Form 2944T, 01-91

OPERATION INSTRUCTIONS

SYSTEM D111 DIGITAL

WHEEL ALIGNER

 Copyright 1991 Hunter Engineering Company

 CONTENTS
1. COMPONENTS ................................................................................................ 1
2. KEYPAD CONTROLS...................................................................................... 3
3. CRT DISPLAY .................................................................................................. 4
3.1 ADDITIONAL K1 – K4 LABELS AND FUNCTIONS ................................................... 5
4. ALIGNMENT TYPES........................................................................................ 7
5. CONDENSED ALIGNMENT PROCEDURES .................................................. 8
5.1 TOTAL 4-WHEEL ALIGNMENT – FOUR SENSORS ................................................. 8
5.2 FRONT THRUST LINE ALIGNMENT – FOUR SENSORS ......................................... 9
5.3 FRONT CENTER LINE ALIGNMENT – FOUR SENSORS ....................................... 10
5.4 TOTAL 4-WHEEL ALIGNMENT – TWO SENSORS ................................................. 11
5.5 FRONT THRUST LINE ALIGNMENT – TWO SENSORS ......................................... 12
5.6 FRONT CENTER LINE ALIGNMENT – TWO SENSORS......................................... 13
6. INTRODUCTION ............................................................................................ 14
6.1 INTRODUCTION ........................................................................................................ 14
6.2 FOR YOUR SAFETY.................................................................................................. 14
7. VEHICLE PREPARATION ............................................................................. 15
7.1 PREPARATION.......................................................................................................... 15
8. ALIGNMENT PROCEDURE........................................................................... 16
8.1 PROCEDURE SELECTION ....................................................................................... 16
8.2 CUSTOMER IDENTIFICATION.................................................................................. 17
8.3 VEHICLE INSPECTION DISPLAY............................................................................. 18
9. SPECIFICATIONS.......................................................................................... 19
9.1 RECALLING SPECIFICATIONS USING THE FACTORY SPECIFICATION
MEMORY .......................................................................................................................... 19
9.2 ENTERING SPECIFICATIONS NOT CONTAINED IN MEMORY ............................. 20
9.3 STORING USER SPECIFICATIONS ......................................................................... 22
10. INSTALLING SENSORS.............................................................................. 24
10.1 INSTALLING FRONT & REAR SENSORS ............................................................. 24
10.2 COMPENSATING SENSORS.................................................................................. 27
11. ALIGNMENT MEASUREMENTS ................................................................. 29
11.1 MEASURING CAMBER AND TOE.......................................................................... 29
11.2 MEASURING CASTER ............................................................................................ 30
11.3 MEASURING S.A.I. AND INCLUDED ANGLE........................................................ 31
11.4 MEASURING CASTER AND SAI/IA SIMULTANEOUSLY (NOT PREFERRED).. 31
11.5 MEASURING TURNING ANGLES .......................................................................... 31
11.6 ADJUSTMENT DISPLAYS ...................................................................................... 32
11.7 VEHICLE ADJUSTMENTS ...................................................................................... 33
12. SET-UP......................................................................................................... 37
12.1 OPERATING THE PRINT-OUT RECORDER .......................................................... 37
12.2 SETTING TIME AND DATE ..................................................................................... 39
12.3 ENTERING INFORMATION FOR THE "WAKE- UP" DISPLAY............................. 39
12.4 SELF-TEST............................................................................................................... 40
13. TROUBLE SHOOTING ................................................................................ 41
 1. COMPONENTS

