regular basis in order to avoid faulty measurements.
Updated 2015-03-02
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Measurement documentation
Order management
Enter the order management menu by pressing . Here you able to search for
previous created orders to continue measuring, view and print them.
You can use the search function to find previous orders, type a date interval or the
vehicle identification number this will reduce the amount of orders shown in the middle list.
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The right side of the screen shows more information on the selected order, when ready
continue by pressing the next button to select the order and return to the start
menu.
Here you are also able to update the order information by pressing the edit button .
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After pressing the edit button you can edit the data in the fields on the right side, when
ready save the changes using by pressing , or undo changes using cancel .
You can also delete an order using the delete button .
Updated 2015-03-06
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Reports
Print the current order using the print button in the start menu.
Select the report type to print in the left list followed by clicking print button in the top
menu.
Depending on the system settings the system will either print a combined report sheet
showing both values ‘before adjustment’ and values ‘after measurement’ on the same
report, or separate report sheets showing the values ‘before adjustment’ and ‘after
adjustment’ respectively.
Updated 2015-03-06
124

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JOSAM cam-aligner

JOSAM cam-aligner user guide

Feature Measurement range

Required operating system

The camera is equipped with an infra-red (IR) flasher, sending out

Inclinometer unit CA1007, inclinometer kit CA ANGLE K

Wireless Server CA1009

The wireless server is connected to a PC and powered via a USB

The wheel adapter is used to mount the cameras

Low friction plates

The low friction plates are used to eliminate friction

Measurement reference definition

Chassis centre line reference

This is the standard measurement reference for the JOSAM

Rear axle reference

The measurement reference line in this case is a line

Install wireless server (Windows 7 and 8.1)

Installing the server device driver manually

Click [System Properties], and then [Device Manager]. Go to step 2.

Step 1 (Windows 8.1)

Step 2 (Windows 7 and 8.1)

Choose to browse your computer for the device driver software.

JOSAM cam-aligner installation

Double click on the ‘Setup’ icon.

The software installation process will start up.

Choose to install the cam-aligner program in a different folder by clicking [Browse] or

Steerbox measurement type:

Click [Pair ] to automatically change the wireless channel to a randomly selected

Report header and preview:

When successful you have now registered the software.

Mount frame gauges

Note! The symmetrical

Mount the self centering frame

Note! To keep the markers clean, make

Make sure the targets are positioned correctly by:

• checking the placement symbols on the target plates

• checking that the positioning

• checking that the positioning screws of the frame

Mounting frame gauges when measuring the axle(s) on a

Mount wheel adapters

Mount reference blocks on wheel adapters

Insert the reference block on the wheel

Tighten the screws on the reference block

Mount inclinometer unit

Create work order

Vehicle identification number (VIN)

Make & Model

When ready continue by pressing the continue button .

Select vehicle type

Select vehicle type

Select axle configuration

Select vehicle specification

Steering gear side

Configure a new axle configuration

and the following window will open.

Click to add a new configuration, or to delete a configuration.

Configure a vehicle specification

and the following window will open.

Select an axle configuration and click to add a new definition, or to delete a

All values window - select measurement

All values vehicle:

Menu options available in all values vehicle are:

Proceed to all values axle