OPERATING INSTRUCTIONS FOR D111 ALIGNER 1. COMPONENTS • 1

1. COMPONENTS • 2 OPERATING INSTRUCTIONS FOR D111 ALIGNER
 2. KEYPAD CONTROLS

OPERATING INSTRUCTIONS FOR D111 ALIGNER 2. KEYPAD CONTROLS • 3

 3. CRT DISPLAY

3. CRT DISPLAY • 4 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 3.1 ADDITIONAL K1 – K4 LABELS AND FUNCTIONS

OPERATING INSTRUCTIONS FOR D111 ALIGNER 3. CRT DISPLAY • 5

3. CRT DISPLAY • 6 OPERATING INSTRUCTIONS FOR D111 ALIGNER
 4. ALIGNMENT TYPES

Geometric Centerline Alignment Thrust Line Alignment Total Four-Wheel Alignment

Toe on each front wheel is
measured and adjusted using the
geometric centerline of the vehicle
as a reference.
Geometric centerline alignment has
been used for many years and may
provide a satisfactory alignment if
the rear wheels are positioned
squarely with the geometric
centerline of the vehicle.
However, if the vehicle's rear wheels of a straight steering wheel as the
(either solid axle or
independent suspension) create a
thrust line that is not identical with
the geometric centerline, the front
end steering geometry will be off
center and the steering wheel will be
cocked as the vehicle moves in a
straight direction.
Aligning the front wheels to the
vehicle's thrust line is a significant
improvement over-aligning to the
geometric centerline.
In the thrust line method, rear
individual toe is measured (but not
adjusted). The thrust line created by
the rear wheels is used as a refer-
ence for aligning the front wheels.
As a result, the operator is assured
vehicle moves straight ahead.
Total four-wheel alignment is the
ultimate wheel alignment service.
Individual rear toe and camber is
measured, then adjusted to the
factory specifications. This
adjustment brings the thrust line of
the rear wheels into coincidence with
the vehicle's geometric centerline.
The front wheels are then aligned to
the identical geometric centerline.
Total four-wheel alignment results in
all four wheels being parallel and the
steering geometry being centered as
the vehicle moves in a straight line.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 4. ALIGNMENT TYPES • 7

 5. CONDENSED ALIGNMENT
PROCEDURES
5.1 TOTAL 4-WHEEL ALIGNMENT – FOUR SENSORS

5. CONDENSED ALIGNMENT PROCEDURES • 8 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 5.2 FRONT THRUST LINE ALIGNMENT – FOUR SENSORS

OPERATING INSTRUCTIONS FOR D111 ALIGNER 5. CONDENSED ALIGNMENT PROCEDURES • 9

 5.3 FRONT CENTER LINE ALIGNMENT – FOUR SENSORS

5. CONDENSED ALIGNMENT PROCEDURES • 10 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 5.4 TOTAL 4-WHEEL ALIGNMENT – TWO SENSORS

OPERATING INSTRUCTIONS FOR D111 ALIGNER 5. CONDENSED ALIGNMENT PROCEDURES • 11

 5.5 FRONT THRUST LINE ALIGNMENT – TWO SENSORS

5. CONDENSED ALIGNMENT PROCEDURES • 12 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 5.6 FRONT CENTER LINE ALIGNMENT – TWO SENSORS

OPERATING INSTRUCTIONS FOR D111 ALIGNER 5. CONDENSED ALIGNMENT PROCEDURES • 13

 6. INTRODUCTION

6.1 INTRODUCTION
In most instances, the messages displayed on the CRT will guide the operator
through the alignment procedure. However, read and familiarize yourself with the
contents of this manual.

This system is equipped with a battery back-up. In the event the AC power to the
system is interrupted, or the unit is turned “OFF” without pressing the , “Reset,”
key twice, any stored alignment information will not be lost.

6.2 FOR YOUR SAFETY

Always use wheel chocks after positioning the vehicle on rack. Use caution when
jacking the vehicle. Read and follow all caution and warning labels affixed to
equipment and tools.

WARNING: This equipment generates, uses, and can radiate radio

frequency energy. If not installed and used in
accordance with the instruction manual, it may cause
interference with electronic devices. It has been tested
and found to comply with the limits for a Class A
computing device pursuant to Subpart J of Part 15 of
FCC Rules, which is designed to provide reasonable
protection against such interference when operated in a
commercial environment. Operation of this equipment in
a residential area is likely to cause interference in which
case the user at his own expense will be required to take
whatever measures may be required to correct the
interference.

6. INTRODUCTION • 14 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 7. VEHICLE PREPARATION

7.1 PREPARATION
Position the vehicle on the alignment rack, apply the emergency brake and chock the
wheels. Check loading of vehicle in accordance with manufacturer's specifications.
Accurately check and adjust tire pressure. Inspect for uneven, worn tires (install best
tires on front). Inspect all suspension and steering linkage components for wear or
damage. A thorough inspection is as important as the alignment measurements
themselves. Refer to section 11, "Vehicle Inspection" display.

During inspection, position the valve stem of the wheel to a 1 o'clock location to
facilitate connecting the sensor safety cables.

NOTE: A set-back condition, axle lateral off-set condition or tread

width variation will not affect the accuracy of the system.

Turn “ON” the unit by pressing the power switch located on the right side of the
console cabinet.

Press , “Reset,” twice within four seconds.

The “Ready for Alignment” display will appear on the CRT.

Press , “Begin Alignment.”

OPERATING INSTRUCTIONS FOR D111 ALIGNER 7. VEHICLE PREPARATION • 15

 8. ALIGNMENT PROCEDURE

8.1 PROCEDURE SELECTION

Alignment Procedure

Press , “Select Alignment Type,” to select total (4-wheel), front (thrust line), or
front (center line) alignment. Selection is available for two or four sensors.

Press , “Continue,” after selecting a procedure.

Alternate Procedure
Press , “Alternate Procedures,” on the “Alignment Procedure Selection” display.

Press , “Select Sensor Type,” to select the type of sensor to be used (multiple
sensor installations only).

Press , “Continue,” after selecting sensor type.

Press , “Select Vehicle Type,” to select the type of vehicle to be aligned:

passenger car, truck/bus (type 1), tuck/bus (type 2), truck/bus (type 3), trailer (single
axle), trailer (double axle), as indicated on the CRT. The type of vehicle selected is
illustrated at the right of the screen.

8. ALIGNMENT PROCEDURE • 16 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 Press , “Select Alignment Type,” to select total (4-wheel), front (thrust line), or
front (center line) alignment. Selection is available for two or four sensors.

Press , “Continue,” after selecting a procedure.

NOTE: Some combinations of two or four sensors, front or total

alignment can not be performed. The system will not allow
selection of mismatched procedures.

8.2 CUSTOMER IDENTIFICATION

Customer information for the printout is entered on the “Customer Identification

Display.” The cursor (green box) indicates the position where a letter or number will
appear.

Enter the required information using the alpha/numeric keypad on the front of the
CRT cabinet.

Press the left arrow to advance to the next line. If the cursor is on the last line, it will
move to the first line.

If an error is made while entering the information, press the “Delete” key to delete the
last character entered.

Corrections can also be made by moving the cursor to the incorrect letter or number
and entering a correct one. Hold the “Control” key and press “L” or “R” to move the
cursor left or right to the incorrect character. Press the correct character key to
change the display.

To insert a character in the middle of a word, move the cursor to position. Hold the
“Control” key and press “I.” A space will be appear for the character to be inserted.

If an incorrect character is to be replaced by a space at the cursor position, hold the

“Control” key and press “C.”

To remove an unwanted character without leaving a space, while holding the

“Control” key, press “P.” The character will be removed and all other characters on
the line will be moved to the left.

Hold the “Control” key and press “Z” to clear the line that the cursor is on and position
the cursor at the left.

Press , "Continue" after entering information.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 8. ALIGNMENT PROCEDURE • 17

 8.3 VEHICLE INSPECTION DISPLAY

The vehicle inspection display provides a complete pre-alignment checklist.

Press , " ↑ " or , “↓” to scroll up and down through the list.

Press "Set Status", one, two, or three times to place an "X" next to the item
inspected (indicated by the arrow) and under the appropriate column - "repair or
replace", "marginal", or "inspected"

Press , then , "Print Inspection,” to obtain a printout of the inspection.

Press , then , "Continue,” after printing inspection.

8. ALIGNMENT PROCEDURE • 18 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 9. SPECIFICATIONS

9.1 RECALLING SPECIFICATIONS USING THE FACTORY

SPECIFICATION MEMORY
ALIGNMENT SPECIFICATION INFORMATION
The alignment specifications stored in the system are based on industry data
available at the time of entry. Because specifications are subject to change, refer to
vehicle manufacturer's service manual and service bulletins if a question arises.

In some cases, it may be necessary to refer to the alignment specification book for
additional specifications.

Press , " ↑ " or , “↓” to scroll up and down through the list until the desired
vehicle manufacturer is indicated by the arrow.

Press , "Enter Manufacturer."

Press , " ↑ " or , “↓” to scroll up and down until the desired year and model
vehicle is indicated by the arrow.

Press , "Enter Model."

Press , "Continue."

The CRT will change to the "Vehicle Specifications" display showing specifications
for the selected vehicle.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 9. SPECIFICATIONS • 19

 The specifications in the system give toe values and tolerances in measurements of
toe-in (+) or toe-out (-).

NOTE: Pressing , "Reduce Tolerances" will only reduce camber

tolerance to ± .25°, caster tolerance to + .50°, and total toe
tolerance to + .063" (1/16", .13° or 1.5mm depending upon
toe units selected). Only tolerances greater than these will
be reduced.

9.2 ENTERING SPECIFICATIONS NOT CONTAINED IN MEMORY

Press , "Continue,” to change the CRT to the "Vehicle Specifications" display.

A highlighted area appears behind the alignment angle for which specifications are to
be entered.

Press twice.

Press , "Select Toe Units", to select the units of measurement for toe: toe
measurement in inches; toe measurement in degrees; toe measurement in millime-
ters at a reference diameter; or toe measurement in inches at a reference diameter
(the reference diameter must be entered also).

Press twice.
Enter the vehicle specifications and tolerances using the following as a guide:
Enter the specification for left front camber.

Example: 1° positive

Press “1,” “Left Arrow.”

9. SPECIFICATIONS • 20 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 When “Left Arrow” is pressed, the value is entered and the highlighted area advances
to the next entry field.

NOTE: Values are not entered until the “Left Arrow” is pressed.

Enter tolerance for left front camber.

Example: + 1/4°

Press “1,” “/,” “4,” “Left Arrow”

NOTE: Use the “→” (Space) key to separate whole numbers and
fractions.

Example: 2 1/2°

Press “2,” “→,” “1,” “/,” “2,” “Left Arrow”

Enter the remaining specifications and tolerances.

NOTES ON ENTERING SPECIFICATIONS

Tolerances may be entered as a single + value or as individual + values and - values.
Press , "Set Spec Format,” if individual + and - values are to be entered.

Tolerances are positive values and are interpreted as plus or minus (+) values unless
entered individually using "Set Spec Format.” Tolerances must not be “0.”

Tolerances that are too large result in inaccurate alignment while tolerances that are
too small make adjustments difficult. As a general rule, camber tolerance is t 1/4°,
caster tolerance is + 1/2°, and total toe tolerance is ± 1/16"(.13°or 1.5mm). Refer to
vehicle manufacturer's tolerance specifications.

Specifications and tolerances may be changed at any time by pressing a key labeled
"Vehicle Specs" and advancing the cursor to the position for the new value to be
entered.

Specifications may be entered as fractions (1/2), decimals (.5), or minutes of a

degree (30/60).

Specifications and tolerances for camber are entered separately for left and right
wheels.

Caster specification and tolerance is a single entry for both front wheels unless
entered individually using , "Set Spec Format."

Specifications are assumed to be positive unless the "-" key is pressed before the
specification.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 9. SPECIFICATIONS • 21

 9.3 STORING USER SPECIFICATIONS
The system can store up to 75 specifications in addition to those contained in the
factory specification memory. Each of these specifications is stored in a slot with
identification. If a slot is empty, the list will show ". . . . ."

To store a specification:

Enter specifications on the "Vehicle Specifications" display.

Turn the memory enable key to the right 90°.

Press twice.

Press , "Spec Memory."

Press , "User Specs."

Press or to select the desired slot.

Press twice.

Press , "Store Specs."

The display will show "Enter Identification" with a line above it and the cursor at the
first position in the line.

Enter the desired identification (up to 25 characters) using the alpha-numeric keypad.

Press the “Left Arrow” to store specification.

9. SPECIFICATIONS • 22 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 To erase the specification contained within a slot, press "Erase Memory."

To cancel the operation, press , "Skip Store."

Once , "Store Specs,” is pressed and "Enter Identification" appears, the store
operation must be completed, canceled, or the slot erased before continuing.

NOTE: Turn the memory enable key switch back to its original
position after entering specs.

To recall these specifications:

Press , "Spec Memory,” to obtain the "Specification Memory" (factory) display.

Press , "User Specs,” to obtain the "Specification Memory" (user) display.

Press or to scroll up or down through the list until the desired identification is
indicated by the arrow.

Press "Enter Vehicle." The CRT will change to the "Vehicle Specifications"
display with the recalled specifications entered.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 9. SPECIFICATIONS • 23

 10. INSTALLING SENSORS

10.1 INSTALLING FRONT & REAR SENSORS

WHEELS WITH RIM LIP:
Place the T-wrench in the "EXPAND" socket of the top cam lock casting.

Position the two lower stud screws or discs on the wheel rim.

Slide the top cam lock casting up to engage the two stud screws or discs with the
wheel rim.

Check that all four screws/discs are contacting the rim.

10. INSTALLING SENSORS • 24 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 Turn the T-wrench 180° to set the cam lock in the locked position. (The locking action
will be from the inside of the rim outward.)

WHEELS WITH NO RIM LIP:

Place the T-wrench in the "CONTRACT" socket of the top cam lock casting.

Position the two lower stud screws on the outside of the rim.

Slide the top cam lock casting down to engage the two top stud screws on the
outside of the rim.

Turn the T-wrench 180° to set the cam lock in the locked position. (The locking action
will be from the outside of the rim inward.)

Test the security of the installation by lightly tugging on the center casting.

Slide center casting up or down on adaptor rods to approximately align it with wheel
center.

Connect sensor safety cable to valve stem of wheel.

NOTE: For small diameter wheels, it may be necessary to remove

the two rod extensions by loosening the lower casting
screws (using the T-wrench) and unscrewing the rod
extensions. Retighten lower casting screws.

Connect the two sensor cables from the console to the front sensors.

On four sensor units, connect the additional two cables between the front and rear
sensors.

INSTALLING REAR TOE LINE SUPPORTS

(TOE LINE or HYBRID SENSORS)
Two sensor systems, hybrid and toe line require the use of rear toe line supports.
Install the rear supports as shown with the pins resting on the wheel rim and the rod
over the top of the tire. The supports should be adjusted to hang approximately at the
wheel centerline.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 10. INSTALLING SENSORS • 25

 NOTE: The same length pin must be used on both left and right
wheels.

After the front sensors and toe line supports have been installed, connect the two
longitudinal toe lines as shown and adjust to remove slack in the lines. Do not stretch
the lines excessively.

Attach all three toe lines (all three toe lines must be installed before starting
compensation).

NOTE: Excessive wind (fans, open exterior doors, etc.) may affect
the toe lines. If necessary, turn off fans or close doors.

10. INSTALLING SENSORS • 26 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 10.2 COMPENSATING SENSORS
CAUTION: Securely chock wheels on axle not being raised during
compensation to prevent vehicle rolling.

Raise either the front or rear wheels.

Select one of the sensors for compensation.
Loosen the sensor lock knob and rotate the wheel 180° until the sensor adaptor is
upside down and the green vertical indicator is on.

Snug down the sensor lock knob.

Rotate the wheel until the sensor is level (as indicated by the level on top of the
sensor).

Momentarily depress (do not hold) the COMPENSATION switch. Do not disturb the
sensor until the red compensation indicator begins to flash.

Loosen the sensor lock knob and rotate wheel 180° until the sensor adaptor is
returned to its original position and the green vertical indicator is on.
Snug down the sensor lock knob.
Rotate the wheel until the sensor is level as indicated by the bubble level.
Momentarily depress the COMPENSATION switch. Do not disturb the sensor until
the red compensation indicator stops flashing and is on continuously. The sensor is
now compensated.
Repeat this procedure for the remaining sensor(s).
After compensating the sensors, remove the lock pins from the turning angle gages
and slip plates.
Make sure the adaptors are vertical, the green vertical indicators are on, and the
sensors are level and locked.
Apply the emergency brake and place the transmission in park.
Lower the vehicle onto the turning angle gages.
Jounce the vehicle.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 10. INSTALLING SENSORS • 27

 NOTES ON COMPENSATION
The sensors may be compensated in any order, however, these precautions must be
followed:

While a sensor is being compensated, the other sensors) and wheels must not be
disturbed. If this should occur, repeat the procedure for the sensor being
compensated.

If the compensation procedure has been started on a sensor to the point where the
red compensation indicator is flashing, the procedure must be completed far that
sensor before beginning to compensate another sensor.

IMPORTANT: When compensating sensors attached to the vehicle drive

wheels, place the transmission in NEUTRAL and rotate the
wheels in the forward direction so that the opposite wheel
does not rotate. (It may be necessary to chock the opposite
wheel to prevent it from rotating.)

If a sensor is removed from any wheel, it must be re-compensated when installed.

During compensation or operation of optical or hybrid sensors, be certain there are

no obstructions blocking the infrared beams between sensors. Should a blockage
occur, the affected sensors) shown on the illustration on the CRT will flash on and off
and the displayed toe measurement of the sensors) will go blank until the obstruction
is cleared.

10. INSTALLING SENSORS • 28 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 11. ALIGNMENT MEASUREMENTS

11.1 MEASURING CAMBER AND TOE

As each sensor is compensated, camber measurements for the corresponding wheel
will be displayed.

After all sensors are compensated, and the vehicle lowered and jounced with the
wheels in a straight-ahead position, alignment measurements will be displayed.

In the front centerline mode, front camber, toe, total toe and set-back measurements
will be displayed.

In the front thrust line mode, front camber, toe, total toe, set-back plus rear camber,
toe, total toe and thrust angle will be displayed.

The "Cross Camber" and "Cross Caster" values represent the difference between the
left and right measurements.

Alignment measurements for CAMBER, CASTER, S.A.I, SETBACK, and THRUST

ANGLE are displayed in degrees. TOE is displayed in the unit of measure selected
by the operator.

A negative SETBACK reading indicates the left wheel is trailing the right wheel. A
negative THRUST ANGLE reading indicates a thrust angle towards the left.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 11. ALIGNMENT MEASUREMENTS • 29

 11.2 MEASURING CASTER
Press a key labeled "Measure Caster" to change the CRT to the "Caster and S.A.I.
Measurement" display.

The adjustment display uses horizontal bar graphs to guide the steering of the
wheels through the caster turn.

These bar graphs are NULL indicators and indicate whether the wheels are steered
too far to the left, too far to the right, or steered correctly (null position).

Movement of the bar graph indicators are controlled by individual wheels. The left bar
graph is controlled by the left wheel, the right bar graph, by the right wheel.
Loosen the front sensor lock knobs. (Be certain the wheel adaptors are vertical.) If a
single bar graph is displayed on the CRT, steer the wheels to the null (straight ahead)
position.
The display will change to show two bar graphs.
Observing the CRT display, steer the wheels to the left until either bar graph
indicates a null position. Hold the steering wheel steady.
After a moment, the bar graph will go blank. Continue to steer the wheels until a null
position is indicated on the other bar graph. Hold the steering wheel steady until that
bar graph goes blank. Two new bar graphs will appear.
Repeat this procedure, steering to the right.
A single bar graph will appear. Steer the wheels to the left until the single bar graph
indicates a null position.
The CRT will change automatically to "Alignment Measurements" and display the
caster measurements.

11. ALIGNMENT MEASUREMENTS • 30 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 11.3 MEASURING S.A.I. AND INCLUDED ANGLE
Press , “S.A.I./I.A.”

Raise the front wheels until they clear the turning angle gages or rack.

Lock the front brakes using the brake pedal depressor and take up any brake slack.

With the wheels in the straight-ahead position, level the front sensors and snug down
the sensor lock knobs.

Complete the S.A.I. turn observing the bar graphs in the same manner as the caster
turn.

When S.A.I. measurements are completed, the CRT will change to the "Alignment
Measurements" display with the S.A.I. and Included Angle measurements shown.

Lower the vehicle.

NOTE: While lowering the vehicle, camber and S.A.I.

measurements will change, Included Angle measurements
will remain constant.

11.4 MEASURING CASTER AND SAI/IA SIMULTANEOUSLY

(NOT PREFERRED)
Press , “Caster and SAI/IA” on the “Caster and SAI Measurements” display.

Lock the front brakes using the brake pedal depressor and take up any brake slack.

Complete the Caster and SAI/IA turn observing the bar graphs in the same manner
as measuring caster only.

When the caster and S.A.I. measurements are completed, the CRT will change to the
"Alignment Measurements" display with the Caster, S.A.I. and Included Angle
measurements shown.

11.5 MEASURING TURNING ANGLES

NOTE: Toe must be adjusted to specification prior to measuring
turning angles.

With the wheels in the straight-ahead position, resting on the turning angle gages
(turning angle gages on zero and lock pins removed), swing the left wheel out 20°
(vehicle left-hand turn).

Read the turning angle of the right wheel on its turning angle scale. (The angle will be
less than 20°. Refer to vehicle manufacturer's specifications).

From the straight-ahead position, swing the right wheel out 20° (vehicle right-hand
turn).

Read the turning angle of the left wheel on its turning angle scale.

NOTE: Some specifications require a turn other than 20°. Refer to

vehicle manufacturer's specification.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 11. ALIGNMENT MEASUREMENTS • 31

 11.6 ADJUSTMENT DISPLAYS
The system utilizes both a bar graph adjustment display and a digital adjustment
display. Whenever a key labeled "Adjust Front Wheels,” "Adjust Rear Wheels" or
"Adjust Toe" is pressed, the corresponding bar graph adjustment display will appear.

Bar Graph Adjustment Display

The bar graphs represent a comparison between the actual measurement and the
entered specifications.

The numerical values next to or above the bar graphs represent the actual
measurement.

As the vehicle is adjusted, the indicator moves in the direction of the adjustment.

The system continually measures the angle being adjusted and compares it to the
specifications and tolerances entered.

The bar graphs indicate the alignment condition as follows:

On these displays, pressing , “Zero Adjust,” will cause the CRT to change to the
digital adjustment display.

11. ALIGNMENT MEASUREMENTS • 32 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 Digital Adjustment Display

The numbers on this display are the differences between the angles measured and
the specification entered. A display of "0" indicates the measured angle equals the
specification.

Press , “Select Adjustment” to display a shim change guide for passenger car
adjustment. The size of the shim and location are shown next to the control arm
illustration. A “-“ indicates a shim must be removed. No “-“ indicates a shim must be
added.

NOTE: The shim changes displayed can vary with individual vehicle
applications.

11.7 VEHICLE ADJUSTMENTS

The vehicle should be adjusted in the following order:

REAR CAMBER (if adjustable)

REAR TOE (if adjustable)
CASTER/CAMBER (one side)
CASTER/CAMBER (opposite side)
FRONT TOE

NOTE: If a sensor is removed during vehicle adjustment, only that

sensor must be re-compensated when re-installed.

Vehicle specifications from the factory specification memory contain illustrations for
adjustments. To view illustrations, press the key labeled “Illustrate Adjustments.” The
display will show the method of adjustment and instructions. Press , “Continue” to
return to the adjustment display.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 11. ALIGNMENT MEASUREMENTS • 33

 ADJUSTING REAR CAMBER AND TOE
Press , “Adjust Rear Wheels.” The CRT will change to the “Vehicle Adjustments”
display.

Adjust rear camber observing the lower left and right bar graphs.

TO ADJUST REAR CAMBER WITH VEHICLE RAISED:

Press twice.

Press , “Raise Rear Wheels” on the “Vehicle Adjustments” display.

Jack up the rear wheels securely and press , “Ready,” as instructed.

Adjust rear camber observing the lower left and right bar graphs.

Press , “Lower Rear Wheels” and lower the vehicle.

TO ADJUST REAR TOE:

Press when labeled “Adjust Rear Wheels.” The CRT will change to the “Vehicle
Adjustments” display.

Adjust rear toe observing the upper left and right bar graphs.

ADJUSTING FRONT CASTER/CAMBER

Press a key labeled "Adjust Front Wheels." The CRT will change to the "Vehicle
Adjustments" display.

11. ALIGNMENT MEASUREMENTS • 34 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 Lock the brakes using a brake pedal depressor and take up any brake slack. (Start
engine before locking brakes on vehicles equipped with power brakes. Turn off
engine after locking brakes.)

Level and lock the sensors.

Make the required camber and caster adjustments, as indicated by the bar graphs.

Press , “Re-measure Caster.”

Re-measure caster to verify the adjustment.

TO ADJUST CASTER/CAMBER WITH VEHICLE RAISED:

Lock the brakes using a brake pedal depressor and take up any brake slack. (Start
engine before locking brakes on vehicles equipped with power brakes. Turn off
engine after locking brakes.)

Level and lock the sensors.

Press twice.

Press , “Raise Front Wheels.”

Jack up the front end securely.
Re-level the sensors, if necessary.

Press , “Ready,” as instructed.

Make the required camber and caster adjustments as indicated by the bar graphs.

Press , “Lower Front Wheels.”

Lower and jounce the vehicle.
Re-measure caster to verify the adjustment.

ADJUSTING FRONT TOE

VEHICLES WITH TWO TIE ROD ADJUSTMENTS:
Start engine, if power steering equipped. Lock the steering wheel in a level, straight-
ahead position as indicated by the steering wheel spoke(s). Turn off engine.

Adjust toe observing the bar graphs or digital adjustment display.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 11. ALIGNMENT MEASUREMENTS • 35

 VEHICLES WITH ONE TIE ROD ADJUSTMENT:
Start engine, if power steering equipped. Lock the steering wheel in a level, straight-
ahead position as indicated by the steering wheel spoke(s). Turn off engine.

Press , “Select Adjustment.”

Adjust toe observing the "Total Toe" bar graph or digital adjustment display.

Adjust center steering using the "Steer Ahead" bar graph, if applicable.

11. ALIGNMENT MEASUREMENTS • 36 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 12. SET-UP

12.1 OPERATING THE PRINT-OUT RECORDER

Four keys on the CRT cabinet operate the printer:

“Print Inspection” on the “Vehicle Inspection” display. The printer will print the
customer ID and the inspection report.

“Print Alignment” on the “Alignment Measurements” display. The printer will

print the customer ID, advertising message, and all alignment measurements
displayed on the CRT.

“Print Specs” on the “Vehicle Specifications” display. The printer will print the
vehicle specifications displayed on the CRT.

“Print Summary” on the “Vehicle Adjustments” display. The printer will print the
advertising message, customer ID, all alignment measurements, and all
specifications entered.
Lights on the front panel indicate printer status and buttons control functions of the
printer.

POWER light - indicates the printer power is on.

ALARM light- lights when paper supply is out. Printer stops until paper is
replenished. The alarm also lights should the printhead become jammed or stopped
during printing.
SELECT light - lights when printer is in select mode.
PITCH (10, 12, 17 lights) - indicates the number of characters per inch to be printed.
Default position is 10. Selection is made using the PITCH button.
MODE (NLO, UTILITY, HSD lights) - indicates the quality of the printer output as near
letter quality (NLO), utility, or high speed draft (HSD). Default position is UTILITY.
Selection is made using the MODE button.
SELECT button - pressing this after the printer is turned on will put the printer in the
deselect mode, not communicating with the system. To return it to the select mode,
press button again Pressing this will also stop the self test.
TOE SET button - to set the top of form (the first printing line) at the current location
of the printhead deselect the printer and press this button.
FORM FEED button - to advance the paper to the next top of form, press this button.
LINE FEED button - to advance the paper one line, press this button.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 12. SET-UP • 37

 To change the ribbon cartridge (P/N 162-42-2):

Remove the access cover by lifting it off.

Slide the printhead to the middle of the printer away from the rollers on the bail.

Grasp the cartridge on both sides and lift up.

Snap the new cartridge on the printhead plate. (Tilt the back of the cartridge so it
slides into the plate, lower the top of the cartridge over the printhead aligning the tabs
on either side with the inserts on the printhead plate.)

Reinstall the access cover.

Rear Feed Paper Loading:

Place the paper behind and under the printer in the box provided.

Remove the access cover and lift the bail.

Open the paper lever.

Take the first sheet of paper and insert it through the paper separator and into the
paper guides.

Continue to slide it until it appears in front of the platen.

Align the holes of the paper with the corresponding pins of the adjustable pin feeds.

Lower the bail.

Use the platen knob to advance to the first printing line.

Replace the access cover.

IMPORTANT: After changing the ribbon cartridge, loading paper, or

clearing a jam, turn the printer off then on using the switch
on the right side of the printer.

12. SET-UP • 38 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 12.2 SETTING TIME AND DATE
Turn unit “ON.”

Press twice.

Press the key.

Press , “Set Time/Date.”

Enter the hour (00-23).
Enter the minute (00-59).
Enter the day (01-31).
Enter the month (01-12).
Enter the last two numbers of the year.

Press , “Continue.”

If an error is made when entering the time and date, press twice and begin
again.

12.3 ENTERING INFORMATION FOR THE "WAKE- UP" DISPLAY

Turn unit “ON.”

Press twice.

Turn the memory key switch to the right 90°.

Press the key.

Press , “Set up the Aligner.”

Press , “Continue” repeatedly until the message “Enter the desired logo for the
wake-up display” is shown.

Enter the desired information using the alphanumeric keypad on the front of the CRT
cabinet.
Press the “Left Arrow” to advance to the next line. If the cursor is on the last line, the
“Left Arrow” will move it to the first line.
If an error is made while entering the information, press the “Delete” key to delete the
last character entered.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 12. SET-UP • 39

 Corrections can also be mad3 by moving the cursor to the incorrect character and
entering a correctly one. Hold the “Control” key and press ”L” or “R” to move the
cursor left or right to the incorrect character. Press the correct character key.
To insert a character in the middle of a word, move the cursor to position. Hold the
“Control” key and press ”I.” A space will appear for the character to be inserted.
If a character is to be replaced by a space at the cursor position, hold the “Control”
key and press ”C.”
To remove an unwanted character at the cursor position, hold the “Control” key and
press “P.” the character will bee removed and all other characters on the line will
move to the left.
Hold the “Control” key and press “Z” to clear the line that the cursor is on and position
the cursor at the left.

Press , “Continue.”
Enter the advertising message for the optional printer using the alpha/numeric
keypad.

Press , “Store Set Up.”

Turn the memory key switch back to its original position.

Press twice.

12.4 SELF-TEST
The system is programmed to test itself when it is turned on. If certain systems fail,
the Self Test display will automatically appear and indicate which system has failed.

In the event the Self Test display indicates a failure, contact the factory service
representative for corrective action.

The Self-Test display may be obtained by pressing when labeled “Test.”

Press , “Continue,” will return the program to the display from which the test
functions were started.

NOTE: Self-test will not cause the system to lose temporary information such
as compensation or specifications.

12. SET-UP • 40 OPERATING INSTRUCTIONS FOR D111 ALIGNER

 13. TROUBLE SHOOTING
If the system fails to respond as expected, assure that all procedures are being
correctly followed. A failure of the program that would cause incorrect alignment
would be shown by the self test display appearing. The symptoms and most likely
causes of an operation error can be found in the table below:
IF THE SYMPTOM IS: THE POSSIBLE
CAUSES ARE:
When compensating, the system fails to respond to the compensate switch on the sensor. A, B, C, O
When viewing the ALIGNMENT MEASUREMENTS display, the measured values do not appear. D, E, F
When performing the caster or SAI procedure, the bar graphs are both blank. G, P
When entering specifications and tolerances, the system ignores some entries. H, L, J
When using the VEHICLE ADJUSTMENT displays, some bar graphs appear blank. D, H, L, K, L
Adjustments were made to camber and caster using the bar graphs, but when caster was M, N
re-measured, camber and/or caster was found to be incorrect.
A. The wheel adaptor must be up-side down to start the procedure. Is the green
indicator light on? The adaptor must be right side up to end the procedure (the
red indicator on continuously). See the instructions on COMPENSATING
SENSORS.
B. Is the red indicator light blinking on another sensor?
C. Are the sensors stable? Is the vehicle being shaken, vibrated or otherwise
disturbed? The engine should be off. Are the toe lines being disturbed?
D. Are the appropriate sensors compensated? See the section on MEASURING
CAMBER AND TOE.
E. Has caster been measured with the caster turn procedure? See the section on
MEASURING CASTER.
F. Have SAI and included angle been measured with the SAI turn procedure? See
the section on MEASURING CASTER and MEASURING SAI and INCLUDED
ANGLE.
G. Are the appropriate sensors compensated? See the sections on MEASURING
CASTER and MEASURING SAI and INCLUDED ANGLE.
H. Are the tolerances non-zero?
I. Are the values reasonable? See the section on ENTERING VEHICLE
SPECIFICATIONS.
J. Was Enter Number" key pressed after the value was keyed ins
K. Were the appropriate specifications entered?
L. Are the appropriate tolerances entered?
M. Was the adjustment procedure followed correctly? Was the sensor LEVEL and
LOCKED, with the brakes LOCKED and the steering wheel STRAIGHT and
LOCKED at the beginning of the adjustment?
N. Was the vehicle leaned on during the adjustment? This may flex the suspensions
causing camber and or caster to be adjusted in error.
O. Is the system calibrated? Refer to service personnel.
P. This normally occurs with optical sensors if the wheels are not steered in the
directions required.
The preceding table assumes the system is functioning properly. If a program failure
should occur, it will be shown on the self-test display.

OPERATING INSTRUCTIONS FOR D111 ALIGNER 13. TROUBLE SHOOTING • 41